Industrial Air Compressor Basics

7 Ways to Save Money on your Compressed Air operating costs

noreply@blogger.com (McGuireAir) — Wed, 31 Jul 2019 18:32:00 +0000

Here are your tips...

1. Find and fix your air leaks
A small leak - no larger than 1/16" can cost an extra $523 a year.* Add a few other small leaks here and there until you have leaks equal to a 1/4" opening...and now that "small leak" can cost you over $8,000 a year.* It is easy to see that what seems like a small leak comes with a very high price tag over time.

Click here to see how to estimate what percent of your CFM’s are air leaks.

2. Lower Air Pressure

A 2 psig change in pressure equals 1% change in horsepower.
Dropping pressure can change the amount of CFM used and you’ll save all that energy needed to make that CFM. Check to see what CFM your equipment actually needs to run efficiently and adjust your pressure to save energy yet still provide the CFM required

3. Use Synthetic Air Compressor Oil and you can reduce AMP draw an average of 8%.

4. Turn off your air compressor when it is not in use.

5. Eliminate any compressed air flow restriction.
Make sure your air line filters are clean.
Make sure your piping is not too small.

6. Use ZERO AIR LOSS DRAINS

This prevents wasting compressed air

7. Keep compressor inlet filter clean
If your Compressor cannot suck in air- then it cannot blow out the air you need.

Call - 336-229-9999 or Email compressors@mcguire.biz

For Industrial Champion Air Compressors, Pumps, Manuals, Dryers

industrialaircompressors.biz

Reelcraft Hose Reels for air hose and other industrial applications

hosereels.biz

Deltech Refrigerated Air Dyers to reduce harmful moisture
in your compressed air system

airdryers.biz

How can I help my Compressor Last Longer?

noreply@blogger.com (McGuireAir) — Tue, 03 Oct 2017 16:04:00 +0000

Answer:

One of the best ways to increase the working life of your air compressor is to establish a regular maintenance program. If you have a Reciprocating Air Compressor - the following information can provide the schedule you need.

Before you perform any maintenance, always do these steps...

Switch main disconnect switch to "off" position to assure no power is entering unit.
"Lock Out" or "Tag Out" all sources of power.
Be sure all air pressure in unit is relieved. Failure to do this may result in injury or equipment damage.

Get More Free Info Now...
Learn all the proper weekly, monthly & annual maintenance steps to keep your compressor working longer...

McGuire Air Compressors

1-336-229-9999
"Real People with Real Air Compressor Experience"

Providing compressor answers that save you time and money.

How do I correctly install and adjust an Air Pressure Switch?

noreply@blogger.com (McGuireAir) — Thu, 20 Jul 2017 17:29:00 +0000

How do I correctly install and adjust an
Air Pressure Switch?

Answer:

We get this question a lot - so we developed a step by step set of directions to help you.

Get your PDF instructions from our resources webpage.

What does a pressure switch do?

Answer:
An air compressor pressure switch is a valuable part of your equipment.

The pressure switch tells your compressor when to stop and when to start and can help you save money and energy.

Need to order a pressure switch?
Call us - 1-336-229-9999

336-229-9999
www.industrialaircompressors.biz
McGuire Air Compressors
"Real People with Real Air Compressor Experience"
compressors@mcguire.biz

OSHA Requires a Compressed Air Safety Shut-Off Valve

noreply@blogger.com (McGuireAir) — Wed, 27 May 2015 16:42:00 +0000

Did you know that OSHA Requires a

Compressed Air Safety Shut-Off Valve?

The OSHA Safety Standard Regulation 29CFR CHXVII Paragraph 1926.302(b)(7) states: All hoses exceeding 1/2-inch inside diameter shall have a safety device at the source of supply or branch line to reduce pressure in case of hose failure.

Prevent dangerous air hose whips and accidents. Protect your most important assets: Your employees and their equipment.

OSHA Compliant COMPRESSED AIR SAFETY SHUT-OFF VALVES offers simple but efficient protection to pneumatic systems in the event of a broken compressed air hose or pipe.

Click here to see how to get the Safety Valves you need to meet OSHA standards.

Call us to order the safety valve and reels you need- 336-299-9999

_______________________________________________________

Another OSHA guideline publication states:
“Hoses, cables, and other equipment shall be kept clear of passageways, ladders and stairs.”

Consider adding reels to increase safety & efficiency with your electrical cords, welding cables, air hose, oil, grease, liquid/water or fuel hoses. This could be one of your most effective equipment additions you’ll ever make…as well as one of the safest!

For more about Hose Reels visit www.hosereels.biz

McGuire Air Compressors, Inc.

"Real People with Real Air Compressor Experience"
336-229-9999
compressors@mcguire.biz

For Industrial Champion Air Compressors, Pumps, Manuals, Dryers

www.industrialaircompressors.biz

Reelcraft Hose Reels for air hose and other industrial applications

www.hosereels.biz

Deltech Refrigerated Air Dyers to reduce harmful moisture in your compressed air system

www.airdryers.biz.

Three Biggest Pay-Offs in changing from mineral oil-based lubricants to Synthetic Compressor lubricants

noreply@blogger.com (McGuireAir) — Wed, 09 Apr 2014 17:10:00 +0000

In today’s competitive and challenging market - you need every advantage you can get!

One simple, yet very significant advantage is selecting Quality Synthetic Compressor Lubricants over conventional, mineral oil-based lubricants for your air compressor.

Three Biggest Pay-Offs in changing from mineral oil-based lubricants to Synthetic Compressor lubricants.

#1. Lower Your Electric Bill by increasing energy efficiency

Compressor Synthetic Lubricants can actually reduce energy consumption in many applications, up to 9% as compared to conventional mineral oils.

Here's how...
> Compressor Synthetic Lubricants help minimize friction between moving parts. ( less friction = less amp draw )

> Energy can be lost due to "churn" as mechanical parts move through oil: Compressor Synthetics Lubricants have a lower viscosity when compared to mineral counterparts of the same ISO viscosity grade , resulting in lower churn energy loss than a mineral oil.

#2. Get a Better Return on Your Investment by extending equipment life

When you lower the energy consumption with compressor synthetic lubricants you decrease friction which means less wear. Less wear = longer life.

Whether your equipment runs in extreme hot or in cold conditions, Compressor Synthetic Lubricants are more effective over a wider range of operating temperatures than mineral-based products.

>In very hot conditions, Compressor Synthetics remain thicker for better protection. Compressor Synthetics do not degrade in high temperatures as fast as mineral-based oils either.

>In lower temperatures, Compressor Synthetics offer excellent flow characteristics, unlike mineral-based oils that tend to get too thick to flow well when cold and can limit protection to critical parts.

#3. Lower Maintenance Costs by using Less Labor & Materials

Compressor Synthetic Lubricants usually last up to 8-10 times longer than mineral oil equivalents. This translates into...
>Reduced oil purchases
>Less used-oil to dispose
>Fewer oil changes - fewer hours your maintenance team must spend on oil changes

>Decreased downtime because of lubricant-related problems such as valve maintenance.

Click here to learn more valuable tips>>

McGuire Air Compressors, Inc.

“Real People with Real Air Compressor Experience”

Email us: compressors@mcguire.biz
Call us: 336-229-9999

For Champion Air Compressors...

https://www.industrialaircompressors.biz/

For Reelcraft Hose…

https://www.hosereels.biz/

For Deltech Refrigerated Air Dryers…
https://www.airdryers.biz/

We need more air pressure! How do I figure out how much more we need?

noreply@blogger.com (McGuireAir) — Wed, 10 Oct 2012 20:38:00 +0000

Does your air pressure keep dropping while you are using your tools & equipment?

Have you added or are planning to add new equipment which uses air?

Are your air compressors working hard all the time- but you just aren’t sure how to figure how much more horsepower you need?

When your business counts on air – you need to know the valuable formulas and steps to help accurately determine how many CFM you use. You also need to know how to accurately figure how much additional CFM and horsepower you need when considering a new air compressor?

Here are some specific formulas that can help you determine how many CFM you presently use and how many more CFM you need to meet your desired PSIG. We will show you how to take this information and use it to determine how much air compressor horsepower you actually need.

Find out how many CFM your air compressor delivers

1. STOP the compressor unit

2. CLOSE the outlet valve on the tank/air receiver

3. DRAIN the condensate from air receiver until there is 0 PSIG -
then close the drain valve

4. NOTE THE TIME- in minutes & seconds (Best to write it down.) Then START THE UNIT.
When the compressor unit stops and unloads – then NOTE THE TIME again – in minutes & seconds. Convert the minutes into seconds and then total the number of seconds it takes between START and STOP/UNLOAD.

5. NOTE the GUAGE PSIG reading

6. NOTE the Air Receiver/Tank GALLON SIZE

7. USE THIS FORMULA:

TANK GALLONS x .538* x PSIG divided by SECONDS

EXAMPLE:

You have an 80 gallon tank, your total start to stop/unload time was
3 minutes and 30 seconds. Change the minutes to seconds timed
(60 x 3= 180 seconds plus 30 seconds which totals 210). You will use the total number of seconds (210) and the noted 175 PSIG within the formula as shown below:

80 multiplied by .536 = 42.88
42.88 multiplied by 175 (Example PSIG) = 7504.00
7504.00 divided by 210 (total seconds)= 35.74 CFM delivered

The example shows that the air compressor is delivering 35.74 cfm

Your Response to this evaluation should be to compare this number with what your air compressor manufacturer says your CFM should be and evaluate how efficiently your compressor is running.
If your air compressor is within 10% of manufacturer's specifications, then the unit is OK, if not - repair unit and recalculate your needs.

Find out how many more CFM you need to raise your PSIG

1 What is your desired pressure ______?
(Our Example125 psig)

2. What is your present operating pressure_______?
(Our Example 70 psig)

3. Divide desired pressure by present operating pressure
(125 psig divided by 70 psig = 1.79)

4. This gives us the X-factor needed for this formula (1.79 )

5. Multiply present air compressor cfm (35.74) by your X-factor (1.79)
(35.74 X 1.79= 63.98 This gives you the total cfm needed –
which is 63.98 for our example)

6. Deduct your present cfm from the needed cfm
(63.98 minus 35.74 present cfm = 28.24)

7. This gives you the additional cfm needed to raise your psig to the level you actually need. (which is 28.24 additional cfm for our example)

Translate your answers into how much horsepower you actually need to operate

Divide your additional cfm needed by 3.5* (see the chart for your *actual compressor type & horsepower)
(28.24 ÷ 3.5 = 8.07 hp, which would be the additional horsepower needed for our example)

This will give you the additional horsepower you actually need.

(We will need to round up the 8.07 hp to 10 hp needed for our example. You will have to round up to the nearest standard
horsepower also.)

*CFM per compressor horsepower chart:

3.5.cfm per hp for small piston compressors ½-30 hp

4 cfm per hp for large piston 40 hp up & small screw compressors 2 hp-30 hp

4.5 cfm per hp for 40 hp-150 hp medium hp screws

5 cfm per hp for 200 hp-2000 hp large screw & centrifugal compressors

Note: Always buy CFM of delivered air at the PSIG you need…not horsepower.

Note: Always invest in at least 20% more CFM than your equipment needs. This will cover extra air usage for such things as air leaks and wear.

