Industrial air compressors are a crucial and fundamental part of the plant's operation (so crucial, in fact, that compressed air is also known as the fourth utility). With so much emphasis on the lifetime of these machines, air compressor maintenance has become key to conserving a company’s funds. When properly maintained, industrial air compression systems decrease downtime, increase production rates, and improve the quality of the air being produced. Two system components that require routine maintenance are the compressor package and the compressor drives. A lot of minor problems can be attended to simply by cleaning, replacing parts as necessary, and doing away with harmful conditions that could hinder the compressor’s working ability. Using a professional air compressor maintenance service will reduce safety hazards and increase the reliability of the air compressor. Components that need to be maintained by the compressor package are the heat exchanger surfaces, the compressors, the air-lubricant separator, the air-inlet filter, the lubricant, and the lubricant filter. Heat exchanger surfaces should be kept clean; if they are not, the air compressor will be less efficient. Air lubricant separators usually perform at 2 or 3psid when new and working at full capacity. Manufacturer manuals suggest changing the air lubricant separators when it reaches a 10psid. Air compressor lubricant often becomes acidic and deteriorates the equipment, therefore decreasing system efficiency. Lubricant-injected rotary compressors require lubrication to be applied to bearings, gears, and contacting rotor surfaces. To prevent reduction of compressor capacity, air-inlet piping should also be cleaned regularly. The compressor drive must be maintained through lubrication and cleaning. It is necessary to keep the air passages clean and clear of obstruction due to the fact that motors require cleaning. All enclosed motor fins should be free of debris to allow the compressor drive to cool. For motors with bearing grease fittings, first clean the grease fitting and remove the drain plug. Then, add new high-quality grease, run the motor for an hour, and finish by replace the drain plug. Excessive bearing wear can be caused by tight belts; on the other hand, loose belts can slip and create wasted energy. It is efficient to check and adjust belts regularly to reduce stretching and deterioration. Lack of maintenance can cause excessive energy consumption, high operating temperatures, poor moisture control, and excessive contamination. Keep in mind that all industrial air compressor equipment should be maintained in accordance with the manufacturers recommendations. Depending on ambient conditions, it may be prudent to carry out maintenance more often than advised by compressor manufacturers.

Choosing an industrial air compressor can be quite difficult due to the many models available. The kind of compressor you buy depends on where and how it will be used. It is important to do your research and understand how air compressors work. You should also understand the various parts that make up an air compressor, such as the motor, the storage tank, the drain, the filters, and the pressure control valve and switch.

First, the motor drives the compressor and is sized according to the air flow and pressure requirements of the process. The motor provides the power for the compressor to produce the proper amount of air. Simply put, the larger the motor, the larger the volume of air flow will be produced and pressurized, which leads to more power being generated in the machine’s output.

Next, the storage tank is where the compressed air is held until it is used. The storage tank is available in many sizes, from small home units to large industrial units. Some smaller units can be easily carried, while some middle size units are mounted on wheels or skids, which make it easier to move them. The larger industrial units are usually frame mounted, and may need machinery to help place them or move them around the work site.

The drain is where excess water is discarded from the tank. When in use, industrial air compressors produce a condensate, such as water vapor, that can build up and cause harm to the system. A drain helps to prevent moisture from forming in the storage tank that can lead to damage further down in the system by providing a place for this excess water to be discarded properly.

Next, the intake filter cleans out dirt and allows for a clean flow of air to compress. The exit filter removes contaminants left in the compressed air, which helps to prevent damages to air tools and system. 

Finally, the control valve regulates the required amount of air pressure. The switch turns the motor of the air compressor on at a minimum pressure requirement and it will turn the motor off at the desired pressure.

Understanding what parts make up an air compressor, as well as understanding what each of the parts does, is vital in choosing an industrial air compressor. Without the proper knowledge, it is difficult to make an educated decision in purchasing your air compressor.

 

Compressed air is a very important day to day commodity, making it the fourth most used utility after electricity, natural gas and water. The efficiency of compressed air is reduced by contaminants such as water vapor, oil and dust. To keep compressed air free from these contaminants one has to use air filters. Choosing the correct air filter can be quite a task. 
Compressed air filters remove any dust, oil aerosols, and water vapor from the compressed air protecting your equipment and delicate instruments. They function to protect equipment, ensuring that the equipment one is using remains safe since the contaminants can cause equipment malfunction. The contaminants wear out the air tools decreasing their efficiency, destroying seals, and damaging finished products.

