Summer-ize your compressor

Summer is quickly approaching. With it brings warm weather, no school, barbecues, swimming pools and fun in the sun. But, for many manufacturers, the hot summer months bring to some not-so-fun challenges for compressed air systems.

Just like any appliance, compressors require regular maintenance. Furnaces need a tune-up before the winter hits, and air conditioners need a checkup before the outdoor temperatures begin to rise. A little preventative maintenance at the change of seasons can save a business from downtime and headaches later in the season.

Compressors are no different.

The challenge in the warm weather is how to keep the compressor room cool when the temperatures continue to rise. Fun in the sun for compressors means condensation, overheating, and working harder to produce the same results. When not appropriately prepped for the hot summer months, compressors tend to work overtime or take an “unplanned” vacation.

Here’s our list of the top ways to prepare your compressor for elevated temperatures during the summer months.

• Check the oil.  The excessive heat tends to ruin most compressor oils, which requires more frequent changes. Changing the oil/fluid on schedule supports proper viscosity for better lubrication and removes moisture, acids, and other contaminants. Also, use our oil analysis to determine the condition of the oil.  Oil sampling should be part of any maintenance program, all the more reason to use a qualified Distributor to care for your system.

• Check the ventilation. Proper ventilation helps with compressor efficiency and keeping the operating temperature down. Put a thermometer in the compressor room to measure the ambient temperature of the room. If the temperature gets above 100° F, add more fresh, cool air to the room. Consider adding ductwork to remove exhaust heat from the room. Higher operating temperatures cause premature failures on the oil as well.

• Examine the receiver tank.  With the additional moisture in the air from the hotter temperatures, if the receiver tank drain isn’t operating properly, it could fill up with water instead of storing air. Also, make sure the tank’s pressure gauge and safety relief valve is working, and that the tank isn’t in the path of exhaust flow. Heating the tank will only re-heat the compressed air and reduce moisture separation.

• Check the fluid system. To ensure proper cooling, lubrication, and to prevent unscheduled downtime, ensure there are no restrictions in the compressor’s fluid circulation. This includes keeping the heat exchangers clean of dust and debris. A plugged heat exchanger will cause overheating very quickly.

• Maintain the water’s pressure, flow, quality, and temperature. It’s beneficial to monitor and maintain the pressure, flow, quality, and temperature of the water used in the cooler to prevent overheating. Making sure there is not an issue with the cooling water supply in water-cooled compressors helps keep operating temperatures in the appropriate ranges.

• Regularly examine drains. It’s essential to clear out blockages or debris to ensure they can handle added water flow that results from condensation. Make sure all the drains on tanks, dryers, and filters are functioning properly. Adjust timer settings on timed drains, or if using manual drains, make sure to check it regularly.

• Check the electrical cabinet. Dirt and dust can form an insulating layer and build up heat on electrical components. Use appropriate precautions when cleaning the electrical cabinet.

• Clean out filters. Dirt, dust, and debris can clog filters and increase the compressor’s operating temperature. Cleaning filters ensures electrical components running correctly and keeps the oil clean longer.

• Maintain air treatment equipment. A majority of air treatment equipment is rated at 100 psig inlet, 100°F inlet temperatures, and 100°F ambient temperatures. An increase of any of these conditions can cause the capacity of your equipment to decrease significantly during hot summer months. Make sure the dryer is getting the coolest air possible, confirm that the condenser is clean, and have a certified refrigerant technician connect a set of gauges to verify appropriate pressures of the refrigerant circuit and to check the refrigerant level.

Don’t wait for heat and humidity to cause compressed air complications. Take steps now and prevent costly downtime from halted production and an expensive emergency service call.