Follow these formulas and you can figure just how much more CFM and air compressor horsepower you really need to get the job done!

Compressor Terms you should know:

Cubic Feet Per Minute (cfm) - Volumetric air flow rate.

"psig" means pounds per square inch, GAGE pressure. Gage pressure is the absolute pressure of something, with the atmospheric pressure subtracted. In practice, when someone gives a pressure in just "psi" they probably mean gage pressure. If they mean absolute, they should be using "psia."

Gauge Pressure - The pressure determined by most instruments and gauges, usually expressed in psig. Barometric pressure must be considered to obtain true or absolute pressure.

Load Time - Time period from when a compressor loads until it unloads.

Unload - (No load) Compressor operation in which no air is delivered due to the intake being closed or modified not to allow inlet air to be trapped.

Receiver - A vessel or tank used for storage of gas under pressure. In a large compressed air system there may be primary and secondary receivers.

McGuire Air Compressors
“Real People with Real Air Compressor Experience”
336-229-9999
Email: compressors@mcguire.biz
or Champion Air Compressors...
https://industrialaircompressors.biz/

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

How to find out how many CFM your compressor delivers

noreply@blogger.com (McGuireAir) — Wed, 09 May 2012 15:53:00 +0000

Here's one of the most used Compressed Air formulas
you should keep on hand...
How to find how many CFM
your air compressor delivers.

Follow these steps to find how many
CFM Your Air Compressor delivers

1. STOP the compressor unit

2. CLOSE the outlet valve on the tank/air receiver

3. DRAIN the condensate from air receiver until there is 0 PSIG -then close the drain valve

4. NOTE THE TIME- minute & second. Then START THE UNIT.
When unit stops/unloads – then NOTE THE TIME again – minute & seconds. Convert minutes into seconds and then total number of seconds it takes between START and STOP/UNLOAD.

5. NOTE the GUAGE PSIG reading

6. NOTE the Air Receiver/Tank GALLON SIZE

7. USE THIS FORMULA:

TANK GALLONS x .538* x PSIG divided by SECONDS

EXAMPLE:
You have an 80 gallon tank, your total seconds timed were 189 and you noted 175 PSIG.

80 multiplied by .536 = 42.88
42.88 multiplied by 175 (example PSIG) = 7504.00
7504.00 divided by 189 (total seconds)= 39.71 CFM delivered

You now know that your air compressor is delivering 39.71 CFM

Your Response to this evaluation should be to compare this number with what your air compressor manufacturer says your CFM should be and evaluate how efficiently your compressor is running.

McGuire Air Compressors, Inc.
"Real People with Real Compressor Experience"

336-229-9999

www.industrialaircompressors.biz

www.hosereels.biz
www.airdryers.biz

8 Reaons to upgrade to Synthetic Air Compressor Oil

noreply@blogger.com (McGuireAir) — Wed, 19 Oct 2011 17:29:00 +0000

Whether you are the business owner or the one who does equipment maintenance…you’ll save time and money by upgrading from mineral-based oils to quality Synthetic Air Compressor Lubricants.

If you are the business owner – you’ll love saving money because you upgraded to synthetic oil!

If you are the one who changes the oil - you’ll be glad to make a lot less oil changes!

Eight proven benefits from upgrading to quality Synthetic Air Compressor Lubricants in Reciprocating Type Compressors:
1- Saves 7%-10% in Electrical Usage in Reciprocating Type Compressors
2- Creates Less Friction which Equals Less Wear
3- Oil Will Last up to 8 Times Longer than mineral based oils
4- No Carbon deposit build-up in Valves or Rings
5- Creates Thermal Stability & Solvency
6- No Seasonal Oil Change as with mineral oil
7- Less Impact on the Environment
8- Saves on Labor & Disposal Cost

Eight proven benefits from upgrading to quality Synthetic Air Compressor Lubricants in Rotary Vane Type Compressors:
1- Saves 8%-12% in Electrical Usage in Rotary Vane Type Compressors
2- Creates Less Friction which Equals Less Wear
3- Synthetic Oil Lasts up to 4 Times Longer than mineral based oils
4- No Carbon build-up in Vanes or Ports
5- Results in Thermal Stability & Solvency
6- No Seasonal Oil Change
7- Less Impact on the Environment
8- Save Money on Labor & Disposal Costs

Upgrading to a good quality Synthetic Compressor Oil gives you leading edge technology in lubricants:
- Profit from big savings overall, even though the initial cost a bit more
-Improve fire-resistance because of the properties of synthetic oils. Cleaner valves and less lubricant reduce the chance of fires and explosions in reciprocating air compressor systems
-Synthetic oils provide cleanliness in reciprocating air compressor crankcases that result in better heat transfer and prevention of moving parts sticking. The result can be less power usage.

There are lots of high-tech, scientific reports about synthetic lubricants you could read, but the bottom line is this: Upgrade to Synthetic Air Compressor Lubricants and save time and money!

Note: Not all synthetic compressor oils are the same. The quality and quantity of the base stocks and additives package are where the difference is. Remember the old saying – “You get what you pay for”? In this case – it’s really is true. Make sure when you upgrade from mineral oil to synthetic that you drain the mineral oil for a complete change. Don’t just “ADD” the synthetic oil to the old mineral oil.

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

How much does your air compressor cost you in electrical energy?

noreply@blogger.com (McGuireAir) — Wed, 27 Apr 2011 17:05:00 +0000

Before we see how much electricity costs, we have to understand how it’s measured. When you buy gas they charge you by the gallon. When you buy electricity they charge you by the kilowatt-hour (KWH). When you use 1000 watts for 1 hour - that unit of energy is called a kilowatt-hour. The kilowatt hour is most commonly known as a billing unit for energy delivered to consumers by electric utilities.

Once you know how much it is costing you in electrical energy…what can you do to REDUCE those costs and save money?

Seven Steps to figure the electrical energy cost of running your air compressor:
Take these first 3 steps to figure your Electrical Cost per Kilowatt Hour (KWH) (we shall use some average examples to help you see how this works)

1. Find your electrical utility bill for the facility where your air compressor operates and find your total amount due on your utility bill.

2. From your utility bill, find the total kilowatts used

3. Use this FORMULA: Total Amount Due ÷ Total KWH Used = KWH Cost

Example:Total Dollar Amount Due Ex: $300.00
Total KWH Used Ex: 2500
Amount Due Divided By Total KWH Used
$300.00 Due ÷ 2500 KWH Used = 0.12 Per KWH
Results: Your Cost Per Kilowatt Hour is $0.12 Cents
(you will use your cost per KWH in the next formula)

In the next 4 Steps – let’s figure the ELECTRICAL ENGERY COST of running your Air Compressor
(we shall use some average examples to help you see how this works)

4. Determine your TOTAL HORSEPOWER (TOTAL HP) using this formula:
Motor Data Plate HP (EX: 25HP) X 110% = (27.5 HP)
NOTE: Most air compressors @ Max PSI use 110% of the rated horsepower

5. Figure your YEARLY HOURS of operation:
# Hours running per day X # days per week X # weeks per year running = The total time the equipment runs in a year.
(Example: 10 Hours Per Day X 5 Days Week X 52 Wks = 2600 HOURS)

6. Find your MOTOR EFFICIENCY (EFF):
MOTOR EFFICIENCY can be found on the motor data plate as a percentage.
(Example=.90 %) It is the ratio of input power minus the output power.

7. Use this FORMULA:
Total HP x .746* x yearly hours compressor operates x KWH cost ÷ motor efficiency = Your Annual Electrical Cost to Operate Your Air Compressor

Using our EXAMPLES given…you can see how to figure your annual electrical costs:
27.5 hp x .746* x 2600 hours x $.12 ÷ .90 = $7111.87 per year to run your air compressor

EXAMPLE ANNUAL ELECTRIAL COST FOR COMPRESSED AIR = $7111.87

Most likely – your air compressor’s electrical costs were a lot more than you thought. Now that you know how much your Air Compressor is costing you in electrical energy…what can you do to REDUCE those costs and save money?
_______________________________________

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

*NOTE: Where does the “.746” come from?
746 watts per hour of electrical energy is required to convert to 1 Horsepower of mechanical energy. KWH= your cost per 1000 watts of electrical energy per hour. KILOWATTS per HP = .746 watts

What size piping does your compressed air system need?

noreply@blogger.com (McGuireAir) — Wed, 09 Feb 2011 16:10:00 +0000

Figuring the correct pipe size for your compressed air distribution system is an important task. Pipe that is sized too small can create big pressure losses and reduce operating efficiency. Replacing piping is costly. On average, 70% of a contracted piping job goes for labor and 30% for materials.
Do you know the biggest mistakes made in figuring compressed air piping sizes?

Many people who plan the piping never consider the fittings or the future.

FITTINGS: Every pipe fitting creates a certain amount of increased frictional air loss that is equal to a specified length of pipe. For every 100 feet of pipe you will have a ONE POUND PRESSURE DROP caused by frictional air loss.
Any turns in the pipe at fittings, ells, tees, and valves increase pressure drops even more. That’s why the EQUIVALENT LENGTH OF PIPE (FT.) for PIPE FITTINGS chart was developed to help you determine the best pipe size for your system.

FUTURE:
Are you planning to add more equipment in the next year or two? Then plan for larger piping now. Since the material costs in piping are low compared to installation or replacement cost, it’s wise to select pipe of an adequate size. If there is any doubt that a pipe size may create a pressure drop, use the next largest size. Remember that an oversize pipe compensates for possible scale build-up and provides for future expansion of the overall air system.

Steps to figuring what size piping your compressed air system needs:

1.     Determine your air compressor’s maximum CFM.

2.     Draw a piping schematic and show all pipe fittings, valves, etc.

3.     Measure and write the corresponding lengths of pipe on your schematic, then total the length of all straight pipes needed and note that on your schematic.

4. Using TABLE 1 find your compressor’s CFM number on the far left column, and then go to the right until you see the column header with nearest length in feet to your total pipe length. Find where the CFM & PIPE LENGTH intersect on the chart and it will show the recommended pipe size for that length.

5.     Take that pipe size to TABLE 2 and use the table to find all the EQUIVELENT LENGTHS OF PIPE needed for each PIPE FITTING. Write these lengths on your piping schematic at each fitting.

6.     TOTAL all the EQUIVELENT LENGTHS OF PIPE needed for each PIPE FITTING and add to your total of straight length of pipe. This will give you a new and more accurate total pipe length needed.

7. Take your new total of EQUIVELENT LENGTH OF PIPE IN FEET back to TABLE 1 and use this number to determine the PIPE SIZE you need.

8. Think of the FUTURE!

Now is the time to plan for larger piping that may needed for additional future equipment.

Table 1

Table 2

For more information on Compressed Air Basics visit

http://www.industrialaircompressors.biz/free-basic-compressed-air-information

McGuire Air Compressors, Inc.
336-229-9999

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How to get the most out of your Air Compressor

noreply@blogger.com (McGuireAir) — Tue, 29 Jun 2010 13:44:00 +0000

Get the most out of your Air Compressor by establishing a regular, well-organized maintenance program and strictly following it.

Such a program is critical to maintaining the performance of a compressed air system and will save you time and money in the long haul. You should use the standard recommended minimum maintenance procedures for air-cooled reciprocating compressors as listed in the checklist below.

