How to improve compressor efficiency and availability
26 April, 2024
Even if you invested in the most reliable compressor on the market, its availability and efficiency are heavily influenced by factors such as working environment, operating conditions and maintenance. What steps can you take to avoid production stops and keep your machines performing at their best?
What are the dos and don’ts to achieve high availability with maximum efficiency?
1. Correct installation
Installing your compressors in a clean environment with moderate temperature and moisture conditions is the first step to achieving optimal performance. Three components majorly contribute to efficiency for your compressor:
Air composition: A compressor sucks in the air around it. In a dusty environment, this means the inlet air filter will be saturated more quickly and will need to be replaced more frequently. If not, critical components of your compressor will suffer.
Temperature: The temperature of the air is directly proportional to the energy a compressor requires to compress. This means that cool air requires less energy and increases the overall air compressor efficiency.
- Humidity: Air compressors installed within humid environments generally tend to rust quicker and affect the overall compression. Ensure you install your air compressor in a dry-air environment to save your compressor from system and component damage.
2. Regular check-up of machine parameters
Following up on equipment parameters such as outlet temperatures and pressures gives the possibility to predict potential problems. This is possible if the data is collected and analyzed continuously. Take advantage of the remote connectivity features of your compressors.
Our standardized checklist for both oil-injected and oil-free air compressors includes essential maintenance procedures that can often be performed in-house or by a skilled technician. Key checks for the efficiency of the compressor include:
Service readings: Monitor air, oil, water, temperature, and pressure levels.
Leak detection: Check for any signs of air, water, and oil leakages.
Air intake inspection: Examine the air intake chamber for any obstructions or contaminants.
Filter assessment: Check all filters and filter elements for cleanliness and functionality.
Valve and switch adjustment: Ensure that all valves and switches are properly adjusted and functioning.
Connection integrity: Examine bolt and coupling connections and rubber inserts for wear or damage.
Fan and motor condition: Check the condition of all fans, air paths, motors, and drive gears.
Cooling system maintenance: Clean the cooling system and verify its correct operation.
Oil quality and level: Change the oil if necessary and check for the presence of water in the oil.
Electrical connections: Inspect for loose wiring and ensure all connections are secure.
Gearcase maintenance: Clean and inspect the gearcase for any issues.
Hose condition: Assess the condition of all hoses for any signs of wear or damage.
3. Proper maintenance plan
Following maintenance recommendations from the manufacturer is another key element. Having a recurring routine of parameters that you check for on a daily, weekly, or monthly basis will keep your machines operating at their best conditions. Here are a list of 8 maintenance tips to improve your air compressor efficiency:
Tighten all fasteners
Clean intake valves
Inspect the hoses
Drain the air receiver tank
Change the air filters
Change the lubricant
Change the separator elements
Cleaning the fuel tank
4. Proper selection of ancillaries
Consumption of air can be fluctuating which can result in a bad compressor operating mode and lower air quality. The impact can be reduced due to proper selection of ancillaries, such as dryers, air vessels, piping system and line filters.
Does a maintenance plan affect my compressors’ efficiency and availability?
A good maintenance plan makes the most of your investment and manages your resources effectively. You won't need to worry about parts inventory, equipment monitoring, service interventions and repairs.
If you are performing maintenance yourself, foresee efficient parts storage, the correct, certified tools and a trained maintenance crew. Keep in mind that you will not be able to file a warranty claim in case of a breakdown resulting from incorrect service.
Are there advanced ways to monitor my equipment?
Visual checks have their limitations, as a lot is happening on the inside of your compressor.
To get further assurance that your machines are running smoothly, follow up on equipment parameters such as outlet temperatures and pressures. If you notice that a parameter is out of the recommended range, contact your supplier as soon as possible.
A manual follow-up means writing down all parameters in a table. As a more user-friendly solution, take advantage of the remote connectivity features of your compressors.
What can I expect from my equipment manufacturer?
Leaving the care for your equipment in the hands of the manufacturer can save you a lot of time and effort. More importantly, it may be the shortest route to maximum air compressor efficiency and equipment availability.
Total Responsibility service plan is the best way to ensure the highest equipment uptime, and it can include the Availability Guarantee, our pledge that your equipment will be available for an agreed percentage of the time.
A promise we can make thanks to:
- SMARTLINK monitoring and remote diagnostic service
- The most efficient operational process
- The proper planning of regular maintenance and proactive extra jobs
FAQs
What is the efficiency factor of a compressor?
The efficiency of a compressor is the ratio of the compressed air output to the input power. Efficiency is calculated by dividing the useful output energy (compressed air) by the input energy (electrical power). In ideal conditions, the efficiency would be 1.0, but in reality, it's always less than 1.0.
Which compressor is best for industrial use?
For industrial use, rotary screw compressors are generally considered the best due to their durability, efficiency, and ability to provide continuous air supply. They are ideal for large-scale operations that require a steady and reliable airflow and can be tailored to specific requirements with various customization options.
Which compressor is more efficient and why?
Axial compressors are generally more efficient due to their design and operation principles. They handle higher flow rates and pressures with less energy loss, making them more efficient in terms of both energy consumption and airflow. Their efficiency comes from the aerodynamics of their blade design, which optimizes air flow and minimizes turbulence.
