New Year, New Service Agreement?
Start your year off strong with scheduled service
We’ve all been there! You know you need to service your compressor but there are simply so many other things to do. There’s inventory to count, customers to assist, administrative odds and ends to complete. Keeping up with all the components of a business takes a lot, and it can be hard to make sure your large machinery is regularly serviced. After all, if things are running well, you probably are not thinking too much about them!
It’s when the machinery stops working that you really start to notice it. However, the best way to keep your compressors, vacuum blowers, and chillers running well is by scheduling regular preventive maintenance. Having a trained technician routinely change out parts and adjust settings is so important to the longevity of your machine. A professional set of eyes can often spot and fix potential trouble areas long before they develop into any true issue.
With regular maintenance, the chance of waking one morning to a broken machine needing a long repair time lessens significantly. The smaller, scheduled repairs aim to keep your machines running smoother and more consistently.
Both the usage and environment of your unit will determine the necessary maintenance interval. However, going longer than a year between service appointments is almost never advisable. There are simply too many intricate components. They need to be examined by a trained professional. Think of service appointments like annual doctor visits for your machine. You may not notice anything wrong, but a knowledgeable person might. Hence, why having that regular scheduled time is so important. Just like with your health, spotting something early typically makes it easier to fix.
If you aren’t sure what you need for your unit, our service department is a great starting place. Our factory-trained technicians know the most up-to-date information regarding industrial machinery and compressed air technologies. Talking with someone in our service department could be the beginning of a great relationship. We’ll listen to what machines you currently have and how they typically run. From there, we’ll work to create a customized plan that matches your service needs. You can even enroll in an official service agreement.
Setting up a service agreement is a great option for many of our customers. It eliminates the burden of having to remember to regularly schedule service. Instead, your units will be added to a reoccurring service list and our department will reach out to you. Service agreements even set the frequency of visits and a timeline of when to perform which tasks, customized to your particular need.
So, as we enter this new decade, how do you want to proceed with your large industrial machinery? We challenge you to take charge and schedule routine service appointments. Maybe, taking better care of your units can become one of your 2020 work goals. However you decide to proceed, we encourage you to think about what’s best for the longevity of your machines.
The Importance of Compressed Air Dryers
Dry air is important for an effective and efficient compressed air system. All atmospheric air contains some level of moisture. As air is compressed, the moisture molecules no longer have room to exist mixed with the air. They have to go somewhere else instead. Without proper treatment, that moisture ends up in your system!
Common symptoms of moisture-riddled systems:
For many years moisture in a system was simply accepted as a nuisance of using a compressor. Mechanical problems inevitable arose and maintenance departments continued to live with them. Regularly draining out condensate from compressors was a standard part of compressor operation. However, this solution failed to improve the general efficiency of the compressor and systems with moisture continue to exhibit a variety of problems.
Most commonly, precipitated moisture dilutes a machine’s lubrication. Less lubrication leads to greater wear and tear in the machine. As the parts grind together more harshly, the chance of failure increases. On the whole, the machine has a shorter lifespan. Parts failures lead to shutdowns, production loss, and unplanned downtime, which costs money and creates unpleasant conditions.
Users of undried air also may experience rust and corrosion inside production machines. Not only does this buildup have an immediate effect on the system, but also it can carry downline and cause more problems for production. If temperatures lower enough, the moisture buildup could even freeze, blocking the systems and potentially causing leaks.
Not only will moisture damage the mechanical elements of a system, but it can be very harmful to the process’s products as well. Moist conditions are ripe for bacteria growth. The system’s swift-moving air can easily sweep up the small bacteria. These and other contaminants are damaging to many products, but can have especially devastating results in processes concerning food & beverage or medical applications. Even in less sensitive capacities, poor air quality has negative effects. For instance, paint often loses its adherence and finishing properties if applied using a moisture-riddled compressed air. Knitting machines begin to stick with traces of oil or water vapor and moisture can damage fabric if damp air is used to blow off lint. In general, if the air being used is not high quality, the end product probably won’t be either.
Moisture in a compressed air system can compromise air quality, limit operational abilities, and contribute to long-term equipment damage.
Choosing the right drying method:
Luckily with some simple adjustments and regular maintenance incorporation, you can prevent the devasting damage of air moisture.
The best approach when addressing compressed air moisture is to talk to a system engineer. Someone who understands the components both of your particular process and the operating conditions of various equipment options. CASCO USA has a team of engineers ready to work through your set-up with you. Also, our online resources strive to educate on which air treatment methods are best for your system.