One person should be given the responsibility of ensuring that all maintenance is performed properly, on schedule, and is adequately documented.

IMPORTANT:
Before performing any maintenance function:
• Switch main disconnect switch to "off" position to assure no power is entering unit.
• "Lock Out" or "Tag Out" all sources of power.
• Be sure all air pressure in unit is relieved. Failure to do this may result in injury or equipment damage.

DAILY MAINTENANCE OR (every 8 hours)
1. Check oil level of both compressor and engine if so equipped. Add quality lubricating oil as required.
2. Drain moisture from tank by opening tank drain valve located in bottom of tank.
3 Check for any unusual noise or vibration
4. Turnoff compressor at the end of each day's operation. Turn off power supply at wall switch.

WEEKLY MAINTENANCE OR (every 100 hours)
1. Clean dust and foreign matter from cylinder head, motor, fan blade, air lines, intercooler and tank.
2. Remove and clean intake air filters.
3. Check V-belts for tightness. The V-belts must be tight enough to transmit the necessary power to the compressor

MONTHLY MAINTENANCE OR (every 500 hours)
1. Change crankcase oil if using CHAMPLUB hydrocarbon based reciprocating oil.
2. Check entire system for air leakage around fittings, connections, and gaskets, using soap solution.
3. Tighten nuts and cap-screws as required.
4. Check and clean compressor valves, replace worn or damaged assemblies & gaskets
5. Pull ring on all pressure relief valves to assure proper operation.

ANNUAL MAINTENANCE OR (every 4000 hours)
1. When CHAMPLUB synthetic lubricant is used, lubricant change intervals may be extended to every 4,000 hours or annually whichever occurs first (change more frequently in harsher conditions).
2. Maintain lubricant level between high- and low-level marks on bayonet gauge. (Discoloration or a higher lubricant level reading may indicate the presence of condensed water). If lubricant is contaminated, drain and replace.

Click Here to Download a Free Reciprocating Maintenance Service Record Checklist Sheet

For your next order of Compressor Lubricants and Filters –
call 336-229-9999…
Or click here for SERVICE KITS and Lubricants

McGuire Air Compressors
336-229-9999
Email: compressors@mcguire.biz

http://www.industrialaircompressors.biz/

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Four keys to maintaining an efficient compressed air system

noreply@blogger.com (McGuireAir) — Tue, 25 May 2010 17:36:00 +0000

Key #1: PREVENTIVE MAINTENANCE
"What is the key to maintaining an efficient compressed air system?"
The best reply would have to be -- Preventive Maintenance.

WHAT IS PREVENTIVE MAINTENANCE?
According to "Wikipedia": Preventive maintenance (PM) has the following meanings:
"The care and servicing by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects. Maintenance, including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring."

*Source: from Federal Standard 1037C and from MIL-STD-188 and from the Department of Defense Dictionary of Military and Associated Terms

Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on. In addition, workers can record equipment information and deterioration so they know to replace or repair worn parts before they cause system failure.
The ideal preventive maintenance program would prevent all equipment failure before it occurs.

BENEFITS OF PREVENTIVE MAINTENANCE:
-Improves system reliability and helps keep equipment working and/or extend the life of the equipment.
-Decreases system downtime and actively helps prevent unbudgeted maintenance expenses from cropping up.
-Decreases the cost of having to replace equipment as often.
-Records operational data that can help you troubleshoot an emerging problem (called "Data Trending")
Data trending is the recording of basic operation parameters including pressures, temperatures, and electrical data. For example, a slowly increasing temperature indicates a variety of maintenance requirements including cooler core cleaning, overloading of system and possible mechanical problems. Another example might include slowly decreasing pressure, indicating increased system flow requirements, reduced compressor performance or increased system leakage. Make sure someone is looking at this data on a regular basis. If the data is never reviewed then the benefit is lost.

THE VALUE OF PREVENTIVE MAINTENANCE:
To determine how valuable regular air compressor PM is to you and your business... you need to know what your "down-time" is worth. In some operations, down-time can cost hundreds, even thousands of dollars an hour.

There are many misconceptions about preventive maintenance...one being that it costs too much.
This line of thinking says regularly scheduled downtime for maintenance costs more than operating the equipment until repair is absolutely necessary...or until the equipment breaks. This may be true for some components, but don't forget to consider the long-term benefits and savings associated with preventive maintenance that have been previously mentioned.
If regular Preventive Maintenance can help reduce unexpected downtime that results in loss of production, time and materials or the ruining of an expensive plant process--then it is well worth the investment. Not to mention that unscheduled shut-downs can be extended if the correct equipment parts or repair technicians are not readily available.

"How effective is your PM program?"
The answer is: "If your PM program isn't finding problems, it isn't effective."

Key #2: CORRECTIVE MAINTENANCE
Corrective maintenance, usually called "repair", is conducted to get equipment working again or fix any problems found during Preventive Maintenance.
The primary goal of maintenance is to avoid or reduce the consequences of failure of your compressed air equipment. PM is designed to preserve and restore equipment reliability by replacing worn components before they actually fail.

Key #3: ASSESSING YOUR EQUIPMENT:
When to maintain and when to replace.
Here are several factors to consider when assessing your compressed air equipment:
-How critical is your compressed air equipment? If equipment fails, what is the impact on production or safety.
-What is the age & history of your equipment.
Equipment histories will prove that most failures occur during infancy (newly installed or recently overhauled) and old-age (self-explanatory).
How many times has this equipment failed in the past?
-How much do you trust this equipment to perform as designed when scheduled to run?
-Do you need newer technology on your equipment?
Assessing the answers to these questions will help you determine when your older equipment needs fixing or replacing. Preventive Maintenance will help your equipment last longer, run better, and save you loads of money in the long haul.

Key #4: KNOWING YOUR EQUIPMENT WHAT IT NEEDS:
-Every piece of compressed air equipment should come with a set of MAINTENANCE INSTRUCTIONS and some type of operations& parts manual. Your operators should review the equipment information and keep it handy for future reference. If you purchased used equipment and don’t have the manuals, contact your equipment distributor for a copy.
- Follow the maintenance guidelines for your equipment.

Click here to view and download a Preventive Maintenance Checklist

Top 7 Air Compressor Related Formulas

noreply@blogger.com (McGuireAir) — Tue, 27 Apr 2010 17:53:00 +0000

Anyone who works with or helps maintain an industrial air compressor should have these valuable compressor related formulas. Print them out and keep them handy…you might need one of them next week!

1. Formula To Find: Belt Length
Compressor Flywheel OD + Motor Pulley OD X 1.57 + 2 X Shaft’s Center To Center Distance In Inches

2. Formula To Find: Motor Pulley OD
Compressor Flywheel OD X Compressor Rpm’s / Motor Rpm’s

3. Formula To Find: Tank OD
Measure Circumference / 3.1416

4. Formula To Find: Volume Of Tank In Gallons
Tank OD X OD X .785 X Tank Length In Inches / 231

5. Formula To Find: PSIA Pressure
14.7 + Gauge Pressure

6. Formula To Find: Compressor CFM Using The Time Method
Tank Gallons X .536 X PSIG Increase / Total Seconds

7. Formula To Find: Motor Max AMP Draw Before Damage Begins
Motor Data Plate AMPS X Data Plate Service Factor

FORMULA SYMBOLS & DEFINITIONS:
/ = divide
X = multiply
+ = add

AMPS = Abbreviation of the plural for Ampere, a unit of electrical current

CFM or cfm = Abbreviation of Cubic feet per minute - a unit of measurement of the flow of a air/gas or liquid that indicates how much volume in cubic feet pass by a stationary point in one minute.

OD = Abbreviation for Outside diameter is a dimension commonly used to specify the size of tubing or pipe.

PSIA or psia = Abbreviation for Pounds per square inch absolute (including atmospheric pressure)

PSIG or psig = Abbreviation for Pounds per Square Inch Gauge

RPM or rpm = Abbreviation for Revolutions per minute is a unit of frequency of rotation: the number of full rotations completed in one minute around a fixed axis. It is used as a measure of rotational speed of a mechanical component.

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

Top 12 Compressed Air Safety Guidelines

noreply@blogger.com (McGuireAir) — Fri, 20 Nov 2009 19:36:00 +0000

Top 12 Compressed Air Safety Guidelines

1. Never apply compressed air to the skin or direct it at a person. Even air at a pressure of 15 psig can cause serious injury. Never use a compressed air hose to clean dirt or dust from your clothing or body.

2. When using compressed air for cleaning purposes, ensure pressure does not exceed 30 psig (per OSHA regulations). Always use goggles or a face shield over approved safety glasses for this application.

3. Wear ear protection. Exposure to excessive noise can damage hearing. Noise reducing mufflers can be fitted to machines to lessen the noise health hazard.

4. Never crimp, couple, or uncouple pressurized hose. Shut off valves and bleed down pressure before making any hose connections.

5. Use heavy duty clamps and fittings made especially for compressed air hose.
Use only the correct type and size of hose end fittings and connections.

6. Never use frayed, damaged or deteriorated hoses. Always store hoses properly and away from heat sources or direct sunlight. A hose failure can cause serious injury. Hose Reels can decrease your chances of injury, as well as help hoses last longer.

7. When blowing compressed air through a hose or air line, ensure that the open end is held securely. A free end can whip and can cause injury. Open the supply air valve carefully and ensure that any ejected particles will be restrained. A blocked hose can become a dangerous “compressed air gun.”

8. Make sure all hoses exceeding 1/2 inch ID have a safety device at the source of supply or branch line to reduce the pressure in case of hose failure (per OSHA regulations).

9. Do not use air directly from a compressor for breathing purposes unless the system has been specifically designed for such purpose and suitable breathing air filters and regulators are in place.

10. Isolating valves should be of the self venting type and designed to be locking in the "off" position so that air pressure cannot be applied accidentally while the machine is being worked on.

11. Never alter or install an A.S.M.E. safety relief valve that has a higher PSIG rating than the pressure vessel rating to which it is installed.

12. Only pressure vessels built to a national or international standard should be used for air receivers.

Provided for your safety by
McGuire Air Compressors, Inc.
336-229-9999
compressors@mcguire.biz
industrialaircompressors.biz

TOP TEN Compressed Air "Rules of Thumb"

noreply@blogger.com (McGuireAir) — Fri, 09 Oct 2009 18:02:00 +0000

Here are our TOP TEN Compressed Air "Rules of Thumb" that we've come up with throughout our 44+ years of experience. These are the things that our compressor customers seem to ask about most.

1. Air Compressor CFM delivery per Horse Power at 100 PSIG:
• For "home owner" type of air compressors---2 to 2.5 CFM per HP
• For Industrial Air-cooled 2-stage air compressors----3.5 CFM per HP
• For Small Vane & Screw air compressors (25 HP or less) 4 CFM per HP
• For large Piston, Screw & Centrifugal air compressors--4.5 to 5 CFM per HP

NOTE: THE MORE CFM PER HP - THE LESS ENERGY USED.

