19 Tips For Using An Air Compressor

A large industrial air compressor requires some particular replacements for separate parts. Depending on the model and brand of the units, the replacement parts for the air compressor may be very difficult to locate through searching online. A warehouse producer who stocks all of the major parts numbers for Atlas Copco, Quincy, Compair, Ingersoll Rand, and other companies are the best bet for quickly locating the exact lubricant, feed line, gasket, and filter necessary for a specific model.

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I. Find Replacements For Air Compressor’s Parts:

Firstly, the thing you will need to learn when using an air compressor is that you need to know where you can find help when you need to replace some parts of your air compressor. Therefore, this part is very important.

1. Search By Brand Name:

The first thing you will need to know is how you can find out and purchase a good air compressor. Online distributors for the replacements of an air compressor’s parts will categorize the parts numbers basing on the part’s designation and also the brand name of the unit. Users can order many replacement parts for Worthington, Sullair, Palatek, Gardner Denver, and Chicago Pneumatic. Several of parts for industrial air compressors are stocked for Quincy and Ingersoll Rand models.

Users can simply locate the exact part by making use of the parts number search program. This system will match the number to a producer and list on the inventory pages of the warehouse.

2. Rebuild Services:

In addition to the accessories and the parts for industrial compressors’ major brand names, users will want to get the benefits of the rebuild and repair services offered by the certain distributors. The air end unit is the most commonly serviced piece of an air compressor. The rebuild service contains replacements of sealing strips, new drive gear sets, rotor balancing, and rotor shaft repair.

For affordable prices on all types of replacement parts for air compressors and fast shipping, you need to believe in a dependable online warehouse to get the exact units in stock all the time. It is highly recommended that you should use the services of a familiar online distributor with the parts for all major producers and brands. This expresses the amount of experiences dealing with particular models and brands, something the customers will overvalue.

3. Reasonable Shipping Costs And Quick Delivery:

When a large industrial air compressor’s replacement part is needed, the top priority is the rapid delivery to the customers. When the industrial air compressor breaks down because of the faulty parts, the production can be completely stopped. That is the reason why users support online distributors that offer next or same day parts shipping.

II. Understand Your System:

Before implementing strategies for energy reduction, be familiar with all aspects of your air compressor.

1. Compressor Parts A To Z:

An industrial air compressor uses several particular parts, many of which have an extremely long usable duration. However, when these parts fail eventually, equipment operators and plant managers have to know where to turn for the replacement items’ fast delivery. A full-services stock supply brand for industrial equipment will have a list of parts by the model and year, or more commonly, the brand name part number.

Some categories of the parts in which most replacements are found contain:

  • Rotary screw air compressor parts
  • Reciprocating air compressor parts
  • Lubricant
  • Heat exchangers
  • Electronic drain valves
  • Dust collector elements
  • Compressed air filters
  • Air receiver tanks
  • Air dryers

The accessories used by a company also need to be replaced periodically. Common parts including hose reels, drain cocks, ball valves, gauges, flex hoses, and drain and safety valves are listed according to the price, manufacturer, and size.

2. Maintenance:

Evaluating the maintenance records, training, and procedures is also very important. You need to make sure that the procedures are inplace for maintaining and operating your air compressor, and that the employees are well-trained in these procedures.

3. Distribution System:

Investigate the distribution system for any problem related to condensation drains, pressure loss, line size, air leaks, and air storage capacity. Verify that every condensation drain is properly working because the drainage inadequate can rise the pressure drop throughout the distribution system.

4. System Diagram:

Develop a sketch of your air compressor, such as compressed air end uses, air supply lines with dimensions, and compressors, to bring about an entire view of the overall compressed air process.

5. System Demand:

Determine all of the compressed air’s uses in the plant. Generate a demand profile by quantifying the volume of air used in every application. Record the amount of air used as a function of time for your air compressor. The equipment specifications for operations using air are the great sources for obtaining data on the rates of air volume use. The profile will highlight the low and peak demand. The compressed air use’s general assessment will help users determine the inappropriate uses of air.