Every process can tolerate different levels of the moisture. To design the most accurate setup, knowing the particular needs of the system are important. Think about how dry the system needs to be. A good way of measuring this quality is by knowing the pressure dew point (PDP). PDP describes the water content in the air. Often it signifies how much moisture a particular system can tolerate. Other important considerations are ambient temperature an inlet temperature. Higher temperatures can generally tolerate more moisture than lower temperature, but it takes more energy to dry systems out in these conditions. Knowing what the typical temperature range is and any common seasonality are important for design purposes.
With all this information in tow, you can work to decide the absolute best match for what your system needs.
How to dry compressed air:
Many options exist to dry compressed air. For applications that can tolerate more moisture, an air receiver tank and water separator may be sufficient. These devices work by cooling air to ambient after its been heated in the pump. Temperature plays a large role in the success of this drying method and often additional equipment is needed.
Adding an air dryer to the system could be the final step in reducing moisture. Refrigerated air dryers cool compressed air after it comes out of the compressor. As the air cools, it can contain less moisture. Some applications may be better suited for a desiccant dryer. The desiccant beads inside the dryer absorb the remaining moisture. Applications requiring high levels of dryness generally need a desiccant dryer. Read more about the different types of air dryers.
Regardless of which drying method you use, the purpose is to remove the moisture before it can move downline. Choosing a reliable air dryer helps to make sure the rest of the system runs correctly. The experts at CASCO USA are ready to improve your system. All you need to do is reach out!
The Extended 5-Year Warranty from Kaeser Compressors
Manufacturers’ extended warranty programs can be confusing. You need to know the requirements, understand what’s covered, and stay in compliance! Luckily for you, we at CASCO USA have a thorough understanding of Kaeser’s extended 5-Year Warranty Program. We’ve decided to help by sharing some of our knowledge below.
The most important question to begin is…
What does the 5-Year Warranty cover?
As a 5-Year Warranty Program participant, your benefits include comprehensive coverage on parts & labor. The warranty lengthens the factory protection on mechanical areas such as the airend, control system, and drive motor of applicable rotary screw Kaeser units. Any eligible issue must be submitted to Kaeser for approval.
What does participation look like?
In order to be eligible for the extended 5-year warranty, users must purchase and install the appropriate annual maintenance kit. These kits contain the high-quality parts and lubricants that ensure the machine receives proper treatment. Regular maintenance remains key to a smooth-running machine with the best performance. Along with the kit to stay in compliance, users must service drive motor bearings according to the recommended time intervals. Maintenance recommendations vary from unit to unit. Be sure you know what is needed or trust your machine service to CASCO USA.
Kaeser also requires users to send regular oil samples. Following the initial oil change from the factory fluid, samples must be sent every 3,000 operation hours. Machines that operate less than 3,000 hours in a year must send in an oil sample at least annually. Every oil sample generates a free fluid analyses. They provide insight into the air system and its general health. In fact, participants with regular fluid analysis tend to catch issues earlier and better comprehend individual components than those without this information.
Users have the option to perform the required services themselves. However, this method is not recommended. With all the necessary steps to proper service, it is easy to miss an important element or improperly document repairs. Little mistakes could prevent warranty claims from approval. In general, having a professional, qualified service team perform service will be better for your machine. Not only can you trust the technicians to know what they are doing, but you also do not have to worry about the hassle of maintaining paperwork. CASCO USA will do that for you!
Why should you participate?
Though Kaeser Compressors prides itself in creating strong, lasting products, occasionally issues do happen. The standard warranty only inclusively covers machines for a maximum of 12 months after startup with coverage of major components up to 24 months. Purchasing an air compressor is a large investment, and you want to be sure to protect your equipment for as long as possible. That’s why participating in the 5-year extended warranty is so great! It lengthens your protection in an easy to understand process.
CASCO USA customers who choose to participate have the support & guidance of our knowledgeable staff. We will work with you to ensure you stay in compliance with Kaeser’s program. Of CASCO USA customers who need to turn in warranty claims, the majority of cases are approved. With our meticulous record-keeping and intelligent staff, we’ll support your machine to the best of our abilities.
Excited about the value participating could bring to your system? Be sure to contact your sales representative about your current eligibility. CASCO USA warranty specialists can also be reached by email (info@cascousa.com) or by phone (724.746.6500).
The Low-Down on Compressor Lubricant
Compressors need lubricant for a variety of reasons. In fact, some may argue that the lubricant is the most important part in keeping a system running smoothly and efficiently. Choosing such an important element may seem daunting. However, the compressed air specialists at CASCO USA are here to help.
