A Short Guide to Moisture Control in Air Compressor Systems

It’s not uncommon for moisture and condensation to accumulate in your compressed air systems. Hence, you need a solution that can help prevent excess condensation in your compressor, especially if you’re in an industry that demands 100% moisture-free condensed air.

Why does your air compressor contain moisture?

Moisture is a natural by-product of the compression process. It just extracts the moisture that already exists in the ambient air.

Some of the common causes of moisture build-up in compressors are:

  • Equipment damage – When the internal parts of compressors wear out, it leads to moisture build-up. This causes the machine to lose its power to extract air as well as heat up, leading to more moisture build-up.
  • Environmental factors – Humid conditions also cause the machine to take in more moisture leading to more condensation.
  • Pressure on the compressor – When your compressor is strained beyond capacity, it gets heated up further more. This is especially the case with piston compressors, which heat up more when used for longer periods of time.

Why is excess moisture harmful?

Excess moisture hampers the workings of your air compressor. Some of the consequences of excess moisture are:

  • Rust and corrosion – Build-up of water in your compressors can lead to rust in and corrosion of the machine and pipes.
  • Damage to pneumatic controls – The machines that rely on pneumatic controls suffer from severe damage when there is moisture build-up inside them. That can result in rust and scale build-up.
  • Rapid wear and tear of production equipment – Moisture can cause the lubrication inside compressors to wash away. This causes metal components to wear away faster.
  • Damaged circuits and in-line filters – In-line filters help clean particles and oil from your compressor. Moisture increases pressure in the machine and reduces the filter’s efficiency.
  • Contamination – Moisture can damage end products, valves, and motors. It can easily contaminate solvents, lubricants, and food products.

How to eliminate excess moisture from your compressor?

Some of the solutions you can try out to remove moisture build-up from your compressors are:

  • Install an air dryer – An air dryer works in tandem with an air compressor to remove moisture. There are four common types of air dryers: refrigerated dryers, desiccant dryers, membrane dryers, and deliquescent dryers.
  • Get a piping system – Piping systems are one of the most cost-efficient systems. In these setups, the metal pipes absorb heat to bring down the air temperature, and can be a good solution for office buildings.

VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. With more than 72 years of industry experience, we provide best-in-class solutions and customized support in this field. We also provide a number of ELGi air compressors. Contact us at +919819907445 and we would be happy to help you determine the right air compressor for your needs.

Why My Air Compressor Is Losing Pressure?

What is Compressed Air Pressure Drop and How Do You Minimize It -  Fluid-Aire Dynamics

Air is drawn in through the inlet valve, compressed to the necessary volume, and released through a discharge valve into a storage tank by air compressors. An electric motor typically powers the compression operation. When the system is using a much greater quantity of energy than before, pressure drops will be apparent. It is important to eliminate or reduce pressure drops wherever possible as this will improve the system’s efficiency and help reduce your maintenance costs.

You can reduce or eliminate the pressure drops in the following ways:

Examine Tubing

If your Elgi air compressor system has tubing, it is crucial to do so in order to ensure that the tubes are still airtight. Tubing issues might also be brought on by rust build-up. It’s time to replace the tubing if you notice any rust accumulation or cracks.

Improve the piping layout

Although it has been demonstrated that piping systems older than five years can leak up to 25% of their capacity, many institutions are sluggish to replace ageing machinery. The majority of institutions still employ galvanised iron, also known as “black iron,” for their Elgi compressed air pipe systems even when a more effective option is available.

Look for worn-out hoses

Air leaks could be caused by kinked or worn-out hoses. Regular hose inspections to ensure they’re in top functioning order may help you detect leaks earlier and prevent problems from getting worse. Verify that none of the hoses in your system are positioned so that they are under stress.

System connections should be taken into account. Each connecting piece needs to be accurate in size and tight. If any of your connection points are unnecessarily convoluted, it might be time to redesign your system with a more straightforward strategy in mind.

Check Regulators

The pressure regulators’ settings could be the source of the pressure drop and energy rise. You can try to reset it, but if the problem persists, it might need to be replaced.

Replace Lubricators

The lubricators on your air compressor must correspond to the system’s actual flow rate. They might need to be altered if they are not operating properly within the constraints of your system.

Filter upkeep or replacement

After leaks have been found and addressed, it’s crucial to take action to stop further breaches from developing. Leaks caused by dust, corrosion-causing moisture, and the accompanying pipe sludge reduce efficiency and raise the possibility of failure or end-product contamination. Regular system maintenance not only minimises risk but also stops new leaks from developing. The quality of compressed air is ensured, and pressure drops are avoided through routine filter changes.

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.

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.

What Type Of Oil Should You Put In Your Commercial Screw Compressor?

