As diverse as the many applications they’re used in, compressed air inspections and maintenance programs can have a huge impact on companies’ overall operations and bottom lines.
At Industrial Compressor Solutions, we understand the importance of high-performing compressed air systems, so our service team comes directly to your facility for in-person evaluations. We review your specific compressed air needs, evaluate your equipment, and take a piece-by-piece approach to inspecting every element of your system in order to determine the best solution.
Common Compressed Air System Issues
Our team of professional engineers evaluates every aspect of your compressed air system, identifying and isolating issues for efficient, speedy compressor repair. Some of the most common compressed air issues we come across include:
- Overheating, low-pressure, or leaking compressors
- Refrigerant leaks, faulty drains, and excess water in dryer systems
- High differential pressure and contamination problems in filters
- Faulty or failing drains
- Leaking or overflowing oil and water separators
- Plant air system leaks
- Faulty regulators and lubricators
- Failing quick disconnects
- Overall air quality and pressure drop issues
Repairing and Managing Air System Leaks
Air leaks can cause serious problems in compressed air systems, negatively affecting multiple areas of production and resulting in:
- Financial loss from the bottom line — When not running efficiently, systems cost more and perform less.
- Productivity loss in tools — Air pressure drops result in subpar tool operation.
- Time loss in production — Maintenance and repair downtime translates directly to lost profits.
- Reduced lifespan of related equipment — Systems compensate for leaking by demanding higher capacity and higher performance than are actually needed.
The Industrial Compressor Solutions team can help to isolate the sources of leaking to ensure optimal system performance and cost-efficiency. Common sources of leaks include:
- Open condensate traps and blow-offs
- Lubricators, regulators, and air hoses
- Control and shut-off valves
- Worn-out disconnects, gaskets, seals, or thread sealants
- Ineffective filters
- Poorly maintained tools or attachments
- Old or idle machines
- Incorrect use or management of air
In addition to isolating and managing leaks, we also check the overall health of your system to ensure that maintenance and setup are up to code and in compliance with important industry standards. We’ll help you avoid any contamination or trouble spots that could lead to future system failure.
Troubleshooting Tips for Compressed Air Systems
Simple steps can be taken to prevent issues in compressed air systems. When managing your compressed air system, keep the following tips in mind:
- Tightening the point of connection is sometimes all it takes to stop a simple leak.
- Careful installation with full attention to proper procedure and investment in high-quality fittings and optimized piping, tubes, hoses, and valves will result in fewer long-term leaks.
- Attentive air management with the use of engineered nozzles, cutoff valves, and coolers can help reduce the overall demand for air pressure and minimize energy consumption and system stress.
- Regular audits, whether walking the line or employing professional full-system audits, can help to identify leaks and eliminate overall system pressure drops.
- Filter maintenance programs help to prevent dust, sludge, humidity problems, and corrosive buildup in a system.
Our team is dedicated to helping you find the right solution for your particular compressed air needs. We regularly repair and replace components for many major brands, including Kaeser, Sullair, Ingersoll Rand, and many more.