Both reciprocating and rotary compressors require specialized lubricant to run. Generally, synthetic or synthetic blends should be used, especially in the case of rotary compressors. Synthetic lubricants have longer life spans and yield better results. Whether you choose a full synthetic or a blend will depend on the specifics of your machine. However, you will never want to put regular motor oil or any sort of non-specific oil into an air compressor. Not only can the non-specialized oil cause problems, but it could even void manufacturer protections.
What is synthetic lubricant?
Synthetic lubricant is created by modifying mineral oil to better fit the needs of air compressors. Usually this modification process involves removing impurities found in the crude oil. The resulting lubricant can seal systems, prevent corrosion, and protect parts against wear. Using the right lubricant can even contribute to reducing energy costs, cooling oil temperatures, & maintenance needs.
Benefits:
Cleaner Machine Operation
Full synthetic compressor lubricant makes the system operation cleaner. There are less byproducts in the fluid and the risk of deposits decrease. With less residue left behind, the compressor does not need to work against itself. The result is a cleaner running system.
Synthetics also have higher flash points. A higher flash point both improves safety and reduces the risk of internal fires. Users should plan on a synthetic lubricant maintaining its properties longer and at higher temperatures than a mineral oil would. Though operating a compressor at too high of a temperature will impact the lifespan and efficiency of the lubricant. Always discuss operating conditions with a qualified compressed air engineer to design the best set-up.
Protection of Parts
Air compressors contain many internal parts that keep the system working. Using synthetics helps to protect these parts. The lubricant not only coats the parts, decreasing system friction & wear and tear, but also the special formula reduces rust and corrosion. The machine can continue to operate as it is supposed to without the fear of buildup causing problems. Synthetic lubricant prevents negative side effects such as damage, efficiency loss, or poor airflow. Instead, the system can simply run.
Cost Savings (Energy Savings)
Cost savings remain the best benefit of using proper lubrication. Both of the above benefits describe how a properly lubricated system requires less work to perform effectively. Whether through decreasing operation errors or decreasing friction between parts, there is simply less “stuff” for the machine to work through. As a result, operation requires less energy. A decrease in energy consumption leads to direct monetary savings.
The secondary way that cost savings appear are through a decreased need for maintenance. As mentioned above, synthetic lubricant better protects internal compressor parts. The parts experience less general wear when they are properly lubricated. They consequentially last much longer and users will need to replace machine parts less frequently. Regular scheduled maintenance should therefore be less invasive and less costly. Not to mentioned the savings by limited unexpected downtime.
Though synthetic options may appear more expensive at first glance. They often last much longer (4-6 times!) than traditional options. With longer operating hours, users will quickly see a return on their investment, and that doesn’t even include the energy savings benefits discussed above!
Choosing the right lubricant
Always refer first to known manufacturer recommendations when trying to decide between lubricant options. Manufacturers have a good understanding of the limitations and the needs of their equipment. Their recommendations come with a good deal of insight and thought. In fact, in some situations, going against manufacturer recommendations can actually prevent consumer protections, such as warranty claims. Be conscious of expectations and available options.
In the case of confusing recommendations, compressed air service specialists, like those at CASCO USA, can help determine exactly what your system needs. They have experience working with a variety of machines and products. They’ll be able to recommend the best option to keep your machine running efficiently, effectively, and smoothly.
Air Receiver Tanks: The Basics
For those not well versed in the compressor industry, an air receiver tank may seem unnecessary. But they are more than mere accessories for rotary screw compressors. Air receiver tanks actually play an incredibly important role in the overall compressed air system. Continue reading for more background on air receiver tanks and their effects on air systems.
Types of Air Receiver Tanks
Two main types of air receivers exist: “wet tanks” and “dry tanks.” The major difference between them is their placement.
Wet tanks are installed before the dryer and should be used in systems that have particularly high humidity levels. The wet tank arrangement allows much of the condensate to drop out of the air before entering the dryer, lightening the dryer’s overall load. A wet tank in combination with condensate drains (More About Condensate Handing) can have many benefits for a system.
Dry tanks are placed downstream of the dryer. This arrangement is especially useful when a system lacks a steady air stream. Dry tanks create protection from surges that can overburden dryers, affecting system pressure, and carrying water down-line. If fast compressor cycles are a concern in a system, then a dry tank arrangement may be a good fix.
Depending on the specifications of a system, a wet tank, a dry tank, or both may be used.
