The Impact of Cold Weather on Air Compressors

Anglian Compressor’s experts warn customers about the significant effects of cold weather on their compressed air systems. Cold temperatures can create various compressor performance issues and safety concerns when not managed appropriately.

Seasonal temperature drops inside the compressor room and related areas can prevent a compressor from starting. Rotary screw compressors experience increases in oil viscosity, leading to overworked equipment and potential shutdowns.

Proactive measures, including regular maintenance and better operational oversight, are required to keep your compressed air system operational. This blog post delves into why colder temperatures are problematic, how to protect your air compressor, and which preventative measures to take.

1. Effects of cold temperatures on air compressors

The impact of cold weather on air compressors potentially worsens performance and causes defects and breakdowns. The design of air compressors allows them to function at temperatures above 5°C or 40°F. Freezing or sub-zero ambient temperatures are not their friends.

Below, we explain what can happen when attempting to operate compressed air systems in the lowest temperature ranges.

Starting difficulties:

Air compressors often have trouble starting when temperatures are in the single digits. Some compressor types include fail-safes to protect their internal parts.

For example, a temperature limit switch inside screw compressors prevents them from starting when temperatures are below 5°centigrade.

Battery performance degrades in frigid conditions. Operating in bone-chilling temperatures causes equipment to become overworked. The batteries drain faster, raising the electrical current and repeatedly tripping electrical breakers.

Increased oil viscosity:

Oil viscosity – its thickness and ability to lubricate equipment successfully – is seriously impaired.

Unfortunately, oil becomes thicker in cold temperatures, forcing motors to run harder to compensate. This adds extra strain to the compressor pump and related equipment, causing faster wear and a reduction in lifespan and increasing the potential for a breakdown.

Energy efficiency is affected, too. Higher amps are required to push the motor’s drive train. Consequently, energy costs rise.

Condensate freezing:

Air systems produce condensate through the compression process. It requires filtering to pass unimpeded through the compressed air piping and escape through the condensate drain.

Overly low internal temperatures cause frozen condensate. This prevents normal airflow and causes air pressurisation drops. Blockages also occur, affecting internal operations.

Moisture stuck in the air system and control lines freezing occurs at approximately 32° Fahrenheit. Drain valves freeze, heat exchangers crack, and air dryers suffer.

Component damage:

Seals and hoses are made from elastomer or rubber materials. These harden in the cold, resulting in reduced flexibility, and they may become brittle. This leads to leaking seals and cracked hoses, causing internal damage and potential downtime.

Both water fittings and hoses are vulnerable to temperature changes. They contract or expand in response to wide temperature variations, creating additional damage unless mitigated through temperature control.

Metallic components are not invulnerable either. Components alter their dimensions because of winter weather temperatures, creating unforeseen misalignment concerns within a larger compressor air generation system.

Talk with our experts at Anglian Compressors to winter-proof your compressed air system.

2. Preventive measures for cold weather operation

Effective operation of air compressor systems in chilly weather is possible. However, initiative-taking measures are required to prevent performance degradation and equipment damage.

Maintain ambient temperature:

Compressor rooms and enclosures used as installation locations require heating to prevent ambient temperatures from falling to critical levels.

This applies to all air equipment, including air compressors, heat exchangers, and air dryers. Exposed machinery pipework and ducting networks, whether indoors or externally situated, require consideration.

Heat recovery, which harnesses waste heat from compressed air systems, is beneficial. However, complete dependence on this method to maintain warmer temperatures is ill-advised. Instead, portable heaters can be used as a separate heating source to rapidly increase internal room temperatures when needed.

Use appropriate lubricants:

Low-viscosity lubricants, designed to function well in colder temperatures, are essential. They reduce the degree to which oil thickens as temperatures decline. This avoids overworking motors, creating additional wear on parts, or using extra energy.

Frequently checking oil levels is vital. This helps to ensure that:

1. There is sufficient oil volume.
2. The oil has not become too thick, preventing successful lubrication.
3. The lubricant has not degraded through overuse.

Regular drainage of condensate:

Condensate can freeze internally. Frozen condensate inside pipes can cause them to burst. Automatic drain valves may freeze or suffer ice-related surface blockages. Water becomes trapped, and air moisture levels increase in receiver tanks. Regular draining of condensate is required to prevent a build-up.

Chilly conditions compromise drying capacities. Refrigerated air dryers suffer from drain valves freezing in an open or closed position. This prevents water drainage via the condensate drain, leading to a moisture build-up and dryer shutdown.

Desiccant air dryers do not fare much better. Moist inlet air causes pipes to freeze, blocking control lines and preventing tower switching valves from operating properly. The discharge air purge muffler can also freeze, causing the machine to fail to dry air.

Insulate exposed components:

Add insulation to hoses, pipes, and valves. This reduces heat loss and keeps temperatures above freezing.

Look for exposed places, areas near frequently opened doorways, and partial outdoor installations. Insulate these locations to increase heat capture and retention – reroute foot traffic to maintain heat levels.

Implement heat tracing:

Apply heat tracing to components at risk of freezing. These heating elements wrap around pipework, drains, and other components. They provide a heat source to prevent internal ice build-ups.

Sensors should be added to monitor temperature levels in vulnerable areas. This will allow operators to move portable heaters to the affected areas before blockages or shutdowns occur.

3. Importance of regular maintenance

Regular maintenance during cold weather is critical. It allows for early detection of significant issues before they cause equipment damage or shutdowns.

Inspecting air filters, intake systems, drains, and oil lubricants prevents seasonal temperature-related issues. This helps to find and eliminate blockages and icy build-ups and rectify inferior lubrication. Inspecting seals and pipes stops excessive wear before it creates unwanted cracks or leakages.

Anglian Compressors offer a full range of winterisation services to protect existing air systems.

Conclusion

Preparing appropriately for chilly temperatures extends the air compressor’s lifespan and improves operational efficiency. Failing to do so is far costlier in operational downtime and repairs than the winterisation process.

Talk with our experts at Anglian Compressors to prevent damage to your air system. We can schedule a winterisation inspection and make appropriate recommendations.