6. System Supply:

Analyze the supply side of your air compressor to determine the types of compressors used and the types, settings, and suitability of the operating conditions, including capacity controls. Understand the hinge capability of the system and its numerous operation modes. Ensure that the air compressor is not too big for the end use. For instance, if the end use just requires air pressure by 50 % of the pressure that your air compressor can produce, it will be considered an oversized air compressor. Once the big picture is in view, the supply side operating conditions can be changed, within the compressed air unit’s constraints in order to meet the need of compressed air’s side uses better.

III. Conservation Strategies:

Determine simple to implement energy conservation chances in your air compressor by conducting a walk-through assessment. Simple conservation chances can lead to the savings up to 25% of the current fee for running the air compressor.

1. V-belts:

You should check the compressor’s v-belts routinely for proper tightness. If the belts are loose, it can more frequently slip, thereby reducing the efficiency of the air compressor.

2. Cooler Intake Air:

When intaking cooler air, which is more dense, the compressor will need less energy to use for producing the levels of pressure as required. For instance, if 90 degree F air intake is tempered with cooler air from another source to 70 degree F, the 20 degree F temperature drop will reduce the operating cost by almost 3.8%.

3. Surge Tank/ Air Receiver:

You should reduce on/off cycling and add one to buffer short-term demand changes if your air compressor does not have an air receiver tank. The tank is sized to the air compressor’s power. For instance, about a 50-gallon air receiver tank will be needed for a 50 hp air compressor.

4. Compressor Size:

If your compressed air system is oversized, you will need to add a smaller-sized air compressor and sequence-controls to improve its operation, making it work more effectively when partially loaded. Sequence-controls can make a number of compressors regular to match the needs for compressed air, as they vary throughout the day.

5. Inlet Air Filters:

Maintain the inlet air filters for preventing the dirt from leading to pressure drops by restricting the air flow to the air compressor. Retrofit your air compressor with large-area air intake filters so that it will decrease the pressure drop.

6. Heat Recovery:

About 80 to 90% of the electric energy used by an air compressor is turned into heat. A properly designed heat recovery unit can regain 50 to 90% of this heat for water or heating air. Approximately 50,000 Btus (British thermal units) an hour is available per 100 cfm of compressor capacity when it fully runs. For instance, a 100 hp compressor fully creates 350 cfm for 75% of the year. If 50% the loss of heat is recovered to heat process water, at $0.50 per therm, the savings of natural gas will be about $4,100 every year.

7. Inappropriate Use Of Compressed Air:

Find out the compressed air’s inappropriate uses at your facility. To cool electrical cabinets, you should use fans or air conditioning instead of using compressed air; use blowers to mix, cool, aspirate, agitate, and inflate packaging; and use low-pressure air for air lances and blow guns.  From unused equipment, disconnect the compressed air source.

8. Identify Artificial Demands:

Artificial need is generated when an end use is supplied higher level of air pressure than the application’s required level. If 50 psi is required for an application but 90 psi is supplied, excess compressed air will be used.  To minimize artificial demand, you can use pressure regulators at the end use.

9. Compressor Pressure:

The air compressor need to produce air at a high enough level of pressure to still meet the lowest level of the end use equipment’s operating pressure while can overcome the losses of pressure in the supply system. The loss of pressure in a properly designed system must be less than 10% of the discharge pressure of the compressor which can be found on a gage on the compressor’s outlet. If the loss of the pressure is higher than 10%, assess your distribution system and determine the areas that cause excess pressure drops. Every decrease of 2 pounds-per-square-inch in compressor pressure will lower your operating fee about 1.5%.

10. Leaks:

Check your air compressor for leaks routinely. A distribution compressor with the equivalent of a quarter-inch diameter leak, running 40 hours per week, under 100 psig (pounds-per-square-inch gauged) of pressure will lose compressed air at about over 100 cfm in rate, taking users more than $2,800 every year. An ultrasonic detector, working in noisy environments, might be necessary to locate leaks.

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