Prepare Your Compressed Air System For Winter: Final Thoughts

December 20, 2016Ken Bean

We’ve covered several topics on preparing your compressed air system for cold weather and just wanted to leave you with a final thought on the topic today.

Heat Recovery

A great way to save money during the winter months is to capture the heat that your compressor is generating with a heat recovery system. Up to 90% of the heat generated by the heat of compression can be captured and utilized elsewhere in the plant with just a little planning and investment. These can include ambient heat for other areas of the plant, pre-heating boiler combustion air and other additional process heating requirements. Even if the temperature’s can’t be brought up to full operating requirements, utilizing the waste heat from the compressor can cut down on alternate heating costs.

System Preparation

It’s never too early or too late to plan and prepare for temperature changes. Especially the extremes of winter and summer. Put the maintenance and planning items on your calendar so you’re not caught off guard by rapidly changing conditions. Just to be sure you’re aware – follow me on twitter where we always announce when high and low temperature events are expected.

Prepare Your Compressed Air System For Winter: More Information

December 13, 2016Ken Bean

We previously discussed winterizing your compressed air system.. Now we continuing with additional cold weather tips.

Be cautious when working in cold weather. It really can be dangerous!

Weatherizing your compressed air system and facility is an important step when preparing for colder months to make sure your compressor continues operating efficiently.

Take the following steps to ensure your compressed air system and plant are prepared for the cold temperatures.

Repair weather stripping

Check weather stripping and replace areas that are worn. This includes outdoor piping or any equipment in poorly temperature controlled areas.

Inspect drains and air intake filters

Openings that are exposed to outdoor conditions can be problematic. Check your drains to assure proper operation and be sure to insulate an lines that carry condensation to area’s exposed to potential freezing conditions. A frozen line does not carry condensate very far and when it backs up into the compressor, catastrophic failures can occur.

Also, be sure that intake filters pulling air from the outdoors has proper rain / snow hoods in place. If they are left unprotected, snow or freezing rain can be drawn into the intake of the compressor and this will create a less than ideal situation.

Plan weatherization

Prepare your system biannually. Prepare your system for the high temperatures of summer and the low temperatures of winter each spring and fall. Regular planned maintenance for your compressed air (and other systems) ensures that nothing is left to chance.

If preparing and maintaining your system seems overwhelming, talk to your compressed air service company. They will be glad to assist in outlining your specific requirements or can develop a maintenance plan to be performed for you with contract specific requirements.

Winterization

November 15, 2016Ken Bean

I have a notification system that lets me know when the temperatures are expected to drop below freezing. Yes, it’s great to know ahead of time so I can plan an indoor day but the real reason for this is to notify my clients through twitter (www.twitter.com/fe_airsystems)

As most already know, compressed air systems can be devastated by freezing temps if your not ready.

When I received my first notice of the season last week I was shocked at far into the year we were. I guess it was the extended summer temperatures that caught me off guard and then but I noticed this weekend my area is predicted to see a low temp of 25 degrees.

I hope you’re keeping track better than me but if not, It’s time to get your compressed air system ready for the cold weather.

This is the first of several posts to help you be cold weather prepared.

Of course maintenance takes place all year long, whether by your own maintenance staff or bringing in your preferred compressed air service specialist but there are a list of additional checks and corrections that need to be made ahead of freezing temperatures.

Check all drains for proper operation

Check drains for obstructions or inefficiencies. If a drain is malfunctioning it can cause serious issues when the temperatures drop. In compressor rooms that are not heated, improperly drained condensate could freeze. If the drain trap is left open, it blows expensive compressed air to the atmosphere and let’s face it – efficiency means everything to companies today. If not already installed consider adding no air loss type auto drains. Be sure to inspect drains in the air system equipment, including dyers, receivers and filters.

Maintain air filters

Filters should be checked regularly for clogs or other problems indicated by a high differential pressure. This unnecessary pressure drop can decrease end-use pressure, causing the entire system to work harder and use more energy. Again, efficiency is king! Coalescing filter housings partially filled with water are at risk for freeze and rupture event and nobody wants to be around that time bomb. .

Locate and repair leaks

Leaks can account for up to 25 percent of compressed air use. Identifying and fixing leaks can lead to huge savings. Did I mention efficiency? Some larger leaks can be heard just walking through the area but smaller leaks will require monitoring equipment. You can purchase and utilize an ultrasonic acoustic leak detector or hire a “Quality” compressed air auditing firm. An auditing company can perform a leak audit only or you can go all out and have them perform a supply & demand side audit to determine additional potential savings for your entire system.

These are the first steps to take when winter is just around the corner. Follow the blog to learn more pre-cold weather tips.