6 Air Compressor Maintenance Tips to Avoid Breakdown

Air compressors of all makes and models require varying degrees of maintenance. Whatever the model or quantity of compressors you use for your operations, it’s essential to regularly inspect the parts and service them, whenever necessary. Failure to perform routine maintenance on your compressors can lead to early failure or expensive repairs.

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Here’s a short guide on how to keep your air compressors running at full capacity:

1. Drain your air receiver tank

Use the drain and plug at the bottom of the compressor to drain the air from the compressor’s air receiver tank. Collection of air in the machine leads to the accumulation of water and moisture while the machine is running, especially during summer, when humidity is higher. The moisture gets collected in the receiver tank and if not drained regularly, it can lead to corrosion of the receiver tank and piping. An automatic and a manual bypass drain during daily inspections is ideal.

2. Inspect the hoses

Hoses are often the most vulnerable parts of compressors because they need to be strong enough to transfer air between the machine and the final point, which can put a lot of strain on them. Checking your hoses on a weekly basis is extremely important. Cold weather also affects hoses — it causes them to crack or corrode and hence leak. Routine checks are ideal for keeping the hoses clean and leak detection devices are ideal to find the leaks.

3. Alter the air filter

Air filters usually trap a lot of junk. The filters are designed to bear a heavy load, without which, a lot of impurities will accumulate and degrade the performance of the compressor. This contamination is critical for industries such as food and beverage, hospitals, and labs. Air filter inspections should be done regularly, especially in dusty conditions.

4. Clean the intake valves

The intake valves of an air compressor must be clean to function fully. When compressors are put to constant use, dust particles and other elements get sucked into the vents. Cleaning the vents at least once every three months is essential.

5. Change the oil

The compressors that run on oil need the oil to be changed regularly as well. Fresh oil helps run the various parts of the engine smoothly. Especially in humid conditions, the oil loses its viscosity and fails to lubricate the different parts.

6. Get it inspected by a professional service team

Allowing a professional service team to regularly check leaks and perform preventive maintenance and required repairs, can offer a lot of peace of mind. Scheduling this regular maintenance can help save time and money in unnecessary breakdown repairs.

Keeping your air compressors healthy and functioning smoothly is essential and possible through regular maintenance. VEMC is an authorized ELGi air compressor dealer and provides end-to-end solutions for all your industrial energy requirements. Guided by more than 72 years of industry expertise, we aim to offer you specialized support in this space. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. Please feel free to contact us at +91 98199 07445, and we will be happy to assist you.

How often should I change the oil in my pump/piston?

How often should I change the oil in my pump/piston?

Air compressors need to be in optimum condition to give the best performance. Maintaining them properly ensures that they last long and help save money in the long run. There are several maintenance routines to consider for a smooth-functioning air compressor. One of the most important routines is changing the oil in the pump or piston of the air compressor. While focusing on other maintenance routines, many people overlook this one, which often leads to poor performance of the air compressors and, in some cases, also causes damage to the systems.

Why is it important to change the oil?

The oil in a compressor has several functions apart from lubrication. It helps the compressor parts to cool down so that the motor doesn’t overheat. The oil also acts as a sealing agent during the compression process.

If the compressor doesn’t have enough oil, it may not perform as efficiently as it’s supposed to. Low oil levels cause the compressor to overheat since air compression produces heat and oil absorbs the heat. Moreover, low oil levels also increase friction, which can lead the compressor to overheat. It’s also important to replace the contaminated oil from the air compressor regularly. Failing to replace the old oil with new oil causes debris and particles to build up and hampers its smooth functioning. Lack of sufficient oil can also increase the chances of rust, wear and tear, and corrosion. Finally, oil has a tendency to oxidise in the presence of water and heat. This reduces its effectiveness which can lead to costly breakdowns.

In some systems, overheating leads to an automatic shutdown. In such situations, the compressor can be used again only after it has cooled down and the oil has been replaced.

How often should the oil in an air compressor be changed?

Air compressors need consistent lubrication to prevent friction on the pumps or pistons and hence, the oil level must be checked regularly. The frequency of changing oil in compressors depends on the type of compressors used. Some compressors need more frequent changes than others and it’s best to consult the user manual that comes with the system. It’s possible to even find the life expectancy of some oils in terms of service hours in some of the manuals.

For rotary screw compressors, the oil should ideally be changed every 2000 hours or 12 months, whichever is earlier. For reciprocating air compressors, the oil needs to be changed every 3 months.

Performing an oil analysis that checks for important factors such as viscosity, particle count, water contamination, and total acid number (TAN) can help determine when to change the oil. It’s ideal to conduct an oil analysis every 500 to 2000 hours, depending on the user manual and the warranty.

