Compressors are designed to operate in ambient temperatures of between 5 and 35°C.  While manufacturers continue to make great advances to ensure reliable operation in temperatures outside of these thresholds, it is still important to consider the siting of the compressor to help minimise extreme lows.

This depends of course on the practicalities of installation and whether the compressor is in a heated compressor room or outside, but it should be remembered that wherever the compressor is housed, it must be well ventilated in order to function reliably.

Protect pipework

Holes in the compressed air pipework will create pressure drops, meaning that the compressor has to work harder and therefore consume more energy in order to maintain the correct system pressure at the point of use.

This is of particular concern during cold weather, as any moisture retained in the compressed air will pool in low points and eventually freeze, blocking pipes and restricting the flow of air or at worst leading to cracks and a costly repair bill.

To avoid such issues, operators should regularly check the condition of the dryers.  Dryers remove the majority of moisture from the air, which is separated as condensate. As well as ensuring this condensate does not enter the compressed air network, it is important to check drains regularly for signs of freezing.

Check fluids

Low temperatures affect air compressor coolants and oils. Oil can thicken or becoming too viscous to enable the working components of the compressor to move freely. Oil that is too old can also contain water, which can freeze at low temperatures, affecting compressor start up and potentially damaging internal components.

Regular servicing to check the health of the lubricating oil is one simple way to avoid costly compressor breakdown.

System design

When compressed air systems are designed, items such as air receivers and coolers are often located outside to benefit from the cooling effects. Other equipment such as control valves, pipes and joints then provide the necessary connections in to the factory building.

As outside temperatures drop material properties change, leading to the potential for brittle fracture, especially of welded joints in air receivers or of valves that may have water vapour pass through them.

While lagging compressed air pipes, installing low power trace heating or wrapping an air receiver may seem like a good solution it is not necessarily the best option. Instead, plant engineers should apply a system approach to combating low temperature operation.

For existing compressed air systems, upgrades need to be proven to be both cost effective and efficient and should include a comprehensive service and maintenance package from a competent and qualified engineer. BCAS member companies can offer a range of quality support packages, ranging from emergency repair through to full condition monitoring, which can predict potential problems with compressor components before they affect system performance.

For new installations, the issue of low temperature operation should be accommodated at the design stage, taking in to account factors such as compressor siting, pipework options and downstream equipment reliability to provide a robust and weather proof system.

So, while it may be cold outside, there is no reason why a compressed system cannot function safely and efficiently.  

Motion Control Industry Awards Dinner

BCAS, through the UK Motion Control Alliance, has announced the launch of the 2016 Motion Control Industry Awards Dinner.

The event is managed by the Motion Control Alliance, comprising the British Compressed Air Society, the British Fluid Power Association and the British Fluid Power Distributors’ Association.

The awards dinner will be on Tuesday 12th April 2016 at the National Conference Centre (which shares the same site as the National Motorcycle Museum in Birmingham), alongside the AirTech exhibition at the NEC, with the aim to recognise and reward the achievements of both individuals and companies in the motion control industry.

Entries are now open on the website, http://mci-awards.com and it is free for any member company or individual within the motion control industry to enter any one of nine categories. Members can put forward entries for themselves and their company, or they can nominate others.

The closing date for all entries is 5:00pm on Wednesday 23rd December 2015.