The role of air compressors in industrial settings is quite crucial. They are used to power various air tools and machinery that take part in the production lines of industries.
There are several different types of air compressors. You ought to choose the one that goes well with your requirements. And for that, you must specify your power, duty cycle and maintenance necessities.
Choosing the right compressor doesn’t ensure its efficient application. Instead, you must emphasise setting up a proper compressed air line installation process to determine optimal operations with compliance and safety.
A] Pre-Installation Planning
Here is a brief understanding of how you can do pre-installation planning for establishing your industrial air compressors within the facility:
1. Site Assessment and Preparation
Before getting ahead with the industrial air compressor installation, you must determine the right location for it. It is always recommended you install them indoors, where the site is dry and clean. Prefer finalising on the location that’s close to the end-application. For better use, keep air compressors separate from other machinery or system units for controlling the air quality.
With such an arrangement, you can ensure there will be no overheating issues, and productivity won’t get hampered due to unwanted noises. The site you choose should also be well-ventilated to keep the air free from dangerous elements such as propane fumes or gasoline.
2. Determining Equipment Requirements
You must specify the associated equipment you would need to approach the compressed air system installation. For that, you will have to calculate the CFM and PSI with respect to industrial application. Calculating CFM would help indicate the flow rate of an air compressor, helping you understand its air-producing capacity for select applications.
To calculate CFM, you must empty the air from your compressor and then refill it to check the time it takes for the tank to be completely filled. Keep an eye on the gauge! Determine the PSI by checking the specifications of the air compressor. Following that, have a look at the electrical needs and gather all essential tools to support the proper air compressor setup for dedicated applications.
3. Compliance and Regulations
You must abide by all the industry standards with respect to the compliance and regulations of installing air compressors. You must take note of the safety, environmental protection, noise and other such regulatory standards and abide by them.
4. Foundation and Mounting
You need to choose a very safe spot for mounting your air compressor. The spot should ensure a stable and flat surface right before using it. It will prevent the system from vibrating during application to prevent accidents or loss of productivity.
B] Air Compressor Installation Steps
Now that you are aware of the prerequisites, here are the steps you must follow in order to seek air compressor configuration and get on with the applications:
Step 1: Electrical Connections
Check the air compressor specifications to confirm the voltage it requires for operating in accordance with the industrial applications. You need to make sure that the service voltage aligns with the compressor’s requirement before it can be installed.
Moreover, it is also crucial for you to see that the compressor is grounded properly. In the end, you should make sure that there’s a proper circuit breaker or fuse installed for being used with the air compressor.
The operating voltage should somewhere be +/- 10% of the voltage mentioned over the compressor nameplate. For the VSD (Variable Speed Drive) compressors, the power supply should mandatorily be symmetrical or three-phase.
Step 2: Cooling System Setup
Proper cooling and ventilation are very important for your air compressor, without which there would be troubles in its operation. The electricity passed onto the compressor is entirely converted to heat during the process. This heat will be passed onto the compressor room, which needs to be cooled down to prevent adverse effects.
You can set up natural ventilation if the compressor room heat doesn’t exceed the mark of 41 degrees Fahrenheit. But, if the heat around the room is anywhere beyond that, you can use forced ventilation through exhaust fans or ducts.
Step 3: Air Intake and Filtration
While seeking air compressor line installation, you should set up the air intake or inlet valve through which the air will enter the system. It is important for you to use the right-sized inlet that goes well with the preceding filter. Once the air is drawn in, it should go through the filter, which will reduce the amount of contaminants going into the compressor system.
A high-quality air filter will protect the compressor system from dust, dirt, oil, solid particles and particulates that flow in with the air. Such filters would protect your system from damage or wear down of parts in the long run.
Step 4: Piping and Distribution
Getting the correct size of pipework is very important for you to get enough flow and consistent pressure at all end applications. The diameter of the pipe will impact directly on the rate of pressure drop. The discharge piping of the compressor should be of equal diameter with respect to its discharge outlet.
Selecting the right pipe would affect the three major areas of an air compressor system, which include air quality, pressure and flow. Choosing improper pipe materials, layout or diameter might obstruct the flow of air and drop the pressure frequently.
Step 5: Condensation Management
The presence of water in the air compressor might damage the parts internally due to corrosion. If you are not taking care of condensate accumulation within the unit, then it will eventually dry upon the metal parts of the compressor motors and trigger rust. As a result, it would cause the air compressor unit to experience drag and overheat.
To prevent such damage, you must get rid of the moisture before it accumulates within the system. While you seek installation of a compressor, you can add external air dryers, integrate a water trap, make use of a piping system to eradicate the moisture and also fit auto drains thereby keeping the system free from condensation effects.
Step 6: Instrumentation and Control Integration
You must install pressure gauges, control systems and flow metres in your air compressor system. All of it would be helpful for you to monitor the compressor performance, alongside keeping track of the pneumatic systems and connected equipment that is using the air.
The control system of your air compressor will allow you to not just monitor but even modify the machine settings. For instance, some compressor controls enable you to automate the loading and unloading aspects while the machine reaches a pre-set pressure level.
Once the air compressor is installed, you should also make sure that these industrial compressors are operated safely. If you are interested, you can refer to our guide, ‘20+ Air Compressor Safety Tips For Users For Safe Operation.’ This will help you use the optima of your air compressors in a safe manner. Now, let’s take a look at the post-installation testing and maintenance requirements.
C] Testing and Post-Installation Maintenance
Once you are done with the compressed air installation, you ought to test the system and run the necessary maintenance to ensure seamless operation of the system. Here are a couple of ways for you to adapt to test the system and implement post-installation maintenance:
1. Ongoing Maintenance and Inspection
Here’s a checklist of regular maintenance or inspections that you must do on the critical air compressor parts. It would help you prevent any possible downtime and ensure that the air compressor system lasts for a long time. The checklist is as follows:
- Change the compressor oil as per the manufacturer’s manual.
- Remove and replace oil-water separators and filters as per the manufacturer’s manual.
- Replace any worn-out compressor belts.
- Check the vents, belts, filters, bearings and other parts for buildup of dust or grime. Clean them if necessary.
- Re-lubricate all the compressor parts.
- Under ongoing maintenance, keep managing the condensation.
- Remove all piping contamination for seamless operations.
- Detect any kind of pressure loss within the piping system.
- Regularly inspect the intake valve and keep it clean.
Conclusion
So, you are now aware of a detailed understanding of how you can approach air compressor setup safely and securely for your industrial applications. Proper installation of compressor and consistent maintenance is the key to ensuring the air compressors give you productive outputs at all times.
You must follow the guide precisely in order to ensure reliability and operational efficiency out of the air compressors connected to your industrial applications. If you are currently looking for a highly efficient industrial air compressor for your production facility, then you can get in touch with us. You would get the best compressors at competitive pricing!