Functions
Air tanks, most obviously, serve the function of storing compressed air. This function is more useful in certain applications. For instance, sandblasting requires more system demand than other processes. Having reserved energy in the tank allows for these high demand activities to continue without draining the entire system’s power. The extra air creates a cushion of power accessible for uses that may exceed the general compressor horsepower.
However, air tanks have an unexpected second use. They can act as an additional heat exchanger. As the air moves through the tank, the general temperature cools approximately 10 degrees. Allowing the air more time to release excess heat lowers the temperature downstream. This decrease not only benefits the longevity of the system equipment, but it also decreases the energy consumption of the rest of the system.
Impact on Energy Consumption
Perhaps the most convincing reasons to install an air receiver tank are the energy benefits. As mentioned above, air tanks can act as heat exchangers with energy saving properties. As the air moves slowly through the tank, the moisture condenses and drains out of the bottom. When the air then moves to the dryer, there is less work to do. Much of the moisture has already been removed. The system dryer can, therefore, use energy more efficiently.
Air receivers also act as a safeguard against waste. By the nature of a rotary screw compressor setup, after every unload, the oil tank vents. The system loses air during this venting, which over time adds up. However, having a properly sized storage tank can lessen waste levels and lower the overall creation levels.
Stored energy in tanks can also reduce peak operation pressure. According to the U.S. Department of Energy, every reduction of 2 PSI results in a 1% decrease in compressor energy consumption. By preventing system pressure peaks, tanks can save a good deal of energy.
Sizing
As with any component of a compressed air system, air receiver tanks need to be sized and fitted to the particular system. Both the variation in consumption demand and the compressor size and modulation strategy will factor into the sizing process.
Though there’s no universal way of sizing an air tank, a common formula is:
t = V (p1-p2) / Cpa
where,
V = volume of the receiver tank (cu ft)
t = time for the receiver to go from upper to lower pressure limits (min)
C = free air needed (scfm)
pa= atmosphere pressure (14.7 psia)
p1 = maximum tank pressure (psia)
p2 = minimum tank pressure (psia)
There are also numerous online tools to help calculate the best size, like this one from Kaeser Compressors. Commonly required information for sizing include flow rate, buffer time, initial receiver pressure, and final receiver pressure.
Of course, talking to one of our system engineers is always the best way to ensure your receiver tank is perfectly sized. They can help with demand and configuration questions, too.
Still unconvinced that an air receiver tank could benefit your system? Check out the following resources to see how a seemingly small adjustment can have large returns for your company.
- The Importance of Using an Air Receiver Tank in a Compressed Air System – Parker
- Air Receivers Specifications – Kaeser Compressors
- Compressed Air Receivers – Engineering ToolBox
Interested in learning more about Compressed Air System components? Check out our Compressed Air 101 Pages.
Designing A Great System with AIRMaster+ Specialists
You want your new compressed air system to run smoothly and efficiently. Your new supply should be ready, useable, and reliable. The design is just as important in this regard as the equipment itself. But how can you be sure that the chosen system layout will deliver exactly what you need it to? By relying on an AIRMaster+ Specialist, of course!
Various software programs exist for the purpose of understanding complex air operation systems. They examine potentially problematic areas and then pinpoint solutions to increase efficiency. However, the most comprehensive of these programs is the AIRMaster+ software tool, sponsored by the US Department of Energy. It allows for modeling of every possible scenario and arrangement. Users can easily test different components and see exactly which set-up will work best for a system
But what exactly is an AIRMaster+ Specialist?
Though AIRMaster+ is available to most everyone, just over 300 people in the world have been designated by the U.S. Department of Energy as AIRMaster+ Specialists. This designation is reserved only for those individuals who have undergone extensive training.
Before even being eligible for this specialist designation, individuals have to have completed a dedicated course on management of compressed air systems. Not only do AIRMaster+ Specialists have a thorough understanding of the software, but they thoroughly understand the complexities of compressed air systems themselves. They know how to change setups and variables to make the most out of the situation.
To earn AIRMaster+ Specialist certification, a mixture of classroom study, written exams, and practical demonstrations have to be completed. Everyone who receives this recognition truly knows how to maximize an air system for efficiency and how to create the most value from a resource.
Where can I find an AIRMaster+ Specialist?
At CASCO USA, several employees have received this designation. Their years of studying compressor systems have resulted in this title, adding to the strength of every CASCO USA system design. With this unique position in the compressor industry, you can trust that our designs will match all of your needs. When looking for quality system designs, trust the established expertise at CASCO USA.