Just as parts of your car and other appliances need to be lubricated in order to perform properly, so does your air compressor. But how can you tell what kind of oil is suitable for your air compressor, particularly a commercial screw compressor? To understand this, let’s first take a look at the role of air compressor oil.

Air compressor oil is a lubricant that helps to reduce the early wear and tear of air compressors. It can either be synthetic or natural and varies in characteristics like makeup and viscosity. It is important to note that air compressor oil is different from motor oil. For one, the latter contains detergent and much more carbon and sulfur.

Apart from lubrication, the benefits of using air compressor oil are many:

1. Absorbs heat

The oil keeps the air compressor at a cooler temperature by soaking in the heat that is emitted.

2. Resisting oxidation

The additives present in air compressor oil help keep the oxidation and acid formation processes at bay.

3. Improves longevity

The additives in air compressor oil also play a role in lengthening its shelf life, keeping the components of the machine protected when in standby mode, and increasing the compatibility of the oil with various conditions.

4. Stands up to the cold

Air compressor oil remains viscous even in cool temperatures, unlike many other lubricants.

The two main types of air compressor oil are standard and synthetic

  1. The standard type of air compressor oil contains a mineral oil base. This makes it cheaper than synthetic and is advisable for light or medium-duty and those who need not use their compressors continuously.
  2. On the other hand, synthetic air compressor oil contains a heavily processed and refined synthetic base. As a professional who runs an air compressor more than thrice a week, this is a suitable option for you. What’s more, synthetic oil keeps the air compressor functioning smoothly and with little to no noise. It also does a good job of preventing it from overheating.

For commercial screw compressors, it is best to use synthetic oil. These do not contain additives or sulfur that can often produce an unwanted buildup on the valves. They are also consumed at a slower rate than the standard kind, help to prolong the life span of the compressor, and stay cooler during operations. What’s more, they create fewer deposits of sludge and carbon that can adversely affect the performance of the machine, and produce air discharge at lower temperatures than standard oil. Synthetic oil also makes for safer operating conditions as its ignition temperatures are much higher than standard oil.

Suffice to say, synthetic oil is the best choice to keep your commercial screw compressor performing optimally.

ELGi Air Lube Oil provides an effective solution to suit various applications and work environments. You can choose this carefully formulated oil as a reliable way to meet your needs in different operating conditions.

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.

5 benefits of regularly changing compressed air filter elements

5 benefits of regularly changing compressed air filter elements

Compressed air is indispensable to a vast number of manufacturing and industrial applications including pneumatic tools, petrochemicals, and food processing, among others. Most compressor systems are fitted with a filtration system to optimize the movement of the air and minimize the risk of contamination. To keep the system functioning smoothly, it is necessary to conduct regular maintenance and replace the components that have become worn out. Parts of the air filtration system in the compressor have a limited shelf life and in order to keep working effectively, they must be checked and replaced periodically. Let’s take a look at five benefits that changing the compressor’s air filter elements regularly provides:

1. Maintain a high quality of compressed air

Changing the air filters regularly makes for a safer, cleaner work environment without the risk of undesirable contaminants that can cause damage to your staff and equipment. To keep the air filtration system unclogged and functioning at peak efficiency, you need to change the air filters as often as required. Check with the manufacturer to know what the recommended frequency of your filters is.

2. Protect adsorption dryer beds

In some systems, using fresh new filters enables the adsorption dryer beds to operate at their most efficient levels. With reduced particulate matter present in the airflow over these, they are going to remain healthy more easily and offer maximum advantage.

3. Decrease operational costs

Changing the air filter parts regularly cuts down on the risk of running into problems with the entire system which can result in downtime, costly repairs, and all-around inefficiency. Without proper maintenance of the air filtration system, the compressor has to work harder to deliver the required airflow. This puts a burden on the compressor and makes it consume more energy and be susceptible to damage and lowered durability.

4. More productivity and profitability

An outcome of conducting consistent maintenance and changing the air filters is that you will benefit from a boost in efficiency, thereby resulting in increased productivity as well as profitability for your business.

5. Sense of assurance

Changing the air filtration parts of your compressor system keeps everything operating much more smoothly than if you did not. It is a habit that gives you peace of mind and a sense of assurance that your system is running at the best of its ability in the safest way possible. It reduces the anxiety and inconvenience of unexpected downtime. This in itself is invaluable when it comes to the daily operation of your business or factory.

These benefits far outweigh the consequences of not changing the air filter parts regularly as required. So, keep them in mind when maintaining your air compressor system!

VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. With more than 72 years of industry experience, we provide best-in-class solutions and customized support in this field. We also provide a number of Elgi air compressors. Contact us at +919819907445 and we would be happy to help you determine the right air compressor for your needs.

