Common
Mistakes That Cause Big Headaches
99%
of all air compressor problems can be traced back to an improper system
installation. Yes,
you read that correctly, the vast majority of the problems we see in the field with
compressed air equipment can usually be traced back to how the equipment was
installed when it was first purchased, new or used. To get the most out of
your air compressor and compressed air system it must be installed
correctly from day one. Trying to save a few dollars here can cost you
big dollars and give you big headaches over the entire useful life of
the compressor and the compressed air system.
Some
of the most common installation mistakes we run into are:
-
Improperly
sequenced equipment within the system, especially
with rotary screw or vane compressors. The most common problem is blowing
the compressor discharge directly into the dryer and then blowing that dry
air into the air receiver. This can result in erratic cycling of the
compressor resulting in high wear on parts and overheating of the
compressor. Another downside to this type of component arrangement is that
the dryer has to deal with all of the water the compressor
produces, let the receiver catch most of that water first and the dryer
only has to rid the air of what remains.
-
Not
installing a properly sized air receiver (tank) in the system.
This
follows close on the heels of the previous mistake. Rotary screw
compressors especially, require a properly sized air receiver. The reason
for this is because these machines are designed to cycle based on the rise and fall of
pressure in the system. A properly sized receiver provides a
"cushion" for the compressor to work against that smoothes out
the loading and unloading of the unit. This makes the compressor cycle
less often and extends the life of the compressor's lubricant by allowing
the machine to run at cooler temperatures.
-
Walling
off the compressor to cut down on noise. This
usually results in equipment that is difficult to access and that gets
ignored by maintenance employees. If you don't service your equipment it will
break down often and so will your bottom line. This type of installation also tends to
direct dirt towards the compressor which plugs up coolers that causes the
compressor overheat.
-
Installing
compressors at inaccessible locations. This
follows walling a compressor off to cut noise but it's worse. It's simple,
if you hang your compressed air equipment from the ceiling or put it on the roof it will never get
looked at or serviced, at least until it stops working. If you don't have
the floor space you'll need to make some. Remember if your compressor dies
your business usually comes to a standstill as well.
-
Not
installing hot air ducting to direct hot air away from rotary screw or
vane compressors. These
types of compressors throw off a lot of heat and that hot air needs
to be directed away from the compressor and especially
refrigerated dryers. You can not install one of these types of compressors
into a room and shut the door to get away from the noise. That is a sure
fire recipe for disaster and will eventually result in the
compressor either, at worst, failing or in the least having major maintenance
problems. If you can get the heat away from the
compressor it will last much longer and you will have far fewer
maintenance headaches to deal with.
