Category Archive: Air Compressor Leaks

Top Tips for Energy-Saving Air Compressor Maintenance

Globally, the air compressor market is quickly growing due to the versatility and cost-effectiveness of air compressor units. Between 2020 and 2028, the market is expected to grow at a rate (CAGR) of 3.4% annually. However, despite the wide adoption of air compressors, many businesses don’t prioritize air compressor maintenance, resulting in increased expenses due to costly repairs or replacements and the associated downtime. Air compressor maintenance offers you many benefits, such as time savings, safety enhancements, and reduced production costs due to less energy consumption. See our guide to inline clean air treatment here.

Top 5 Energy Saving Tips

Energy SavingRegardless of your specific industry or application, a well-maintained air compressor plays a vital part in reducing energy consumption. Here are five top tips you can implement to increase the energy savings from your air compressor: 

Cost Saving Advice: Hoses, Fittings, and Waste

Check your fittings regularly, ensuring they create a tight seal. Loose fittings are a significant cause of leaks in air compressor units. If the fittings seem corroded or worn out, you should repair or replace them immediately. Consider inspecting hoses since they act as the system’s key connection points, and any damage to the hose could disrupt the entire system. Hoses usually get damaged during cold weather or bent, resulting in corrosion or cracks. Additionally, drain your unit’s receiver tank to avoid suboptimal operation due to a lack of storage capacity. 

Apply Proper Controls to Multiple Compressor Units

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Top Tips for Energy Saving Air Compressor Maintenance

Proper controls maintain steady system pressure and ensure that only the required compressor units are brought online. This eliminates the inappropriate use of compressed air and ensures each unit is operating at peak efficiency. The controls are also helpful in turning off compressor units that are not needed or not being used.

Ensure Piping & Storage are Properly Sized

The problem with most systems is the lack of adequate storage and piping. When sizing piping, it should optimize the transfer of compressed air at the desired flow and pressure to the point of use. Having wider piping from two to three inches can minimize the pressure to around 50%. On the other hand, reducing the distance traveled by air can lower pressure by about 30%-40%. Having the wrong storage size can result in issues with production or increased costs due to wasted energy. 

Change Your Air Filters Regularly

Air filters should be inspected monthly and replaced regularly. Drops in pressure as little as two psi can cost about 1% in compressor horsepower efficiency. Regular inspection and replacement maintain air quality and reduce the chance of pressure dropping. There are several point-of-use and air-line filters in a typical system, which should also be maintained regularly.  

Reduce the Operating Pressure to the Lowest Possible Setting

A common rule for most compressors indicates that every 2-psi reduction in system operating pressure can result in 1% in compressor energy-saving efficiency. Continuously adjust the pressure setting to reach the lowest possible setting without compromising performance. Additionally, centralized systems using multiple compressors can be set to run using a central controller. Turning down the pressure on your compressor even 10 PSIG is a 5% savings in electrical costs.

Contact Compressed Air Systems for More Advice

Maintaining your air compressor is essential to ensure daily operations and equipment continue running without interruption. At Compressed Air Systems, we are proudly celebrating nearly 60 years of delivering superior equipment design and engineering, custom turnkey installations, compressed air leak detection and elimination, air compressor rentals and services, and more. We have partnered with Kaeser to create a long and productive business partnership as a proud supplier of Kaeser air compressors. Get in touch with us today for more information about our services.

This One Thing Could Cost Your Air Compressor Thousands

Air compressors serve as essential components in a wide range of industrial and manufacturing applications. Regular compressed air maintenance is crucial for ensuring optimal performance and efficiency. Neglecting to perform regular air compressor services increases the risk of performance issues, which can result in extra expenditures as well as increased downtime. Air leakage, in particular, is one of the most costly compressed air system problems.

Intentional and Unintentional Leaks

No matter how big or small, air compressor leaks can be very bad for business. Below are some of the most common signs of unintentional air leakage.

  • Wear and tear is common in any type of air compressor. Over time, valves on your air compressor may loosen, allowing for air leakage. Checking the valves occasionally may help in preventing unintentional air seepage.
  • Air compressor systems rely on strong, sealed piping to release air with the right amount of pressure. Having holes in the piping or tubing of your unit can lead to multiple air compressor issues.
  • If the drain trap that funnels condensed water from your air compressor is faulty or open, air compressor leaks and water leakage can occur. These issues can also lead to more serious damage over time.

Air compressor leaks are sometimes intentional, brought about to assist in equipment cleaning, drying, employees cleaning off clothing, sweeping floors, etc. Although these leaks are created purposefully, they can still be taxing on your system, and many users end up misusing or wasting air.

Monitoring the frequency of intentional leaks will help in limiting the amount of wasted air. After all, your business is paying for every bit of air used.

Where the Costs Add Up

The biggest issue surrounding air compressor maintenance is the hidden cost of potential leaks. Most companies assume there is a higher cost associated with regular maintenance than reactionary repairs. However, an air compressor that isn’t regularly maintained will inevitably lead to higher costs over time.

In fact, a compressor air system that isn’t regularly serviced operates on a 20% leak rate on average, and some air compressors may lose up to 30% of their air. System leaks can also lead to higher energy bills. When your compressed air system maintenance falls to the wayside, production can be affected in a big way.

Leak Solutions

compressed air leak detectionPerforming regular maintenance on your system is the best proactive method for handling air compressor leaks. The earlier the detection of a leak, the better.

Make sure the company performing checks on your compressed air system does a comprehensive walk-through. They should be testing hoses, tubes, pressure regulators, and couple fittings to determine if there is leakage. They should also be utilizing sophisticated ultrasonic leak detectors.

An ultrasonic leak detector will pinpoint the location of the leak in your air compressor or lines. Having an ultrasonic leak detector on hand may also prove useful in between scheduled maintenance checks. A tool like the Jorc Locator can detect leaks up to 33 feet away, and also provides audible and visual indications of air leakages, making it easier to find the leak.

Stay Proactive With Compressed Air Systems

At Compressed Air Systems, Inc., we’re here to ensure that your air compressor is in tip-top shape. Our experts are at the forefront of compressed air solutions and are well-versed in all aspects of air compressor and system maintenance and upkeep.

For more info on how proper maintenance can save you headaches, check out our Importance of Minimizing Compressed Air Leaks Guide. Or, you can Contact one of our service team members today for help in determining whether your air compressor is in need of auditing or maintenance services.

So You Think You Have a Compressed Air Leak?

If you suspect that air leakage is negatively affecting your compressor, you need to take immediate action to correct the issue. Leakage is a more significant problem than many people realize; the smallest unintentional leak can lead to poor performance and wasted energy within your system.

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