Engineers and plant operators can prevent operating costs and power expenditure from escalating by selecting the right lubricant and optimising compressor operating conditions. You can do the same with your air compressor in Singapore. Here are five tips to keep costs down and maximise performance.
Choose the right air filter and inlet location
Reducing running costs starts at the inlet, the cooler the incoming air, the less power required to produce line pressure. For best results, the air intake should be strategically placed. A clean, dry, shaded outside area at least 1.8 m above the ground is recommended. Minimising the pressure drop through intake ducts when running at full capacity will also assist in lowering operating costs.
Optimise the operating temperature
To ensure optimum operation of reciprocating compressors, keep the cooling water temperature around 5.5ºC above the inlet air temperature. It stops moisture from condensing in the water-cooled cylinders. At the outlet, the temperature should be below 49°C.
For air-cooled compressors, regular checks and cleaning can avoid the problem of dirt clogging the fins of fans and preventing them from operating effectively. Condensed water also needs to be properly drained.
Match lubricants to conditions
Compressors will perform best when they are lubricated with products that match their operating conditions. These lubricants must also be properly stored and dispensed in the right quantities.
For reciprocating air compressors, maintaining the right lubricant feed rate is important; a feed rate that is too low or high can increase wear on cylinders and rings, and increase oil consumption and overheating.
Eliminate moisture and maintain equipment efficiency
Fixing the damage caused by unwanted moisture in compressed air systems can make up as much as 5% of plant maintenance costs, so keeping it to a minimum is crucial. One good practice is to use after-coolers and dryers to remove water from the air discharged by compressors. It reduces condensation in the air distribution system.
Stop leaks and store air reserves safely
Leaks in any part of the air system can increase operating costs, as compressors need to compress more air than in a leak-free system. The storage of reserve air should be made safe and efficient. The best practice is to arrange air receivers to completely drain oil or condensed water from the compressor or after-cooler outlet. A spring-loaded safety valve installed at the receiver is an important safety measure and should be regularly tested to make sure it is in good working condition.
Proper setup, regular maintenance and quality lubrication can help improve the energy efficiency and performance of air compressors and reduce overall operating costs.
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