Essential Tips for Winter-Proofing Your Air Compressor for the Cold Weather

Did you know that the ideal operating temperature for a compressor typically ranges between 5° to 35° Celsius? This means that winter’s frigid temperatures can have a substantial impact on your compressed air system, especially if the ambient temperatures in your compressor room fall below this range. Time to explore how you can guard you air compressors against the harsh Canadian winter. 

Plunging winter temperatures can cause both short-term and long-term damage to your air compressors. One key example is frozen condensate, which can clog/crack critical components within the larger compressor system. Other components such as control lines, drain valves, compressed air filters, and heat exchangers are also at risk of freezing and cracking. 

• Frozen Water & Icy Oil. Of all the issues that tend to arise when temperatures drop below freezing, one of the most troubling has to do with water and oil. It’s essential to do timely assessments of every location where liquid could be isolated and to identify any possible areas where leaks might occur. Oil temperature should also be monitored and regulated; else, the oil could drop to a coldness level causing it to thicken and renders it unable to lubricate or seal the machinery, which then means it takes more power to operate the compressor pump. Icy oil can also cause a compressor to malfunction or stop working altogether. Keep an eye on this – the motor’s lifetime can decrease if this continues for a long period of time.
• Ambient Temperature. The ambient temperature of your compressor system is decisive. Have a rotary screw compressor that’s refusing to start in the cold? There’s a good chance this is due to the low ambient air temperature limit switch (which many screw compressors are equipped with), which prevents the compressor from starting if the ambient conditions are below 5 degrees Celsius.

    To prevent such events, you can take appropriate measures with a small space-heating system.

    Heat recovery can also be used to heat the premises to protect the  compressed air system from frost.

• Drain Condensate. Condensate is a common occurrence in air compressors. It forms in the system and settles in low places, including tanks. In the winter, unaddressed condensate can freeze and burst pipes. It’s important to inspect your tanks several times each week during winter – as well as throughout the other months of the year – to ensure that condensation buildup doesn’t occur. If even the slightest amount of moisture accumulates, drain it immediately. Whenever an abundance of moisture appears within the span of a couple days, it could be a sign of something much worse within your system. You can also consider installing an automatic drainage valve; it’s a small fix that will prevent the need for larger repairs.
• Winterize the Outside Pipes and Condensate Drains. If temperatures in your area are expected to drop to freezing levels, apply heat trace tape over any exposed parts of your drain lines; this will stop them from freezing. Pipes that lead through unheated outdoor areas or production areas are particularly dangerous here. The trace heating on pipes thus prevents ice particles from reaching the end product via the compressed air network.

Above all, you should pay attention to this if you have a cold dryer in use. This is  because exposed pipes can have a lower temperature than the dew point of the dryer. This, in turn, can lead to condensation. You should also keep an eye on the air intakes, which should be protected from heavy rain or even snow so that no ice can form at the air intake.

• Monitor Refrigerated Air Dryers in Cold Conditions: In winter, refrigerated air dryers may perform too efficiently, potentially causing moisture to freeze and damage the system. Regularly check for ice buildup to protect your equipment.
• Prevent Freezing in Desiccant Air Dryers: Ensure proper drying capacity by keeping an eye on wet incoming air. Ice can form inside piping and valves, reducing airflow and causing malfunctions, so it's important to maintain consistent airflow.
• Guard Against Component Corrosion: Cold temperatures can lead to higher moisture levels in your compressor system. Regular maintenance can help prevent rust and corrosion from developing over time due to increased condensate.
• Use Trace Heating. Trace heating on pipes can help prevent freezing throughout the air compressor and distribution system. This is especially important if any pipes pass through cold or outdoor areas where they could freeze and pass ice particles down the line to end-uses.
• Know Your Dew Points. Winter months require a lower dew point. A compressor that works sufficiently during daytime temperatures might prove insufficient after dusk! Some facilities also have systems where compressed air is sent from one point to another with lines that go both inside and outside of the facility. In these kinds of plants, the system handles two differing temperatures simultaneously with the same equipment. Generally, a compressed air system should have its dew point set at least 20 degrees below the lowest expected.