2. Air Receiver Size needed for these types of inlet control:
• Modulating Control------------ 0 to 1 gallon per CFM
• On-Line/Off-Line-------------- 3 to 4 gallons per CFM
• Stop-Start / Variable Speed--- 4 to 6 gallons per CFM

NOTE: THE MORE AIR STORAGE - THE LESS ENERGY USED

3. Amperage per Horse Power:
115 Volts-------1 phase--------10 amps per horse power
230 Volts-------1 phase-------- 5 amps per horse power
208 Volts-------3 phase-------- 3 amps per horse power
230 Volts-------3 phase-------- 2.5 amps per horse power
460 Volts-------3 phase-------- 1.25 amps per horse power
574 Volts-------3 phase-------- 1 amp per horse power

NOTE: THE MORE ENERGY EFFICIENT THE MOTOR - THE LESS ENERGY
IS USED.

4. Air Piping Size by CFM and Pressure Drop:
• Compressor Room Header--0.25 PSIG pressure drop per 100 feet of piping
• Main Line---------------0.5 PSIG pressure drop per 100 feet of piping
• Loop Line---------------1 PSIG pressure drop per 100 feet of piping
• Branch Line-------------2 PSIG pressure drop per 100 feet of piping

NOTE: THE LESS AIR PRESSURE DROP - THE LESS ENERGY USED.

5. Size Compressed Air Line Filters to be twice (2x) your compressor CFM flow rate.
• This will lower your pressure drop approximately 2-3 PSIG and save 1% on energy costs.
• Elements will last twice (2x) as long and save on maintenance costs.

6. Lowering Compressor Pressure settings 2 PSIG will result in a 1% energy savings.

7. Lowering Compressor Inlet Air Temperature 10° F will result in a 2% energy savings.

8. The average energy cost to operate an air compressor is approximately $0.10 per horse power per hour.

9. Compressed air system leaks totaling the size of a ¼" orifice, at 100 PSIG, running 24 hours a day will waste approximately $15,000 worth of electrical energy a year.

10. Using Synthetic Compressor Lubricants can save you up to 9% of the energy cost of operating your compressor.

>>>>Click here to learn more about basic air compressor maintenance>>>>

McGuire Air Compressors
336-229-9999
email: compressors@mcguire.biz

https://industrialaircompressors.biz/

https://airdryers.biz/

https://hosereels.biz/

Warm weather increases harmful compressed air moisture

noreply@blogger.com (McGuireAir) — Tue, 09 Jun 2009 18:04:00 +0000

Ask a Question:
There is more moisture in my compressed air in the warm weather. Can this water or moisture be damaging my compressed air system?

Answer:

Absolutely! Water corrodes pipes, valves, machinery controls. None of this is good. When controls malfunction, production can stop or product can be impaired and all this costs you time and money.
In summer’s warmer temperatures moisture and condensation occurs more frequently.

Why? The reason is warm air can hold more moisture than cooler air. Therefore when the temperatures rise in the heat of spring and summer, then the amount of moisture in the air around you and your compressed air also rises. In more humid regions of the country, compressed air systems can be challenged by this moisture increase.

Many processes need to remove moisture from their compressed air. One such example is spray painting. Condensed water droplets in a painting process can ruin the end result. Other examples are pharmaceutical production and medical applications that need clean, dry compressed air.

Ask a Question:

How does water or moisture get into my compressed air?

Answer:
Through your Compressor inlet.

Water vapor (humidity-moisture) enters the air system through the air compressor inlet air filter.
The air compressor sucks in approximately 7 cubic feet of atmospheric air at 0 psig, and that volume of air is compressed into 1 cubic feet of air at 100 psig.

The water vapor (humidity-moisture) that was in the seven (7) cubic feet of atmospheric air is now compressed into ONE (1) cubic feet of compressed air.

There are 3 forms of water in compressed air:

1. Liquid water
2. Aerosol (mist)
3. Vapor (gas)

Water in Aerosol or Vapor form is more difficult to remove and requires the use of a Compressed Air Dryer.
Refrigerated Air Dryers can be the solution to water and moisture in your Compressed Air System

HOW A REFRIGERATED AIR DRYER WORKS

The refrigerated air dryer cools the incoming compressed air first in an air-to-air heat exchanger where the outgoing cool dry air pre-cools the hot incoming air and condenses some moisture out.

Then the incoming air enters an air-to-refrigerant heat exchanger where the air is cooled to 38º F by the liquid refrigerant. This process causes the moisture to condense into liquid water and it is drained away.

The out going air then enters the air-to-air heat exchanger and is warmed up to keep the outside of pipes from sweating.

The refrigeration compressor pumps hot hi-pressure gas refrigerant (Freon) into the condenser which transfers the heat from the refrigerant gas to the ambient air as the gas condenses into a liquid.

The liquid refrigerant (Freon) is then metered to a cold low pressure where it enters the air-to-refrigerant heat exchanger and the heat from the hot compressed air is adsorbed into the cold refrigerant (Freon). The refrigeration compressor then sucks low pressure hot gas refrigerant (Freon) into the refrigeration compressor and the cycle starts over again.

McGuire Air Compressors
“Real People with Real Air Compressor Experience”
336-229-9999
Email: compressors@mcguire.biz

https://industrialaircompressors.biz/

https://airdryers.biz/

https://hosereels.biz/

How to prevent moisture from damaging your compressed air system

noreply@blogger.com (McGuireAir) — Fri, 01 May 2009 15:44:00 +0000

Ask a Question:
Can moisture damage my compressed air system?

ANSWER:
Liquid water in a compressed air stream increases the cost of operation. It contributes to unnecessary product rejects and countless hours of unscheduled maintenance. Air tool lubricant gets washed away creating unnecessary wear. Highly acidic, this condensed water eats away at air motors and valves and, contaminates finished goods.
Invest in the correct drying technology for your application and the compressed air lines stay dry. Dry air will also pay your big dividends for years to come.

Ask a Question:
How does damaging moisture get in your compressed air system?

ANSWER:
At an ambient temperature of 75°F and 75% relative humidity, a typical 100 HP (500 scfm) air compressor inhales 90 gallons of water vapor every 24 hours. Discharging air at 100°F and 100 psig, a well maintained aftercooler may remove about 57 gallons. That leaves 33 gallons inside your air system.

At the CAGI ADF 100 design standard of 38°F, a refrigerated dryer removes an additional 29 gallons. The remaining 4 gallons safely pass through the system as water vapor. Because there is usually a rise in air temperature during compression, condensation often does not occur within your compressor itself.

Condensation in your compressed air system usually happens as compressed air cools when passing through the discharge piping. This condensed water must be drawn out of your line by a separator and a trap. While approximately two-thirds of the water vapor is converted to liquid from the system in an effective aftercooler, there is still a lot of water vapor remaining in the compressed air which is "saturated" at the exit temperature from the aftercooler.

Compressed Air Dryers have been designed and developed to help remove water vapor from the compressed air in a controlled manner in order to provide you with a required "quality of dry air" needed for your equipment and processes.

Ask a Question:
How DRY should my compressed air be?

ANSWER:
"Dryness" can be relative. Air that is dry for one type of application my not be dry enough for another. There will always some moisture present in your compressed air system regardless of the degree of drying.
There are different types of dryers available with varying degrees of moisture removal. First - you need to determine the required "degree of dryness" for your Compressed Air System, which is specified in the "Pressure Dew Point" (PDP) at a certain pressure.

It is not a good practice to specify a pressure dew point a lot lower than your application's requirements. This can result in more costly equipment and increased operating expenses. Determining the PRESSURE DEW POINT TEMPERATURE will help you determine the "dew point class" of the dryer you need.

Ask a Question:
What is "PRESSURE DEW POINT"?

ANSWER:
Pressure Dew Point - For a given pressure, the temperature at which water VAPOR will begin to condense INTO liquid water.

Ask a Question:
What pressure dew point do I need?

ANSWER:
First - here's some information to help you understand pressure dew point: The lowest pressure dew point class for a refrigerated dryer is Class 4. Class 4 delivers a pressure dew point of +38°F.
Refrigerated dryers should not operate below the Class 4 range because the water vapor will freeze in the dryer. The highest pressure dew point for a refrigerated dryer is Class 6. Class 6 delivers a pressure dew point of +50°F.
The highest practical pressure dew point because higher pressure dew point causes condensation in downstream piping.

WAYS TO DETERMINE PRESSURE DEW POINT:
1. Ask the Manufacturer what the pressure dew point (PDP) requirements are for your equipment.
2. You can CALCULATE PRESSURE DEW POINT TEMPERATURE you need.

Here's how:
1. Determine the lowest ambient temperature your compressed air piping system will be exposed to.
Check the location of air lines throughout air conditioned or unheated areas underground or between buildings. (For example, your compressor and piping is inside your facility and the lowest air temperature it would ever be exposed to is 58ºF.)

2. Now you need to take that temperature number and lower it by 20º. (For example, your 58ºF lowest ambient temperature -20º = (38º PDP NEEDED)
This will give the PRESSURE DEW POINT TEMPERATURE needed to prevent liquid water forming downstream.

Determining the PRESSURE DEW POINT TEMPERATURE will help you determine the "dew point class" of the dryer you need. These "classifications" are industry standards for compressed air dryers as established by the ISO (International Organization for Standardization).

ISO 8573.1 AIR QUALITY CLASSES of PRESSURE DEW POINTS
THAT APPLY TO REFRIGERATED AIR DRYERS:
Class 4 maximum pressure dew point +38 º F
Class 5 maximum pressure dew point +45 º F
Class 6 maximum pressure dew point +50 º F

The lower the dew point, the dryer the air. These "classifications" are industry standards for compressed air dryers are established by the ISO (International Organization for Standardization).

Ask a Question:
What is the most popular type of compressed air dryer?

ANSWER:
The REFRIGERATED AIR DRYER has become the most widely used dryer in general industrial plant air applications, providing a pressure dew point of 35°F to 39°F.

Refrigerated dryers deliver 33°F to 39°F dew point to provide the best value with low initial cost and low cost of operation. They are the best choice when the ambient temperature where the compressed air is used will remain higher than the pressure dew point. A 33°F to 39°F dew point is ideal for most indoor areas wherepeople comfort is maintained.

Ask a Question:
How does a Refrigerated Air Dryer work?

ANSWER:
The basic principle is similar to a domestic refrigerator or home air conditioning system. The compressed air is cooled in an air-to-refrigerant heat exchanger to about 35°F, at which point the condensed moisture is drained off. The air is then reheated in an air-to-air heat exchanger by means of the incoming air, which also is pre-cooled before entering the air-to-refrigerant heat exchanger.

This means that the compressed air leaving the dryer has a pressure dew point of 35°F to 40°F. A lower dew point is not feasible in this type of dryer as the condensate would freeze at 32°F or lower. In a non-cycling refrigerated dryer, the refrigerant circulates continuously through the system.

Because both the flow of compressed air and ambient temperatures vary, a hot gas bypass valve is often used to regulate the flow of the refrigerant and maintain stable operating conditions within the refrigerant system.
Usually in most designs, the refrigerant evaporated within the air-to-refrigerant heat exchanger (evaporator) and is condensed after compression by an air- or water-to-refrigerant heat exchanger (condenser.) This type of design provided a rapid response to changes in operating loads.

Four Advantages of Refrigerated Air Dryers:
• Low initial capital cost
• Relatively low operating cost
• Low maintenance costs
• Not damaged by lubricant in the air system

*Refrigerated air dryers do have a limited dew point capability. Where a pressure dew point of less than 35°F is required, a refrigerant-type dryer cannot be used.

