Maintaining your peace of mind

Air Compressor Maintenance 

Let’s face it. At some point, no matter how high quality the product is, equipment or machinery will break down. Breakdowns can have major impacts on the efficiency of your production which in a worst-case scenario, can cost your business thousands of dollars. While breakdowns are inevitable, regular and professional air compressor maintenance assures the reliability and quality of your equipment.

So why should I invest in maintenance?

With regular maintenance, you lower the risk of your compressed air system breaking down which ultimately leads to lower profitability. Think of your air system like a car being serviced. Filters and fluids are replaced, cooling water is inspected, belts are adjusted, and leaks are identified and repaired. These regular checkups ensure your compressed air system remains reliable throughout its lifetime.

Without servicing, system integrity could be compromised when undetected problems deteriorate, leading to damage. At some point, this will cost you a lot to repair.

Can’t I just pay for maintenance when I need it?

Sure, but keep in mind that you’ll have to closely monitor your compressor’s service requirements and order each service separately. A slow procurement process can lead to a delayed service which potentially means an increase in overall costs.

What are the risks of delaying my maintenance checks?

Most parts within your compressed air system have a specified lifespan. Failure to replace them on time can impact your compressor’s overall efficiency and reliability. Not only does this increase ongoing production costs but also the chance of a breakdown occurring which can have an even bigger impact on profitability.

How do energy costs affect my budget?

The biggest part of the total cost of ownership for compressed air equipment is energy consumption. If you fail to properly maintain your air compressor system, pressure drops may occur, decreasing the system’s efficiency.

During an average compressor’s lifetime of around 10 years, the cost of compressed air is roughly divided up as 73% energy costs with the remaining 27% divided between capital costs, installation and maintenance. In reality, producing 1 kW of compressed air requires 8 kW of electricity. So, if you’re not evaluating the energy performance of your system, you are potentially converting your money into thin air.

How often should my receiver be inspected?

Under the Occupational Safety and Health Regulations 1996 requirements and AS/NZS 3788:2006, routine biennial inspections of pressure vessels is mandatory. 

Pressure vessels used in the workplace present a lot of potential dangers when not properly maintained which can cause damage to property, injury and even death. This is why it’s essential to properly install and service receivers and ensure that all of your equipment complies with the relevant AS standards and Worksafe WA regulations.

Do I have to register my receiver?

As per the Occupational Safety and Health Regulations 1996 along with AS/NZS 3788:2006, registration of pressure vessels is mandatory in order to assess safety and to detect any dangerous deterioration.

Interested in learning more about Nessco Pressure Systems servicing and maintenance capabilities? Then get in contact today. 

The Huge Impact of Laminar Flow

Laminar flow is an integral component of compressed air efficiency.

 

Believe it or not, laminar flow is controlled solely by the airline used in a compressed air system. To fully understand the effects of laminar flow in a compressed air system, we need to explain exactly what it is.

Fluids & gases are unique in their ability to travel. Unlike solid molecules that remain stationary whose molecules tend to join others of the same kind, fluid molecules aren’t so picky. Fluid molecules, such as gases and liquids, partner with different molecules and are difficult to stop.

Candle Smoke Laminar FlowLaminar flow describes the ease with which these fluids travel; good laminar flow describes fluid traveling as straight as possible. On the contrary, when fluid is not traveling straight, the result is turbulence, or a reduction in laminar flow. This is depicted in the image on the right; as the smoke comes off the candle, it is smooth and straight (this would be considered perfect laminar flow). As it travels away, the molecules display imperfect laminar flow.

Turbulent air flow essentially results in an inefficient compressed air system. This may not seem like a major concern; however, it has huge impacts on compressor efficiency. Fluid molecules bounce and circle within their path, causing huge energy wastage. In compressed air systems, this turbulent airflow results in pressure drop. How do you avoid this from happening? It all comes down to compressed air system design.

The design and material of the air pipe, as well as the positioning of elbows and joints, has a direct correlation to laminar flow and pressure drop. To avoid high energy consumption of your compressed air system, reducing pressure drop is key.

If your system is experiencing high pressure drop, your compressor has to work overtime to provide the required air pressure. When your compressor works overtime, it not only increases your maintenance costs, but also your energy bills.

Laminar flow works in conjunction with the “boundary layer”; this is the very first layer of compressed air that touches the wall of the pipe. Through the use of Infinity fittings, such as the Infinity Reducing tee, the air can travel down the dropper with ease, creating a smooth transition without disruption to the laminar flow.

 


 

NPS can perform post installation tests on your compressed air system, such as air audits and compressed air efficiency reports. For more information or to speak with our experienced technicians, call us on 1300 290 638 or click here!