Running a lubricated screw compressor at light loading can lead to a critical issue known as oil carryover, where excess lubrication oil escapes the compressor into the downstream air system. This problem, while often overlooked, can result in costly operational challenges, particularly in food processing plants where air purity is critical. Lubricated screw compressors rely […]
Compressed air fail: Oil accumulation
During a walk-through audit, a compressed air auditor noticed a pail collecting lubricant from a filter drain. The pail was almost completely full, causing the auditor some concern. He knew that this was a sign of several possible problems. High oil or lubricant accumulation downstream of a lubricated screw compressor is often caused by issues […]
Compressed air fail: Gunk in drains
By Ron Marshall An industrial plant started having trouble with its air dryer. No matter what the maintenance personnel tried, they could not achieve adequate dew point values. Nobody suspected the upstream condensate drain — especially because, when tested, it did not release any excess condensate or oil. Finally, it was disassembled and found to […]
Compressed air fail: Flow meters
A compressed air auditor did a study at a plastic products plant. Before the study, the maintenance manager had mentioned he was extremely proud that he had 100% redundancy in his system. After the study, the auditor had to tell him some bad news — every one of his compressors were running to service his […]
Compressed air fail: How to create compressed air leaks with poor practices
Compressed air leaks are a silent and costly thief of energy, often accounting for 20-30% of wasted energy in industrial systems. While leaks can happen naturally over time, poor practices can accelerate their creation. Understanding the role of piping, end-use equipment, and maintenance in contributing to leaks can help highlight the importance of good practices. […]
Compressed air fail: Inadequate backup
During compressed air audits, we often find that industrial plants lack the capacity reserve required to ensure the plant can run with adequate pressure — even if the largest compressor fails. Having extra reliable compressors and dryers can go a long way in providing for a reliable flow of compressed air, even in the face […]
What are compressed air pressure/flow controllers?
By Ron Marshall A compressed air pressure/flow controller is a device designed to regulate the pressure and flow of compressed air delivered to a system, ensuring consistent performance and efficiency. It acts as a buffer between the supply and demand sides of the system, maintaining steady downstream pressure despite fluctuations in demand or upstream conditions. […]
How do acoustic imagers help in compressed air systems?
The development of acoustic imagers has transformed the way compressed air leak audits are done, saving time for the user. Acoustic imagers are advanced tools used to detect gas leaks by capturing and visualizing high-frequency sounds that are typically inaudible to the human ear. When compressed air or gas escapes through cracks, holes, or loose […]
Compressed air fail: Inside the box thinking?
“Inside the box” thinking involves sticking to conventional methods and solutions that are tried and tested. For example: Routine maintenance: Regularly replacing filters and addressing leaks are standard practices to improve efficiency. Equipment upgrades: Replacing old compressors with newer, more energy-efficient models is a typical step. Basic monitoring: Installing pressure gauges and ensuring the system […]
Five big improvements for your compressed air system
By Ron Marshall Improving the efficiency of your air compressor system doesn’t always require a large investment. Small, cost-effective changes can lead to significant energy savings, reduced operational costs, and a longer system lifespan. Here are five practical and low-cost strategies to boost the efficiency of your air compressor. Fix leaks Air leaks are […]