For more in-depth information visit www.AirDryers.biz

Compressed air definitions you should know from Compressed Air & Gas Institute:
Dew Point - The temperature at which moisture in the air will begin to condense if the air is cooled at constant pressure. At this point the relative humidity is 100%.Dew points may be expressed at an operating pressure or at atmospheric pressure. Operating pressure should be specified when using "pressure dew point."

Pressure Drop - Loss of pressure in a compressed air system or component due to friction or restriction.Typically, the pressure drop through a compressed air dryer is 3 to 5 psi and should be taken into account in system requirements.

SOURCES:"Improving Compressed Air System Performance- A sourcebook for industry" U.S. Department of Energy Energy Efficiency and Renewable Energy; "Best Practices for Compressed Air Systems" by CA; Compressed Air & Gas Institute (CAGI).

Keys to maintaining an efficient compressed air system

noreply@blogger.com (McGuireAir) — Fri, 23 Jan 2009 16:17:00 +0000

Ask a Question:
"What are the keys to maintaining an efficient compressed air system?"

Answer:
Key #1: PREVENTIVE MAINTENANCE

"What is the key to maintaining an efficient compressed air system?" The best reply would have to be -- Preventive Maintenance.

WHAT IS PREVENTIVE MAINTENANCE?
According to "Wikipedia": Preventive maintenance (PM) has the following meanings:

"The care and servicing by personnel for the purpose of maintaining equipment
and facilities in satisfactory operating condition by providing for systematic
inspection, detection, and correction of incipient failures either before they
occur or before they develop into major defects. Maintenance, including tests,
measurements, adjustments, and parts replacement, performed specifically to
prevent faults from occurring."

*Source: from Federal Standard 1037C and from MIL-STD-188 and from the Department of Defense Dictionary of Military and Associated Terms

Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on. In addition, workers can record equipment information and deterioration so they know to replace or repair worn parts before they cause system failure.

The ideal preventive maintenance program would prevent all equipment failure before it occurs.

BENEFITS OF PREVENTIVE MAINTENANCE:
-Improves system reliability and helps keep equipment working and/or extend the life of the equipment.
-Decreases system downtime and actively helps prevent unbudgeted maintenance expenses from cropping up.
-Decreases the cost of having to replace equipment as often.
-Records operational data that can help you troubleshoot an emerging problem (called "Data Trending")
Data trending is the recording of basic operation parameters including pressures, temperatures, and electrical data. For example, a slowly increasing temperature indicates a variety of maintenance requirements including cooler core cleaning, overloading of system and possible mechanical problems. Another example might include slowly decreasing pressure, indicating increased system flow requirements, reduced compressor performance or increased system leakage. Make sure someone is looking at this data on a regular basis. If the data is never reviewed then the benefit is lost.

THE VALUE OF PREVENTIVE MAINTENANCE:
To determine how valuable regular air compressor PM is to you and your business... you need to know what your "down-time" is worth. In some operations, down-time can cost hundreds, even thousands of dollars an hour.

There are many misconceptions about preventive maintenance...one being that it costs too much. This line of thinking says regularly scheduled downtime for maintenance costs more than operating the equipment until repair is absolutely necessary...or until the equipment breaks. This may be true for some components, but don't forget to consider the long-term benefits and savings associated with preventive maintenance that have been previously mentioned.

If regular Preventive Maintenance can help reduce unexpected downtime that results in loss of production, time and materials or the ruining of an expensive plant process--then it is well worth the investment. Not to mention that unscheduled shut-downs can be extended if the correct equipment parts or repair technicians are not readily available.
"How effective is your PM program?"
The answer is: "If your PM program isn't finding problems, it isn't effective."

Key #2: CORRECTIVE MAINTENANCE
Corrective maintenance, usually called "repair", is conducted to get equipment working again or fix any problems found during Preventive Maintenance.

The primary goal of maintenance is to avoid or reduce the consequences of failure of your compressed air equipment. PM is designed to preserve and restore equipment reliability by replacing worn components before they actually fail.

Key #3: ASSESSING YOUR EQUIPMENT: When to maintain and when to replace.

Here are several factors to consider when assessing your compressed air equipment:
-How critical is your compressed air equipment? If equipment fails, what is the impact on production or safety.
-What is the age & history of your equipment.
Equipment histories will prove that most failures occur during infancy (newly installed or recently overhauled) and old-age (self-explanatory).
How many times has this equipment failed in the past?
-How much do you trust this equipment to perform as designed when scheduled to run?
-Do you need newer technology on your equipment?

Assessing the answers to these questions will help you determine when your older equipment needs fixing or replacing. Preventive Maintenance will help your equipment last longer, run better, and save you loads of money in the long haul.

Key #4: KNOWING YOUR EQUIPMENT WHAT IT NEEDS:
-Every piece of compressed air equipment should come with a set of MAINTENANCE INSTRUCTIONS and some type of operations& parts manual. Your operators should review the equipment information and keep it handy for future reference. If you purchased used equipment and don’t have the manuals, contact your equipment distributor for a copy.
- Follow the maintenance guidelines for your equipment.

BASIC PREVENTIVE MAINTENANCE CHECK LIST FOR
RECIPROCATING (PISTON) AIR COMPRESSORS:

Before performing any maintenance function, switch main disconnect switch to "off" position to assure no power is entering unit. "Lock Out" or "Tag Out" all sources of power. Be sure all air pressure in unit is relieved. Failure to do this may result in injury or equipment damage.

DAILY MAINTENANCE

1. Check oil level of both compressor and engine if so equipped. Add quality air compressor lubricant as required.
2. Drain moisture from tank by opening tank drain valve located in bottom of tank. Do not open drain valve if tank pressure exceeds 25 PSIG.
3. Stop, Look & Listen for any unusual noise, failure to compress, overheating, vibrations or belt slippage and correct before damage of a serious nature develops.
4. Turn off compressor at the end of each day's operation. Turn off power supply.

WEEKLY MAINTENANCE
1. Clean dust and foreign matter from cylinder head, motor, fan blade, air lines, intercooler and tank.
2. Remove and clean intake air filters
WARNING
Do not exceed 15 PSIG nozzle pressure when cleaning element parts with compressed air. Do not direct compressed air against human skin. Serious injury could result. Never wash elements in fuel oil, gasoline or flammable solvent.

3. Check V-belts for tightness. The V-belts must be tight enough to transmit the necessary power to the
compressor. Adjust the V-belts as follows:
a. Remove bolts and guard to access compressor drive.
b. Loosen mounting hardware which secures motor to base. Slide motor within slots of base plate to
desired position.
c. Check the manufacturer’s specifications for correct belt tension. Apply pressure with belt tension checker to one belt at midpoint span. Make further adjustments if necessary.
d. Check the alignment of pulleys. Adjust if necessary.
e. Tighten mounting hardware to secure motor on base.
f. Re-install guard and secure with bolts.

WARNING
Never operate unit without belt guard in place. Removal will expose rotating parts which can cause injury or equipment damage.

EVERY 90 DAYS OR 500 HOURS MAINTENANCE
1. Change crankcase oil. Use type and grade oil as specified.
2. Check entire system for air leakage around fittings, connections, and gaskets, using an ultrasonic leak detector or using soap solution and brush.
3. Tighten nuts and cap-screws as required.
4. Check and clean compressor valves, replace gasket valve assembly when worn or damaged.

CAUTION
Valves must be reinstalled in original position. Valve gaskets should be replaced each time valves are serviced.

5. Pull ring on all pressure relief valves to assure proper operation.

GENERAL MAINTENANCE NOTES:

PRESSURE RELIEF VALVE: The pressure relief valve is an automatic pop valve. Each valve is properly adjusted for the maximum pressure permitted by tank specifications and working pressure of the unit on which it is installed. If it should pop, it will be necessary to drain all the air out of the tank in order to reseat properly. Do not readjust.

TANK DRAIN VALVE: Drain valve is located at bottom of tank. Open drain valve daily to drain condensation.
Do not open drain valve if tank pressure exceeds 25 PSIG. The automatic tank drain equipped compressor requires draining manually once a week.

PRESSURE SWITCH: The pressure switch is automatic and will start compressor at low pressure and stop when the maximum pressure is reached. It is adjusted to start and stop compressor at the proper pressure for the unit on which it is installed. Do not readjust.

BELTS: Drive belts must be kept tight enough to prevent slipping. If belts slip or squeak, see V-belt maintenance in preceding section.

CAUTION
If belts are too tight, overload will be put on motor and motor bearings.

COMPRESSOR VALVES: If compressor fails to pump air or seems slow in filling up tank, disconnect unit from power source, drain air tank, and remove valves and clean thoroughly, using compressed air and a soft wire brush.
After cleaning exceptional care must be taken that all parts are replaced in exactly the same position and all joints must be tight or the compressor will not function properly.
When all valves are replaced, perform a timed pump-up test and check to see that it meets factory specifications.
Valve gaskets should be replaced each time valves are removed from pump.

Bottom Line:

One of the main keys to maintaining an efficient compressed air system has been and still is “Preventive Maintenance.”

McGuire Air Compressors
“Real People with Real Air Compressor Experience”
336-229-9999
Email: compressors@mcguire.biz

For Champion Air Compressors...
https://industrialaircompressors.biz/

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

Do you meet OSHA’s guidelines for workplace hose safety?

noreply@blogger.com (McGuireAir) — Fri, 19 Dec 2008 15:24:00 +0000

How Hose Reels offer an effective and practical solution to minimizing potential accidents, while increasing safety and efficiency in all types of industries

Ask a Question:
What does OSHA say about workplace hose safety?

Answer:
An OSHA guideline publication states:

“Hoses, cables, and other equipment shall be kept clear of passageways, ladders and stairs.”

OSHA says reduce your slips, trips and falls.
Slips, trips and falls constitute the majority of general industry accidents, which cause 15% of all accidental deaths, and are second only to motor vehicles as a cause of fatalities. The OSHA standard for walking and working surfaces apply to all permanent places of employment, except where only domestic, mining, or agricultural work is performed. www.osha.gov

Consider adding reels to increase safety & efficiency with your electrical cords, welding cables, air hose, oil, grease, liquid/water or fuel hoses.

Ask a Question:
Why should my business use Hose Reels?

Answer:
If your business or plant has multiple air hoses, electrical cords or welding cables- then industrial air hose reels and cord and cable reels can be one of your most effective equipment additions you’ll ever make…as well as one of the safest!

How safe are your workplace walkways?

Hose reels are an important part of workplace safety. Tripping accidents- which include tripping over hose –unfortunately are a main cause listed on incident reports. Adding hose reels can provide a cost effective solution to helping reduce accidents, while increasing safety and efficiency in all types of industries.
Hose reels offer an effective and practical solution to minimizing potential accidents, while increasing safety and efficiency in all types of industries. Reels may be spring rewind, manual hand rewind, or in cases of very heavy, long hoses- motorized reels work best.

Five Reasons to use Air Hose Reels:

1. Efficiency- Hose reels make all your hose handling more efficient. - An organized, clean workplace is proven to be more efficie- Maintaining hose within easy reach saves time and money.- Reels also provide a quick and efficient way to store the hose, electrical cords or welding cables after each use…unlike an operator having to stop and coil them up manually. - Many industries strive to improve efficiencies (and safety) by implementing more efficient tools and equipment to increase productivity and reduce worker effort in doing a task. Reels are inexpensive and indeed are a "tool" that can help meet such goals.

