H2: Taking Out The Guesswork & Ensuring Peace Of Mind

• We understand that the day-to-day running of your facility will take precedence, often resulting in compressor servicing taking a back burner
• This is why we aim to provide you with all the information you need to take the guesswork out of compressor servicing to ensure complete peace of mind
• Below are some of the questions we’ve found are the most frequently asked

 

Servicing & Replacement:

How often should a compressor be serviced?

Typically, the recurring maintenance intervals will depend on the operating hours and time of your air compressor. Even if a compressor doesn’t reach its operating hours within 6 to 12 months or until the next recurring maintenance, it will still require a service. This is due to wearing parts and filters, which are subject to an ageing process. Operational safety and the guarantee of trouble-free operation are essential, which is why it’s recommended to observe the specified maintenance intervals depending on the type of plant. The minimum interval is once per year.

 

How often must I change my compressed air filter, whether that may be an oil filter, air filter, fine separator filter, or compressed air mains filter?

The answer depends entirely on the type of filter element and its function. That being said, filter elements should typically always be changed every 6 months or at least every 12 months.

 

Why should I replace my filter element regularly?

No matter the filter type or function, regular replacement is vital to ensure a continuous supply of high-quality compressed air and to reduce energy costs.

 

How often must the oil be changed?

An oil change and recurring maintenance often go hand in hand. However, this can depend on the type of compressor oil you use. For example, whilst mineral compressor oil should be changed every 4000 operating hours, synthetic oils can usually be operated twice as long. You also need to consider the installation and suction conditions, as these factors may cause oil change intervals to vary. If you’re in any doubt, it’s recommended to have the oil condition tested in the laboratory using a comprehensive oil analysis (oil check).

 

What kind of oil should I use?

This is a commonly debated question, but in principle, a compressor oil approved by the plant manufacturer is the best bet and must be used. Compressor oil is of great importance for oil-lubricated screw systems and must cool, compress and lubricate. However, it also needs the property of being separable again afterwards. Depending on the application of your compressed air system, mineral oils can also be used as can synthetic or food oils.

 

When do I have to replace the compressor stage?

The compressor stage in an oil-lubricated screw compressor is often subject to bearing wear due to its design. The bearing manufacturers specify a running performance of approximately 35,000 operating hours for their bearings. Therefore, we recommend the preventative exchange of bearings once they have reached this number of operating hours. The Assure Service Agreements and Warranty ensure the preventive exchange is regulated.

 

How long is the lifetime of a compressor, and how can it be extended?

The major factor that contributes to the service life of an air compressor is its operating hours, not necessarily its year of manufacture. Therefore, it’s not necessarily possible to accurately quantify a service life. Due to subsidy programmes and technical progress, it should instead be examined whether an ecological and economic added value can be created by replacing an older compressed air system. This value may otherwise be achieved by modifying existing systems, for example, by retrofitting heat recovery systems or by replacing energy-efficient electric motors.

 

Compressor Testing:

When do I have to carry out a pressure vessel test?

The recurrent pressure vessel inspection is regulated by the Ordinance on Industrial Safety and Health (BetrSichV), which specifies that a visual inspection should be performed every 5 years and a pressure test every 10.

 

If the pressure volume product is less than 1000L (maximum permissible pressure of the tank x tank volume < 1000L), this test can be performed by a competent person.

 

If the volume is over > 1000L, the test must be carried out by an expert from an approved inspection body (ZÜS), such as TÜV or DEKRA.

 

Do I have to take a DGUV3 test at the plants, and if so, when?

The DGUV 3 test is an accident prevention regulation of the German Social Accident Insurance (DGUV). The DGUV 3, in particular, deals in detail with electrical systems and equipment used commercially. The recurrent inspection of compressors is based on the risk assessment for air compressors. As a rule, this inspection must take place every 4 years and can be carried out by a service technician in connection with maintenance.

 

Servicing Agreements & Monitoring:

Can I obtain a bespoke service agreement for my compressor?

Every compressed air system has its own unique requirements and features. It’s possible to obtain a service agreement for each of these requirements and determine the scope of the servicing agreement yourself. In this way, together we ensure that operational reliability and operating costs are guaranteed.

 

Is there a monitoring system for the compressors?

For all air compressors, we offer the iConn compressor service, which monitors the operating conditions of the compressors, thus enabling 24/7 monitoring of your plant. Ecoplant is another service we offer that uses AI to ensure you maximise your system’s efficiency.

 

Energy Saving:

Can I retrofit a heat recovery system on my old compressor?

Heat recovery is an incredibly effective way to increase energy savings by recycling and repurposing the heat created by the compression process. In principle, a heat recovery system can be retrofitted to an old compressor. However, the design must be agreed upon to ensure safety and efficiency.

 

Does it make sense to switch off the refrigeration dryer at the end of production to save energy?

Ecologically, it’s always sensible to switch off unnecessary energy consumers. However, when it comes to refrigeration dryers, it should always be remembered that the dryer capacity is not immediately available after the dryer has been switched on. Refrigerant dryers need a pre-run to cool down its system. The time for this varies from dryer to dryer, so as a precaution, the dryer should be switched on half an hour before the compressor starts.

 

If the dryer cannot be started in time, the air dryer should remain switched on permanently. This is because the costs and energy required to remove the condensate from the piping system far exceed the possible savings by switching off the refrigeration dryer.

 

General Questions:

Why does the compressor tank heat up?

Heat is a natural by-product of the compression process. The release of heat during compression thus heats the compressed air and the oil, causing the tank to heat up.

 

How much compressed air can flow through a pipe?

This depends entirely on several factors, including material, conditions, and pipe diameter. For more information, check the specifications on CompAir’s EPL Pipework page https://www.compair.com/en-gb/products/epl-piping.

 

Can an air compressor explode?

You should always bear in mind that compressed air can be dangerous and, therefore, should be used with appropriate caution. Even high-quality compressed air equipment can have defects if used, handled or maintained incorrectly. Since the compressed air is under high pressure, there is, of course, a risk of sudden decompression in the event of a defect.

 

Can the container of an air compressor be welded?

In the event that the vessel of a compressor needs to be welded, the welding process must be performed by an ASME-certified welder, as all pressure vessels supplied by our provider, CompAir, are certified. Therefore, ASME-certified welders must also carry out any welding work on these vessels.

 

Does the operation of an air compressor produce carbon monoxide?

In principle, air compressors compress the ambient air. Whilst electrically powered air compressors don’t produce carbon monoxide when operating, they may suck in and compress carbon monoxide if it’s present in the ambient air. Make sure to always check the applicable regulations if you have any concerns about carbon monoxide.

 

Does a compressor filled with compressed air weigh more?

If the air reservoir contains compressed air, it weighs more than it would if it was empty. As a general rule, you should never move or work on compressed air equipment under pressure or connected to the power supply.

 

Any other questions? Please contact us, and one of our experts will be happy to help.