How to Get Your Compressed Air System Ready for Winter?

Air compressors are mainly utilized to provide the so called fourth utility, or compressed air, but while doing so, the air compressors also generate great amounts of heat, which can be recovered and used in various processes within a plant or facility. In optimal conditions, as much as 90 percent of the heat produced by compressing air can be recovered. A heat recovery system can offset the cost of producing hot water for washrooms and equipment cleaning and act as a heating source for a workspace, warehouse, loading dock or entryway. Look for rebates or grants from the local utility providers to help offset the cost of investment in a new, more efficient equipment with energy recovery capabilities. Some utility providers offer grants to promote sustainable energy, which is used towards heat recovery systems, and for replacing a fixed speed compressor with a variable speed driven model. Please contact your local utility provider or a compressed air sales professional for more information on these special offerings. Useful tip: If winter-proofing your compressed air system feels too daunting, invest in an ongoing maintenance plan from your air compressor provider. Well-maintained plants are often the most energy efficient and suffer from less downtime as compared to the plants that avoid making maintenance a top priority.

Condensate drains might be one of the most ignored or forgotten about components when it comes to compressed air systems. Oftentimes these drains either do not exist, or are installed and kept out of sight, out of mind, which in either case can lead to potential problems. The main job of a condensate drain is to release the unwanted water out of specific equipment, whether air compressor, air receiver, dryer and or filter. These drains play an important role, as oftentimes its existence eliminates the need for manual drainage of equipment. The two main types of drains found in today’s compressed air systems are timer and zero loss electronic drain valve. Time drains are a very popular option, as they are cost effective and easy to install, while being quite reliable. The problem with timer drains is that the intervals between drain cycles have to be adjusted depending on the season and or application need, as improper timing can cause condensate retention, while keeping it open too long wastes unnecessary compressed air. No waste electronic drains are becoming more popular nowadays, as they do not waste any compressed air during the release of condensation and can be easily maintained with a simple rebuilt kit. Considering the small orifice on these drains, it is important to check and test the drains to ensure the opening is clear of any obstructions to allow for proper operations. As a rule of thumb, drains should be rebuilt and or replaced at least one a year and considering the inexpensive nature of this product, it is usually the memory that causes us to forget about them rather than the actual expense. Add drains to your routine maintenance checklist to ensure their effectiveness.

Similar to drains, filters are oftentimes an afterthought when it comes to compressed air systems. However, filters play an important role in ensuring proper air purity needed for a given application. Blocked and or oversaturated filters will not have the same capability to remove dust, particles, oil and or liquid out of compressed air, therefore leading to possible contamination. In addition, clogged filters result in system wide pressure drops, which can affect production and equipment shut downs or cause the compressed air system to work harder and increase energy consumption over time. It is advised and preferred to perform scheduled checks and maintenance on air filters to ensure proper air purity and seamless operations. An annual replacement of the filter element is recommended to avoid any risks.

It is oftentimes difficult to locate or hear an air leak within the compressed air piping system, but that does not mean that air leaks do not exist. On the contrary, depending on the age of piping system and its configuration, air leaks can account for 25% or more of compressed air usage within a given plant. Air leaks can be classified as artificial air demand, as they exist to only waste compressed air and do not serve any purpose other than causing your compressed air system to run inefficiently. Some larger leaks can be heard and can easily be catered to, but it is the smaller ones that should require the most attention before they become a bigger problem and cause potential pressure drops and interruption in the production process. Smaller leaks are difficult to detect, therefore it is advised to invest in a compressed air audit in order to recognize and repair the existing leaks, which will lead to higher productivity and efficiency from your compressed air system.