2. Safety- Hoses, when not in actual use, left lying randomly coiled on the floor or ground, may present major tripping hazards and can result in injury.- Reels decrease you chances of injuries from tripping.- Reels prevent hose, cords and cable from cluttering walkways.- Using electrical cords or extension leads in industrial situations often presents significant safety hazards. The use of spring rewind electrical cord reels can offer significant safety benefits.- Reduce accidents and insurance expense…slips, trips and falls are the leading cause of work stoppage in industry.

3. Protects Equipment- Hoses, electrical cords, and welding cable can last five times longer when stored on a reel and help save you from replacing them as often.- Storing hoses, cords, and cables on reels prevents them from being stepped on or run over by equipment, increasing their service life.- Reels can often provide a solution for protecting electrical cables from damage when not in use, damage that could potentially cause electrocution.

4. Minimizes Leakages- Hoses on reels can reduce the threat of expensive air leakages.- Using hose reels reduces leakage and spills of expensive fluids.

5. Increase Productivity- Easily locating your air hoses when and where you need them can increase productivity. - Using hose, cord and cable reels benefits an employer by increasing the safety of the work environment and increasing efficiency.- All these factors help improve your work environment, which saves you time, equipment and money.

For more about Hose Reels visit www.hosereels.biz

What Contaminates Your Compressed Air?

noreply@blogger.com (McGuireAir) — Sat, 22 Nov 2008 22:49:00 +0000

Clean, dry, oil free compressed air and gas is a basic need for many industries.
One drop of unwanted oil can cause an entire automated process to malfunction.
It can cause seals in pneumatic valves and cylinders to swell, resulting in sluggish operation - or in worst cases, complete seizure of moving parts.

3 things that can contaminate your compressed air system and ruin your product or processes:

1) Solid particles come from ambient air contaminants like dust and from rusted, oxidized pipework. They will cause pneumatic equipment to malfunction, cause instrument and control failures, and contaminate end products.

2) Condensed water droplets come from the humidity in ambient air.
Water will oxidize pipework and pneumatic equipment, ruin paint finishes and end products.

3) Liquid oil and oil vapors are introduced by compressor lubricants and by hydrocarbon vapors present in ambient air. Oil-free compressed air is particularly important in food and pharmaceutical processes.

Compressed Air Filters effectively and efficiently remove solid particles, remnants of oil, water mist and other liquid from compressed air and gas which can...
-wear out pneumatic machinery
-block valves and orifices, causing high maintenance
-corrode piping systems which cause costly air leaks
-result in abrupt equipment stoppages, lost product, time and money

How to clean your Compressed Air...

Depending on the level of air purity required, different levels of filtration and types of filters are used. Filters are used in conjunction with other "filtering equipment" - such as a Water Separator or Compressed Air Dryer- to help remove harmful contaminates from your system.

General Purpose Filters - also called "particulate filters" are used to remove solid particles.
Oil and Oil Vapor Removal Filters - also called "coalescing-type filters" are used to remove oil and vapors.

A particulate filter is recommended after a desiccant-type dryer to remove desiccant fines.
A coalescing-type filter is recommended before a desiccant type dryer to prevent fouling of the desiccant bed.
Additional filtration may also be needed to meet requirements for specific end uses.
Compressed air filters downstream of the air compressor are generally required for the removal of
contaminants, such as particulates, condensate, and lubricant.

Listed below are types of filtration equipment available in today's market. The specifications offered are from Champion Air Compressors as a market example.

Water Separator
Installation: after an air compressors’ (or a stand-alone) aftercooler
Design: One-stage filtration with two stainless steel orifice tubes. Labyrinth style air flow path removes liquid water by forcing abrupt directional changes.
Performance*: Handles bulk liquid inlet loads to 30,000 ppm w/w and provides 10 micron solid particulate separation. Efficient to flows as low as 5% of rated flow.

Separator/Filter
Installation: after an air compressors’ (or a stand-alone) aftercooler or as a prefilter to a refrigerated dryer
Design: Two-stage filtration with first stage of two stainless steel orifice tubes which remove bulk liquids and solid particulates to 10 micron. Second stage has in-depth coalescing fiber media which captures solid particulates to 3 micron.
Performance*: Handles bulk liquid inlet loads to 25,000 ppm w/w and
provides 3 micron solid particulate filtration.

General Purpose Filter
Installation: 1 micron particulate prefilter for refrigerated dryers and high efficiency oil removal filters.
Design: Two-stage filtration with a first stage of multiple layers of fiber media which pre-filter the air. Second stage has in-depth coalescing fiber media which coalesces oil aerosols and removes finer particulates to 1 micron.
Performance*: Handles bulk liquid inlet loads to 2,000 ppm w/w, provides 1 micron solid particulate filtration and oil removal to 1 ppm.

Dry Particulate Filter
Installation: Dry, solid particulate after-filter for heatless desiccant dryers
Design: Two-stage filtration with life-prolonging outside/in air flow with first stage of alternate layers of fiber media and a media screen capturing large particulates. Second stage captures finer particulates. Not designed for any liquid loading.
Performance*: Provides 1 micron solid particulate filtration of desiccant dust.

High Efficiency Particulate Filter
Installation: Prefilter to desiccant and membrane dryers, after-filter to refrigerated dryers and stand-alone oil removal at the point-of-use of compressed air.
Design: Two-stage filtration with a first stage of multiple layers of fiber media which prefilter the air. Second stage has in-depth coalescing fiber media which coalesces oil aerosols. Includes an outer-coated, closed cell foam sleeve.
Performance*: Handles bulk liquid water inlet loads to 1,000 ppm w/w and provides 0.008 ppm oil aerosol removal and 0.01 micron solid particulate separation.

Maximum Efficiency Oil Removal Filter
Installation: Prefilter to desiccant and membrane dryers with a Grade C prefilter, oil-free air applications.
Design: Two-stage filtration with a first stage of a coated, closed-cell foam sleeve which acts as a prefilter and flow disperser. Second stage has in-depth coalescing fiber media which coalesces fine oil aerosols. Includes an outer-coated, closed cell foam sleeve.
Performance*: Handles bulk liquid water inlet loads to 100 ppm w/w and provides 0.0008 ppm oil aerosol removal and 0.01 micron solid particulate separation.

Oil Vapor Removal Filter
Installation: After-filter to high efficiency liquid oil removal filters for true oil-free applications.
Design: Two-stage filtration with a generously-sized first stage of a stabilized bed of carbon particles which remove the majority of the oil vapor. Second stage has multiple layers of fiber media with bonded microfine carbon particles which remove the remaining oil vapors. Includes an outer-coated, closed cell foam sleeve which prevents fiber migration.
Performance**: No liquid should be present at filter inlet. Provides 0.003 ppm w/w oil (as a vapor) removal and 0.01 micron solid particulate separation.

* Filter efficiencies have been established in accordance with CAGI standard ADF400 and are based on 100°F (38°C) inlet temperature
** Filter efficiency has been established in accordance with CAGI standard ADF500 and is based on 100°F (38°C) inlet temperature

FILTRATION TIPS:
Filtration only to the level required by each compressed air application will minimize pressure drop and resultant energy consumption.
Elements should also be replaced as indicated by pressure differential to minimize pressure drop and energy consumption, and should be checked at least annually.
You can customize your air treatment applications by choosing the combination of dryers, filters, and separators that give you the level of clean air or gas that you need.

Who establishes quality industry standards for filters?

ISO 8573.1 was developed in 1992 by ISO (International Organization for Standardization) to help plant engineers specify desired compressed air quality globally by providing “Quality Classes” for solid particulates, humidity and oil. Quality classes provide engineers with an internationally accepted unit of measure.

A typical pharmaceutical plant, for example, would have a compressed air specification of ISO Quality Classes 1.2.1.
This is equivalent to 0.1 micron particulate filtration, -40°F (-40°C) dew point, and 0.008 ppm (0.01 mg/m3) oil filtration.
No matter what language is spoken and what unit of measure is used, using ISO 8573.1 Air Quality Classes ensures that your factory will get the compressed air quality you specified.

McGuire Air Compressors
“Real People with Real Air Compressor Experience”
336-229-9999
Email: compressors@mcguire.biz

https://industrialaircompressors.biz/

https://airdryers.biz/

https://hosereels.biz/

How to tell when your compressor needs an air dryer

noreply@blogger.com (McGuireAir) — Wed, 08 Oct 2008 16:57:00 +0000

Ask a Question:

Can water or moisture be damaging my compressed air system?

Answer:

Absolutely! Water corrodes pipes, valves, machinery controls. None of this is good.

When controls malfunction, production can stop or product can be impaired and all this costs you time and money. Water in Aerosol or Vapor form is more difficult to remove and requires the use of a Compressed Air Dryer.

Ask a Question:

How does water or moisture get into my compressed air?

Answer:

Through your Compressor inlet.

Water vapor (humidity-moisture) enters the air system through the air compressor inlet air filter. The air compressor sucks in approximately 7 cubic feet of atmospheric air at 0 psig, and that volume of air is compressed into 1 cubic feet of air at 100 psig. The water vapor (humidity-moisture) that was in the 7 cubic feet of atmospheric air is now compressed into 1 cubic feet of compressed air.

There are 3 forms of water in compressed air:

Liquid water

Aerosol (mist)

Vapor (gas)

Any of these forms of moisture can create problems down the road in equipment or may create serious problems in your process or end product today.

Ask a Question:

How to tell if you need a Refrigerated Air Dryer?

Answer:

If you are experiencing the following problems...then you may need a Refrigerated Compressed Air Dryer:

Liquid water is in your air lines and hoses

Water vapor sprays out of your tool exhaust

Pipe lines corrode and rust

Paint Sprayer has water spots in the paint

Your Equipment Manufacturer specifies "DRY AIR"

Ask a Question:

What can help remove moisture from my Compressed Air System?

Answer:

Refrigerated Air Dryers can be one of the best solutions to removing water and moisture from youCompressed Air System.

Ask a Question:

How does a Refrigerated Air Dryer Work?

Answer:

• The refrigerated air dryer cools the incoming compressed air first in an air-to-air heat exchanger where the outgoing cool dry air pre-cools the hot incoming air and condenses some moisture out.

• Then the incoming air enters an air-to-refrigerant heat exchanger where the air is cooled to 38º F by the liquid refrigerant. This process causes the moisture to condense into liquid water and it is drained away. The out going air then enters the air-to-air heat exchanger and is warmed up to keep the outside of pipes from sweating.

• The refrigeration compressor pumps hot hi-pressure gas refrigerant (Freon) into the condenser which transfers the heat from the refrigerant gas to the ambient air as the gas condenses into a liquid.

• The liquid refrigerant (Freon) is then metered to a cold low pressure where it enters the air-to-refrigerant heat exchanger and the heat from the hot compressed air is adsorbed into the cold refrigerant (Freon). The refrigeration compressor then sucks low pressure hot gas refrigerant (Freon) into the refrigeration compressor and the cycle starts over again.

BOTTOM LINE:

If you are experiencing unwanted moisture and water in your Compressed Air System, then seriously consider the addition of a Refrigerated Air Dryer. After all - what is the best way to spend your money --on constant maintenance, failed equipment and ruined end products or by investing in a properly sized compressed air dryer?