There are several types of compressed air filters. The compressor intake filter is the first line of defense; it blocks large particles and removes chemical contaminants. Oil injected rotary screw compressors have an air/oil separator. This type of filter allows compressed air to pass while filtering water and oil droplets. The compressed air then passes on to the coalescing filter. Coalescing filters are found in high oil air compressors. 

The Coalescing filter removes water and oil aerosols very effectively since it compresses the fine particles to droplets and draining them. It is highly effective even in removing large solids. The particulate filter is 1 to 3µm and stops very fine scale metal oxides and finer contaminant particles. There is also a high particulate filter operates at high temperatures to filter out contaminants and is mostly used with high temperature housing. The vapor filter is also referred to as the charcoal filter and is mostly used to absorb water vapor since charcoal is highly hygroscopic.

When choosing an air filter one should note the specific manufacturer and the type of air compressor that one uses. There are many compressed air filter manufacturers in the market today making choosing the correct air filter rather difficult. In general, the correct air filter for your compressor system is determined by the filter element. To choose the correct filter one has to know the conditions under which the compressor works, and whether it has to filter more of dust, oil or water vapor. One also has to consider the temperature of the environment in which the filter will be functioning in since temperature may affect your filter. Compressed air filters are an effective method of keeping contamin

Choosing an industrial air compressor can be quite difficult due to the many models available. The kind of compressor you buy depends on where and how it will be used. It is important to do your research and understand how air compressors work. You should also understand the various parts that make up an air compressor, such as the motor, the storage tank, the drain, the filters, and the pressure control valve and switch.

First, the motor drives the compressor and is sized according to the air flow and pressure requirements of the process. The motor provides the power for the compressor to produce the proper amount of air. Simply put, the larger the motor, the larger the volume of air flow will be produced and pressurized, which leads to more power being generated in the machine’s output.

Next, the storage tank is where the compressed air is held until it is used. The storage tank is available in many sizes, from small home units to large industrial units. Some smaller units can be easily carried, while some middle size units are mounted on wheels or skids, which make it easier to move them. The larger industrial units are usually frame mounted, and may need machinery to help place them or move them around the work site.

The drain is where excess water is discarded from the tank. When in use, industrial air compressors produce a condensate, such as water vapor, that can build up and cause harm to the system. A drain helps to prevent moisture from forming in the storage tank that can lead to damage further down in the system by providing a place for this excess water to be discarded properly.

Next, the intake filter cleans out dirt and allows for a clean flow of air to compress. The exit filter removes contaminants left in the compressed air, which helps to prevent damages to air tools and system. 

Finally, the control valve regulates the required amount of air pressure. The switch turns the motor of the air compressor on at a minimum pressure requirement and it will turn the motor off at the desired pressure.

Understanding what parts make up an air compressor, as well as understanding what each of the parts does, is vital in choosing an industrial air compressor. Without the proper knowledge, it is difficult to make an educated decision in purchasing your air compressor.

Maintaining the efficiency, capability, and cleanliness of an air compressor system is of vital importance when running a business that requires one. Understanding that typical air compressors have schedules of maintenance, the procedures for handling each specific maintenance intervals is extremely important in taking care of an air compressor, and can help prevent problems before they begin. Neglecting to adequately maintain an air compressor could have disastrous effects on product safety, energy costs and unscheduled compressor down time.

When assessing the importance of preventive maintenance for an air compressor system, the first factor will always be cost. Costs can skyrocket when maintenance related efficiency is poor, for example a 100 horsepower motor that drops pressure output by even 4 psi can lead to thousands of dollar in increased energy costs per year. Scheduled maintenance will often diagnose and fix such inefficiencies by allowing for baseline measurements to be taken regarding output at regular intervals. Reduced outputs can be handled and overall system problems can be solved before energy costs increase, or products begin to suffer.

Many who do not undertake preventive maintenance also fail to realize the impact it can have on product contamination. Filters that are designed specifically for certain pressure ranges often fail when output is lowered due to poor maintenance, and particulates that were normally caught in the filter make it into products, significantly reducing quality. This can further impact costs by loss of product due to quality issues.

Routine maintenance should be performed consistently to assist in diagnosing problems and alleviating down time. One would do well to note that this procedure is not exactly the same for any model, and many units come with specific maintenance plans that should be followed to the letter. With that said, before beginning a maintenance plan, always be sure that the power is off, that any sources of power to the unit are locked out, and that all pressure in the unit is exhausted. Failure to do any of the above can result in system damage or personnel injury.

A good maintenance plan can be performed as often as daily or weekly and requires a basic check of the compressor and accessories. Any unusual vibration or noises should be noted during these checks as well, and excess moisture should be drained from the tank drain valve.