AIRMaster+ Specialist certifications are the culmination of years of hard work and dedication to the compressed air industry. Not only do they differentiate our employees, but they demonstrate the commitment to excellence that differentiates CASCO USA.
For more information on the DoE AIRMaster+ program, click here.
Importance of Air Treatment For Your Compressed Air System
Clean, quality air is crucial to having a well-running compressed air system. However, since the source air comes from the surrounding ambient, it most likely contains contaminants and particles — which are not ideal to flow into the compressor system! How then should the air be cleaned? With proper air treatment, of course! Without this crucial system support, your system may experience a variety of problems.
Common Problems of Poor Air Treatment:
Contaminants are not compressible
Contaminants include environment particles such as dirt, chemical, and water vapor as well as contaminants from the compressor itself such as lubricant particles. In general, these contaminants cannot be compressed. The unfiltered air is then forced into a smaller space. The now concentrated contaminants cause buildup in piping, valves, and machinery.
Moisture can cause equipment damage.
Water vapor is one of the most common particles in ambient air. Compressing the air, reduces its ability to hold water vapor and the liquid water must drop out. This moisture can then move down line and cause problems at the point of use. Some common effects include rust and corrosion of lines and machinery, poor finishes of sprayed paints and coatings, and product contamination. Remove this moisture through a drying process to alleviate these issues.
Improper quality for application.
Each compressed air application is slightly different from the next. In order to have the best final system, knowing exactly what your system requires is useful. Each piece of air treatment adds costs in the form of equipment, maintenance, energy, and pressure drop. Sometimes a bit of contamination could be tolerable and the extra effort in installation air treatment equipment would complicate the system. Customizing a system to your needs is the best way to really build the necessary system. Know the specified class for particulate, humidity, and oil to determine proper air quality. This rating expressed as a number in the form X.Y.Z. can be found from most OEMs. Incorrect treatment adds extra processing costs and hassle to a system. Generally, you want to build a system matching the lowest common denominator of need. Add extra treatment to specific areas if necessary.
To ensure your system has high quality air, you’ll need to use proper air treatment methods. Depending on your system you may need refrigerated air dryers, desiccant dryers, or inline filtration. Luckily, CASCO USA stocks all of this equipment and more. To learn about this topic in more depth, be sure to visit our Compressed Air 101: Air Treatment page or contact us to discuss the specifics of your system. Don’t wait and suffer problems; protect your system today!
Signs Your Compressor Is Too Cold
The cold breezes of winter are upon us. As outside temperatures begin to drop, you’ll want to be sure to check on your air compressor. Ideally, the air surrounding a compressor should not drop below 40 degrees Fahrenheit. However, often machines kept outside or in poorly insulated areas have ambient temperatures that fall below this level, especially in the winter time. If that is the situation for your system, be sure to keep an eye out for any of the following conditions. They may indicate your compressor is experiencing cold related problems.
Corrosion
The cold will limit the system’s ability to remove excess moisture created during the compression process. Allowing this moisture to set in the system could cause corrosion in system controls and components.
Frozen Condensate
If ambient temperatures are cold enough, that extra moisture may actually freeze. Any areas where condensate gathers are especially prone to freezing. The frozen condensate may cause blockages or breakage in pipes or other system components leading to larger issues in your system.
Electrical Use Increase
With dropping temperatures comes thickening oil. The oil should not freeze, but the resulting sludge consistency will not flow nicely through the system. More electricity will be required to move the material through the components and keep everything lubricated as necessary. If energy costs are increasing, thickened oil may be the problem.
If you are noticing any of these signs in your compressor, your air compressor may be at the wrong temperature. The best way to deal with these problems is to schedule service with an air compressor specialist as soon as possible. No matter the make or model CASCO USA’s service personnel are experienced and ready for the challenge.
Following the service, be sure to follow any specific instruction the technician gives you. Also, performing regular maintenance for the duration of the winter can help to keep your air compressor working well. By cleaning out ice, draining condensate, and checking oil levels, you may catch the little problems before they spread across the entire system. Taking care of your compressor requires daily efforts!
Video: Maximizing Compressed Air Systems
We understand that compressed air systems are very complex. There’s many moving pieces and everything has to come together just so. Luckily for you, our compressed air experts have compiled a video explaining key methods to increase compressed air efficiency.
Watch the video below to start minimizing your losses today. For more information on maximizing compressed air systems, visit our Compressed Air 101 page.
Video: Positive Displacement Compressors
Positive Displacement Compressors are the most common air compressors for industrial applications. Learn more about the different types and their uses below.
For more information, be sure to visit our Compressed Air 101 page about positive displacement compressors.