Experience proves it! Remove Water and Moisture to improve Compressed Air Quality & Efficiency!

Increase Production - less down time due to moisture related equipment problems

Reduce loss due to inferior products ruined by moisture in lines

Bring more profit to your bottom line

Learn More about Refrigerated Air Dryers https://airdryers.biz/

McGuire Air Compressors
“Real People with Real Air Compressor Experience”
336-229-9999
Email: compressors@mcguire.biz

For Champion Air Compressors...
https://industrialaircompressors.biz/

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

Air Hose Leaks and Air Hose Saftey

noreply@blogger.com (McGuireAir) — Fri, 25 Jul 2008 15:01:00 +0000

Compressed Air ANSWERS & TIPS are
Important Information to pass on to those who work with
Your company’s compressed air systems & related equipment

How Air Hose Reels can save you time and money and increase satefy.
Plus - tips to prevent losing up to 30% of your compressed air because of
AIR LEAKS.

Ask a Question:
What does OSHA say about hose safety?

Answer: An OSHA guideline publication states:
“Hoses, cables, and other equipment shall be kept clear of passageways, ladders and stairs.”

OSHA says reduce your slips, trips and falls.
Slips, trips and falls constitute the majority of general industry accidents, which cause 15% of all accidental deaths, and are second only to motor vehicles as a cause of fatalities. The OSHA standard for walking and working surfaces apply to all permanent places of employment, except where only domestic, mining, or agricultural work is performed. www.osha.gov

Consider adding reels to increase safety & efficiency with your electrical cords, welding cables, air hose, oil, grease, liquid/water or fuel hoses.

Ask a Question:
Why should my plant use Air Hose Reels with our air tools?

Answer: If your business or plant has multiple air hoses running from your air compressor to a variety of air tools, then industrial air hose reels can be one of your most effective equipment additions you’ll ever make…as well as one of the safest!

Here’s 5 Reasons to use Air Hose Reels:
1. Efficiency
Hose reels make all your hose handling more efficient. An organized, clean workplace is proven to be more efficient.
2. Safety
Hose reels decrease you chances of injuries from tripping hazards. Reduce accidents and insurance expense: Slips, trips and falls are the leading cause of work stoppage in industry.
3. Protects Equipment
Hoses (and cords) last five times longer when stored on a reel. This can save you from replacing hoses as often.
4. Stops Leakages
Hoses on reels can reduce the threat of expensive air leakages.
5. Increase Productivity
Locating your air hoses when and where you need them increases productivity. All these factors help improve your work environment, which saves you time, equipment and money.

For more about Hose Reels visit www.hosereels.biz

Have you ever wondered what that hissing sound is when you walk through your plant or shop area? Most likely it’s a COMPRESSED AIR LEAK.

But what about the air leaks you can’t hear? Size cannot be judged by sound.

Do You know how much your AIR LEAKS are costing you?

A Department of Energy publications states:
“Compressed air leaks can account for 20% to 30% of compressors cfm output in small to medium size plants.”

In other words- you could be losing up to 30% of your compressed air because of AIR LEAKS! That’s your money leaking away! It is worth the effort to find and fix your air leaks.

Ask a Question:
How do you estimate the SIZE and COST of an AIR LEAK?

Answer:
Here’s how to estimate the size of air leaks:
It’s not very hard. We’ll use the “TIME METHOD” to estimate percentages of loss due to air leaks in your plant.
1.Turn OFF all air operated end-user equipment.
2.Start your air compressor and let it cycle 5 times.
3.Time the OFF-LINE/UNLOAD TIME
(not pumping time) using your watch. (Example: 5 minutes)
4.Time the ON-LINE/LOAD TIME
(pumping time) using your watch. (Example: 2 minutes)
5.Calculate total percentage of air leaks
as follows: Add the OFF / UNLOAD and the
ON / LOAD times together:
Example: T(5 minutes) + T (2 minutes)= 7 minutes
Divide ON / LOAD time T (2 minutes) by the total minutes: 2 ÷ 7 = 0.29

The result tells you 29% of your air compressor’s CFM’s are doing nothing but maintaining your AIR LEAKS.

How to figure the cost of air leaks:
Based on values from the Compressed Air & Gas Handbook, we can assume
4* CFM per air compressor horsepower. So, if you have a 100 HP compressor and the above determined 29% air leaks -use this formula:
100 HP x 4*=400 CFM x 29% (.29 air leak loss) = 116 wasted CFM.
As the chart below shows, you now know that you are
losing over $13,000 a year because of AIR LEAKS.

SIZE OF YOUR LEAK--CFM AIR LOSS--WASTED DOLLARS @YEAR
Orifice Diameter Inches
1/32 ------------------1.6 -------------- $211.70
3/32 -----------------14.5 --------------$1905.30
1/4 -----------------104.0 -------------$13665.60
1/2 -----------------415.0 -------------$54531.00

*These figures are based on values from the Compressed Air & Gas Institute Handbook. Calculations assume a conservative cost of $.25 /1000 cubic feet of compressed air, 100% coefficient of flow and working 8,760 hours/year at 100 psig.

McGuire Air Compressors, Inc.
“Real People with Real Air Compressor Experience”

For Champion Air Compressors...

https://industrialaircompressors.biz/

For Reelcraft Hose Reels for Air, Water, Oil & fluid
plus Electric Cord Reels & Welding Cable Reels...

https://hosereels.biz/

For Deltech Refrigerated Air Dryers...

https://airdryers.biz/

Email: compressors@mcguire.biz

Call us:
336-229-9999

Air Compressor Trouble Shooting Tips

noreply@blogger.com (McGuireAir) — Wed, 25 Jun 2008 17:58:00 +0000

Ask a Question:
What are some good trouble shooting tips to help me maintain my compressed air system?

Answer:
Here are some great Air Compressor Trouble Shooting Tips to help you or anyone providing the regular maintenance for your compressed air system.
Below are listed several very common problems, their probable cause and some usual remedies for the trouble.
Of course, there can be multiple problems and unique circumstances to every compressor issue...but these tend to solve the most common situations.

PROBLEM:
Low pressure at point of use

Probable Cause: Remedial Action
Leaks in distribution piping: Check lines, connections and valves for leaks
Clogged filter elements: Clean or replace filter elements
Fouled dryer heat exchanger: Clean heat exchangerLow pressure at compressor discharge: See below

PROBLEM:
Low pressure at compressor discharge

Probable Cause: Remedial Action
For systems with modulating load controls, improper adjustment of air capacity system:
Follow manufacturer's recommendation for adjustment of air capacity system

Worn or broken valves Improper air pressure switch setting: Check valves and repair or replace as required
Follow manufacturer's recommendations for setting air pressure switch

Improper air pressure switch setting: Follow manufacturer's recommendations for setting air pressure switch

PROBLEM:
Water in lines

Probable Cause: Remedial Action
Failed condensate traps: Clean, repair, or replace the trap
Failed or undersized compressed air dryer: Repair or replace dryer. If you do not have an Compressed Air Dryer, consider adding this equipment.

PROBLEM:
Liquid oil in air lines

Probable Cause: Remedial Action
Faulty air/oil separation: Check air/oil separation system; change separator element
Compressor oil level too high: Follow manufacturer's recommendation for proper oil level

PROBLEM:
Dirt, rust or scale in air lines

Probable Cause: Remedial Action
In the absence of liquid water, normal aging of the air lines: Install filters at point of use

PROBLEM:
Excessive service to load/hour ratio

Probable Cause: Remedial Action
System idling too much:
For multiple compressor system: consider sequencing controls to minimize compressor idle time
Adjust idle time according to manufacturer's recommendations

Improper pressure switch setting: Readjust according to manufacturer's recommendations

PROBLEM:
Elevated compressor temperature

Probable Cause: Remedial Action
Restricted air flow: Clean cooler exterior and check inlet filter mats

PROBLEM:
Restricted water flow

Remedial Action:
Check water flow, pressure, and quality; clean heat exchanger as needed

PROBLEM:
Low oil level

Remedial Action:
Check compressor oil level, add oil as required

PROBLEM:
Restricted oil flow

Remedial Action:
Remove restriction, replace parts as required

PROBLEM:
Excessive ambient temperature

Remedial Action:
Improper ventilation to compressor; check with manufacturer to determine maximum operating temperature

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

Are you wasting compressed air?

noreply@blogger.com (McGuireAir) — Wed, 14 May 2008 20:49:00 +0000

Potentially Inappropriate Uses of Compressed Air

Compressed air is clean, readily available, and simple to use.As a result, compressed air is often chosen for applications forwhich other energy sources are more economical. Inappropriate uses of compressed air include anyapplication that can be done more effectively or more efficiently by a method other than compressed air.

Don't WASTE your Compressed Air.
Check your facility for wasteful and perhaps even un-safe uses of compressed air.

Examples of potentially inappropriate uses of compressed air include:
• Open blowing
• Sparging
• Aspirating
• Atomizing
• Padding
• Dilute-phase transport
• Dense-phase transport
• Vacuum generation
• Personnel cooling
• Open hand-held blowguns or lances
• Diaphragm pumps
• Cabinet cooling
• Vacuum venturis.

Here's an explaination of each potentially inappropriate use and a suggested alternative:

Open Blowing

Open blowing is using compressed air applied with an open, unregulated tube, hose, or pipe for one of these applications:
• Cooling
• Bearing cooling
• Drying
• Clean-up
• Draining compressed air lines
• Clearing jams on conveyors.

The alternatives to open blowing are vast.

Some are:
• Brushes
• Brooms
• Dust collection systems
• Non-air-loss auto drains
• Blowers
• Blowers with knives
• Electric fans
• Electric barrel pumps
• Mixers
• Nozzles.

Sparging

Sparging is aerating, agitating, oxygenating, orpercolating liquid with compressed air. This is a particularly inappropriate application because liquid can be wicked into a dry gas, increasing the dew point.The lower the dew point of the compressed air, the more severe the wicking effect. This can occur with oil, caustics, water rinse materials, etc.
Alternatives to sparging include low-pressure blowers and mixers.

Aspirating
Aspirating is using compressed air to induce the flow of another gas with compressed air such as flue gas.
An alternative is a low-pressure blower.

Atomizing
Atomizing is the use of compressed air to disperseor deliver a liquid to a process as an aerosol. Anexample is atomizing fuel into a boiler. Fluctuating pressure can affect combustion efficiency.
An alternative is a low-pressure blower.

Padding
Padding is using compressed air to transport liquids and light solids. Air is dispensed over the material to be moved. The expansion of the air moves the material. The material is usually only moved short distances. An example is unloading tanks or tank cars. Molecular diffusion and wicking are typical problems with padding.
An alternative is low to medium pressure blowers.

Dilute-Phase Transport
Dilute-phase transport is used in transporting solids, such as powdery material, in a diluted format with compressed air. Molecular diffusion and wicking are typical problems with dilute phase transport.
An alternative is a low- or high-pressure blower or a low pressure air compressor designed for 35 psig. The pressure required depends upon the moisture content and size of the material being transported.