Here’s What You Need to Know About ISO Classes for Compressed Air Quality

What You Need to Know About ISO Classes for Compressed Air Quality

We’ve heard the term “ISO standards” quite frequently. But what exactly are they, and why are they so important? Let’s take a look at the concept. The International Standards Organisation (ISO) is a non-governmental body made up of a network of institutes from 159 different countries. ISO is the world’s largest developer and publisher of international standards and is accepted universally.

Compressed air is an indispensable utility that is used widely across different industries. But, compressed air is not all of uniform quality. Some uses, such as pharmaceutical production and food handling, call for impeccable quality and cleanliness of the air. In other cases, the primary objective may be to ensure the lifetime and reliability of industrial tools that are powered by air. The ISO standards play a key role in determining the level of air purity required for your particular application. Meeting ISO standards is also important in maintaining and protecting the quality of your production. In some cases, not complying with them can lead to heavy penalties or even your production facility being shut down!

The ISO 8573 air quality standards and ISO 12500 compressed air filter standards help lay a sound foundation for selecting the right air treatment products. ISO8573 is the compressed air quality standard and comprises nine separate parts — part 1 for quality requirements of the compressed air, and parts 2 to 9 for the methods of testing for a range of contaminants.

Compressed air contains contaminants like moisture and pollutants, and must be filtered according to the application’s requirements. Usually, the purer the air must be, the more costly it is to produce. This is why it is crucial to choose the right levels of air purity in order to reduce costs and benefit the environment.

The ISO 8573-1:2010 is a useful tool that makes the task of choosing the right air purity for your application that much easier. It ranks the acceptable levels of different types of contaminants as classes.

The ISO 8573-1:2010 standard is divided into three groups of contaminants—solid particles, water (including liquid and vapor), and oil. Each of these categories is further classified into ten different purity classes — eight for particulates, ten for water, and five for oil. The lower the assigned number to a category, the higher the air purity requirement for it. For example, class 5 would require far less air purity than class 1.

Now that you know how to match the ISO class to the compressed air quality required, how will you select a filter? The answer is simple — just find the particular ISO class on the filter. Once you identify the ISO class for your particular task, planning the equipment you would need becomes much easier.

VEMC provides a variety of Elgi air compressors. For more help with understanding ISO classes for compressed air quality, contact us on +919819907445 and we would be happy to assist you. VEMC is ISO 9001:2015 certified and is a pioneer in the field of electromechanical engineering products, allied equipment, and services.

How To Achieve Efficiency, Performance, And Quality Compressed Air Strategy

Compressed air is a common source of energy that is used across several industries, including manufacturing. Compressed air can also prove to be quite expensive, often consuming more energy than most equipment in a manufacturing plant. The good news is that compressed air systems can be greatly improved in efficiency, performance, and quality with the right strategy. 

There are three main components of the air compression system that influences performance, efficiency and quality. Let’s take a look at them.

Composition of the air intake

Clean air intake by the system allows the compressed air to move smoothly through it. Contaminated air is impure, so a build-up of it over time leads to wear and tear, and makes the storage capacity suffer.

Temperature of the air intake

The cooler the air, the less energy is required to compress it. The temperature of the intake air determines its density.

Humidity

Moisture can harm the air compression system if it collects inside because it causes the parts to rust. It can also catalyse wear and tear, and leaks while reducing the storage capacity. Making sure the air is dry will more likely prevent such damage to the system.

You can also optimize the design of the air compression system to increase its efficiency. There are three ways to do this:

Cooldown intake air

Since the energy required to compress cool air is less than that for warmer air, you can move the system into a shaded area to lower the temperature of the intake air.

Straighten the path

Sharp bends or narrow delivery lines can increase friction and the number of pressure drops in the system. Implement a straighter path into the system to get higher pressure, thus reducing the overall amount of energy required to compress the air.

Use several small compressors

Larger air compressors consume more energy per unit while working with only a partial load, thus making it inefficient. Try using multiple smaller air compressors with sequencing controls so that you can shut down portions of the system just by turning off some of the compressors.

Other practices that help your air compressor perform at optimal efficiency are:

Maintaining the compressor

Regularly check the air compressor system for any leaks, premature wear and tear, and the build-up of contaminants. Ensure that procedures are in place and train employees to operate the system properly.

Changing filters

Filters make sure that only the cleanest air reaches users. However, these filters may get clogged up with dirt, grease, dust, and other contaminants. Clean them often so that the system does not consume more energy to function due to a pressure drop as a result of clogged filters. You can also deploy longer-life and low pressure drop filters of a size suited to the maximum flow rate.The above practices will go a long way in achieving efficiency, performance, and quality of your air compressor system. VEMC offers a number of ELGi air compressors. Contact us on +919819907445 and we would be happy to help you determine the right air compressor for your needs. VEMC is ISO 9001:2015 certified and is a pioneer in the field of electromechanical engineering products, allied equipment, and services