Efficient Plant September 2021 - 25

compressed-air systems
Regular
Checks Keep
Compressed Air
Efficient
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Compressed-air systems typically have 25% of their air production
diverted through leaks in lines, gaskets, fittings, valves, clamps, and
connections.
POORLY MAINTAINED compressed-air systems can be
the source of significant energy waste and reduced production
efficiency. If your system was properly specified and the compressor
seems to be running more than normal and/or workers are
constantly asking for more air, it's likely that your maintenance
program needs some adjustment. A first step is to establish a
regular, preferably daily, check of basic compressed-air-system
components. The larger the system, the more critical the checks
become. These tips and tricks, compiled by Brad Taylor of Fluid
Aire Dynamics, Schaumburg, IL, provide a good starting point
for a program aimed at optimizing your compressed-air system
performance.
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For more information about compressed-air systems, visit
fluidairedynamics.com.
SEPTEMBER 2021
FOLLOW INSTRUCTIONS
It may seem obvious but reading the manual for your air compressor is
a brief time investment with big payoff. You'll learn the recommended
maintenance schedule and operating guidelines for your unit. With this
information, you can extend equipment life and minimize downtime.
CHECK OIL LEVELS DAILY
Operating with insufficient oil is a quick way to seriously damage a
compressor.
CLEAN INTAKE VENTS
Keep air intakes clean, especially if the environment is dirty or dusty.
Buildup on intake vents forces the compressor to work harder and robs it
of pressure.
REPLACE THE SEPARATOR ELEMENT
The separator element needs to be replaced every 2,000 to 8,000 hr. of
use (depending upon make and model of the compressor) and prevents
excessive oil usage. Analysis has shown that compressor energy costs
rise by 1% for every 2 psi of separator pressure drop.
KEEP THINGS TIGHT
Vibration from compressor operation can loosen screws, nuts, and bolts.
Check them periodically and tighten the loose ones.
KEEP AN EYE ON HOSES
Inspect all of your compressor's hoses regularly because any cracks can
lead to leaks, which in turn strain the compressor's other components.
Replace any hoses that are cracked or damaged.
DRAIN MOISTURE AND CONTAMINANTS
The receiver tank collects moisture from the air that it's compressing.
Empty this regularly to prevent water build up in the system. Also, check
systems such as filters and separators that remove oil and other contaminants.
Watch for condensate stuck upstream of the drain.
MONITOR TEMPERATURE
The manufacturer will specify acceptable operating ranges. Excessive heat
will cause extraordinary wear and shorten your compressor's life. To help
with this, the compressor may have a built-in safety shutdown system if it
gets too hot. Test this feature to make sure it's functioning properly.
PATROL FOR LEAKS
Leaks can originate from lines, gaskets, fittings, valves, clamps, and connections.
They can divert an estimated 25% of compressed air, so check
the entire system regularly. Ultrasonic leak detectors can be helpful.
LOOK AND LISTEN
Keep your ears tuned for strange noises and watch for things such as
excessive vibration or belts that slip. Know what your compressor's
gauges should read when it's operating normally. If you monitor your
machine closely, you can prevent major damage. EP
EFFICIENTPLANTMAG.COM | 25
http://www.fluidairedynamics.com http://www.EFFICIENTPLANTMAG.COM
Efficient Plant September 2021

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