Dense-Phase Transport
Dense-phase transport is used to transport solids in a batch format. This usually involves weighing a batch in a transport vessel, padding the vessel with compressed air, forcing the batch into a transport line, and moving it in an initial plug with a boost o fcompressed air at the beginning of the transport pipe.Once the material is moving in a plug, the operation may fluidize the material in a semi-dense or moderate dilute-phase using fluidizers or booster nozzles along the transport path. The material is typically transported to a holding vessel that dispenses it on an as-needed basis using pad air from the secondary transport vessel to move it to the use location. A typical application would be the dense-phase transport of carbon black.

There are typically four compressed air elements to the transport. These elements are control air for the equipment, pad air for the initial transporter, transport air to move it in the piping, and fluidizers or booster nozzles along the transport piping. Most dense-phase manufacturers specify 80 to 90 psig with one singlel ine supporting the entire process. The control air and booster nozzles typically use pressures in the 60 to70 psig range. The actual article psig required for the pad air and the transport air is typically 30 to 45 psig. Because of the lack of storage in most of these applications and the high-volume, short-cycle transport times, the original equipment manufacturers request 80 to 90 psig and use the entire supply system as the storage tank. As this usually has a negative impact onthe plant air system, separate compressors, filters, and dryers are applied to this process at the elevated pressure.

Alternatives include supporting the control air,pad air, and boosters with regulated plant air plusmetered storage, and using a two-stage, positivedisplacementblower (28 psig) or single-stage compressor(40 to 50 psig) for the transport air. Another alternativeis to use metered storage for both the pad air andtransport cycle. This necessitates providing the entirer equirement from storage and metered recovery percycle, with a metering adjustment to refill the vessel just before the next transport cycle. The storage should be sized to displace the required air first for the padand then for the transport cycles within an allowable pressure drop to terminate the transport cycle pressureat the required article pressure. This will flatten the volumetric load on the system, eliminate any impacton other users, and reduce the peak energy required to support the process.

Vacuum Generation
The term vacuum generation describes applications where compressed air is used in conjunction with aventuri, eductor, or ejector to generate a negative pressuremass flow. Typical applications are hold-downs or 55-gallon, drum-mounted, compressed air vacuum cleaners. This is by far the most inefficient applicationin industry with less than 4 percent total efficiency, although for very intermittent use (less than 30 percentload factor), compressed air can be a reasonably efficient solution.
An alternative is a vacuum pump. If a compressed-air-generated vacuum is required, install a solenoid valve on the compressed air supply line to shut this application off when it is not needed. Vacuum generators are used throughout industry.

Some applications for vacuum generators include:
• Shop vacuums
• Drum pumps
• Palletizers
• Depalletizers
• Box makers
• Packaging equipment
• Automatic die-cutting equipment.

Vacuum generators are selected for safety, ease of installation, physical size of the generator, the fact that no electricity is required at the point-of-use, and low first cost. Vacuum generators are usually less economical to operate than central vacuum systems.

As a rule, in a base load situation, if the vacuum generator is operating less than 30 percent of the time,it will be more economical to operate than a central vacuum system. Otherwise, vacuum generators are, in general, less effective at pulling a vacuum and cost as much as five times more to operate than a dedicated vacuum pump. Using vacuum generators for shop vacuums and drum pumps, which are typically peak load applications, could cause another compressor to turn on and stay on until it times out. Having to operate a second compressor because of the added demand associated with a vacuum generator eliminates any apparent savings associated with a vacuum generator, even if it operates only once a day for a short period of time.

A dedicated vacuum pump, or the use of central vacuum system will provide more suction force at a fraction of the cost of vacuum produced by compressed air. In this case, it is significantly more cost effective to provide a system that is designed into the machine from the beginning than to retrofit a piece of equipment.This can be accomplished by being proactive at the time the machine specifications are prepared and the purchase orders issued. Vacuum generators must be applied properly and only after taking life cyclecosts into consideration.

Vacuum venturis are a common form for vacuum generation with compressed air systems. In a venturi system, compressed air is forced through a conical nozzle. Its velocity increases and a decrease in pressure occurs. This principle, discovered by 18th century physicist G. B. Venturi, can be used to generate vacuum without a single moving part.

Multi-stage venturi devices provide a more efficient ratio of vacuum flow to compressed airconsumed than single-stage venturi devices. Where vacuum requirements vary significantly, or are cyclical with a duty cycle of less than 30 percent, multi-stage,venturi-type vacuum generators with pressure regulators and automatic shut-off controls on the compressed air supply may be more efficient than continuously operating mechanical-vacuum pump systems. These devices also can be equipped with a vacuum switch that signals a solenoid valve to shut off the air supply when a set vacuum level is attained, thus reducing air consumption in non-porous applications. They may also be suitable where it is impractical to have a central vacuum system, particularly where the uses may not be confined to one area.

Personnel Cooling
Personnel cooling is when operators direct compressed air onto themselves for ventilation. This is dangerous because it can shoot particulates into the skin. A 1/4-inch tube blowing air on an operator can consume 15 to 25 brake horsepower (bhp) of compressed air.
An alternative is fractional horsepower fans of 1/4 bhp or less.

Open Hand-Held Blowguns or Lances
Unregulated hand-held blowing is not only a violation of most health and safety codes, but is also very dangerous. Hand-held blowguns that conform to all occupational health and safety standards should be used.

There are different styles of blowguns that candeliver various airflows, velocities, and concentrations.The proper gun must be selected for each application. Pipes installed in the end of hose and unregulated non-approved guns must not be used. Blowguns must have no more than 30 psig discharge nozzle pressure.The nozzle should be constructed to relieve back pressure if the nozzle is plugged or blocked. The blowgun must also have a spring-operated throttle mechanism so it shuts off automatically if it is dropped.

Diaphragm Pumps
A common error is to not size diaphragm pumpsf or the maximum viscosity, highest pressure, and highest volume required. The result is poor performance and an increased supply pressure requirement.
Diaphragm pumps are commonly found installed without regulators and speed control valves. Those diaphragm pumps that are installed with regulators are found with the regulators adjusted higher than necessary. This is often because of undersized regulators and supply piping or hose. The higher-than-necessary setting of the regulator increases the demand on the compressed air system and increases operating costs.With a higher pressure setting, the amount of compressed air admitted into the diaphragm chamber is increased above that which is actually required tomove the product. The amount of product actually transferred remains the same, but the amount of air used increases with the increased pressure.

The regulator should be adjusted to equal the maximum head that the pump is required to provide.A flow control valve installed up stream of the regulato rwill accomplish the required speed control. Operating the diaphragm pump without speed control increases the rate of compressed air consumption by increasing the strokes per minute of the diaphragm pump. The speed control should be adjusted to pump product in the maximum allowable time. As a general rule, the regulator and flow control valve are not included with the standard pump package. Also, when the pump has no liquid or slurry to pump, it will rapid cycle, wearing out the diaphragm and wasting air. The pump controls must be configured to turn the pump off when there is nothing to pump.

Cabinet Cooling
Cabinet cooling should not be confused with panel purging. The following are typical applications where cabinet cooling is found.
• Programmable controllers
• Line control cabinets
• Motor control centers
• Relay panels
• Numerical control systems
• Modular control centers
• Computer cabinets.

When first cost is the driving factor, open tubes, air bars (copper tube with holes drilled long the lengthof the tube) and vortex tube coolers are often used to cool cabinets. When life-cycle costs are taken into consideration, these choices prove to be expensive. It is not uncommon to find an open tube or air bar consuming 7-1/2 horsepower (hp) of compressed air to cool a cabinet. Vortex tube coolers can be an improvement over open tubes and air bars because they areoften cycled with a thermostat control, which reduces air consumption. However, air to air, air to water and refrigerated cabinet coolers are available that only use1/3 hp to accomplish the same task.

Other Potentially Inappropriate Uses
Other improper uses of compressed air are unregulated end uses and those that supply air to abandoned equipment, both of which are described below.

Unregulated End Uses
A pressure regulator is used to limit maximum end use pressure and is placed in the distribution system just prior to the end use. If an end use operates without a regulator, it uses full system pressure. This results in increased system air demand and energy use, since the end use is using air at this higher pressure. High pressure levels can also increase equipment wear, resulting in higher maintenance costs and shorter end use equipment life.

Abandoned Equipment
Many plants undergo numerous equipment configuration changes over time. In some cases, plant equipment is no longer used. Air flow to this unused equipment should be stopped, preferably as far back inthe distribution system as possible without affecting operating equipment.

Using Compressed Air
As a general rule, compressed air should only be used if safety enhancements, significant productivity gains, or labor reductions will result. If compressed air is used for an application, the amount of air used should be the minimum necessary - quantity and pressure and should be used for the shortest possible duration.

Compressed air use should also be constantly monitored and re-evaluated.

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How to Minimize Pressure Drops in your Compressed Air System

noreply@blogger.com (McGuireAir) — Wed, 07 May 2008 14:12:00 +0000

Ask a Question:
What causes pressure drop in my compressed air system?

Answer:
Any type of obstruction, restriction, or roughness in the system will cause resistance to air flow and cause pressure drop.

In the distribution system, the highest pressure drops usually are found at the points-of-use, including undersized or leaking hoses, tubes, disconnects, filters, regulators and lubricators (FRLs).

On the supply side of the system, air/lubricant separators, aftercoolers, moisture separators, dryers and filters can be the main items causing significant pressure drops. The maximum pressure drop from the supply side to the points-of-use will occur when the compressed air flow rate and temperature are highest.

Your Compressed Air System components should be selected based upon these conditions and the manufacturer of each component should be requested to supply pressure drop information under these conditions. When selecting filters, remember that they will get dirty. Dirt loading characteristics are also important selection criteria.

Large end users who purchase substantial quantities of components should work with their suppliers to ensure that products meet the desired specifications for differential pressure and other characteristics.

The distribution piping system often is diagnosed as having excess pressure drop because a point-of-use pressure regulator cannot sustain the required downstream pressure. If such a regulator is set at 85 psig and the regulator and/or the upstream filter has a pressure drop of 20 psi, the system upstream of the filter and regulator would have to maintain at least 105 psig. The 20 psi pressure drop may be blamed on the system piping rather than on the components at fault. The correct diagnosis requires pressure measurements at different points in the system to identify the component(s) causing the excess pressure drop. In this case, the filter element should be replaced or the filter regulator size needs to be increased, not the piping.

How to Minimize Pressure Drop
Minimizing pressure drop requires a “systems approach” in design and maintenance of the system. Air treatment components, such as aftercoolers, moisture separators, dryers, and filters, should be selected with the lowest possible pressure drop at specified maximum operating conditions. When installed, the recommended maintenance procedures should be followed and documented.

Additional ways to minimize pressure drop are as follows:
• Properly design the distribution system.
• Operate and maintain air filtering and drying equipment to reduce the effects of moisture, such as pipe corrosion.
• Select aftercoolers, separators, dryers and filters having the lowest possible pressure drop for the rated conditions.
• Reduce the distance the air travels through the distribution system.
• Specify pressure regulators, lubricators, hoses, and connections having the best performance characteristics at the lowest pressure differential. These components must be sized based upon the actual rate of flow and not the average rate of flow.

*SOURCE: Improving Compressed Air System Performance: A Sourcebook for Industry is a cooperative effort of the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) Best Practices and the Compressed Air Challenge®.

McGuire Air Compressors
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Email: compressors@mcguire.biz

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"Real People with Real Air Compressor Experience"

Providing compressor answers that save you time and money.

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you should keep on hand...
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your air compressor delivers.