VEMC, an authorised ELGi compressor dealer in Mumbai, supplies ELGi air and reciprocating compressors that are ideal for both commercial and industrial operations. Our range of screw and piston (reciprocating) compressors are cost-effective and offer long-lasting solutions for light-to-heavy-duty industrial applications. To know more about our range of compressed air systems and for help in choosing the right one, contact us on +91 98199 07445. VEMC is a 72-years-old young organization with ISO 9001:2015 certification and is CRISIL MSE-1 rated.

Five Benefits Of Upgrading Your Air Compressor

Upgrade Your Air Compressor to Save Money and Energy

Industries of today are leaning towards initiatives that can reduce carbon footprint and are generally more sustainable for long term use. But when a business considers upgrading its air compressor system, it may be daunted by the initial costs. However, the benefits of upgrading can often far outweigh these. Let’s take a look at five advantages of making the move:

High return on investment

A major benefit of upgrading your air compressor is the resulting return on investment. Most often, the return on investment of upgrading is higher than the cost. This might be in the form of energy savings and other efficiency-increasing benefits.

Significant energy savings

Another huge advantage of upgrading your air compressor is the savings on energy that it yields. On average, the costs of electricity account for a whopping 80% of total costs. An up-to-date system runs much more efficiently than a worn down one and hence, leads to a significant reduction in electricity bills. This way, the upgraded system makes up for the initial cost rapidly.

Higher uptime and reliability

Air compressors, like most other systems, require maintenance from time to time. However, while maintenance takes place, the system will experience downtime. The higher the downtime, the more the possibility of losing revenue. Systems that are upgraded as needed face less downtime. Additionally, they have lower chances of breaking down and are much more reliable for regular operations, helping you to minimize production losses.

Avail of government incentives

Most governments including India’s Bureau of Energy Efficiency, have introduced initiatives to cut down the use of energy by energy-intensive industries. Called PAT Cycle VI, the Indian government offers incentives if your business adopts equipment that consumes less energy to operate. This also serves to increase your return on investment while reaping the benefits of this act.

Better health and safety for everyone at work

Upgraded air compressor systems also improve the environmental working conditions of your site. By drastically enhancing the quality of the air at work, your employees’ health and safety will be protected. As a result, they will fall sick much less than before, which means they will probably take fewer days off from work, thus increasing their productivity.

Overall, upgrading your air compressor is a step in the right direction. Consult an expert to review the health and status of your current system. If it needs an upgrade, you will now understand why getting it is a prudent decision.

VEMC is an authorized dealer of Elgi air compressors and provides end-to-end solutions for all your industrial energy requirements. Guided by more than 72 years of industry expertise, we aim to offer you specialized support in this space. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. Please feel free to contact us at +91 98199 07445, and we will be happy to assist you.

How a Differential Pressure Gauge Can Help to Maintain the Air Quality in a Compressed Air System

How a Differential Pressure Gauge Can Help to Maintain the Air Quality in a Compressed Air System

What is differential pressure?

Differential pressure (DP) refers to the difference between two applied points of pressure. When this value tends to fluctuate significantly in a process system, it can be an indication that the component is in need of repair, replacement or maintenance. This is why, it becomes important to understand how to read differential pressure to keep functioning at optimal levels without the equipment breaking down.

What is a differential pressure gauge?

A differential pressure gauge is an instrument that is used to measure the differential pressure in a system and display the results visually. It can monitor the status of the air filter, which is an integral part of most compressed air systems. While the air filter performs a key function in removing contaminants entering the system, it creates a resulting change in pressure between the entry and exit points of the system. With passing time, these points accumulate dirt and get clogged, thus increasing the differential pressure.

A differential pressure gauge can track the changes in differential pressure in the system and alert you when it has reached a point when the filter must be replaced. This is a major benefit in operating an air system, as it can help minimize downtime from a malfunctioning and conduct timely maintenance as and when required.

Here is a look at some important facts about using differential pressure gauges:

  • Although a differential pressure gauge is an indicator of air quality, it does not directly influence the quality of the air that goes out from the system. However, it checks the condition of the air filter in the system and plays a large role in keeping it healthy.
  • If you have a compressed air filter fitted with a differential pressure indicator or monitor, keep in mind that this differs from a true differential pressure guage. Such devices are not as accurate or calibrated as the latter.
  • Be careful not to fall into the trap of thinking that you must only change your compressed air system’s filter when there is an increase in the differential pressure. A marked fluctuation in differential pressure means that the air compressor has to function at higher pressures for prolonged periods of time to overcome the same. So, fluctuations can occur regardless of the condition of the air filter. Besides, any wear and tear in the filter can sometimes prevent the differential pressure from showing a change, despite being clogged up.

A differential pressure gauge is a valuable tool to monitor the condition of the air filter in a compressed air system, which is instrumental in ensuring that the system maintains high standards of air quality.

VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. We are also an authorized dealer of Elgi air compressors. With over 72 years of industry expertise, we aim to offer you end-to-end solutions and specialized support in this space. Please contact us on +91 98199 07445, and we will be happy to help you meet your requirements.