OUR AIR COMPRESSOR SERVICES
Getting your air compressor installed correctly is critical to ensure optimal performance. A poor installation means you will not get the most from your compressed air, increasing costs and downtime. An inefficient system that requires just one bar of extra pressure from your compressor to operate effectively, increases energy costs by 7%.
In the worst cases, bad installations increase the likelihood of damage, increasing maintenance requirements and significantly shortening the lifespan of your compressor.
A good installation considers your current needs and provides the power you need for it’s purpose. It will be efficient, ensuring that as much energy as possible gets to where you want it. It will also be built for the future, ready to grow with your business as needed, without creating problems as it adapts.
Above all, it must be safe. Investing in a high-quality installation ensures it will meet all the legal and regulatory requirements and keep your staff safe.
Choosing the right air compressor
Your air compressor will be the heart of your installation; making the right choice is the first step.
You must choose a compressor that meets your requirements, offering the pressure, airflow, and duty cycle to meet your operational demands. A good practice is to pick a compressor that exceeds your peak demands; this helps reduce wear and tear and allows some room for future growth.
Small rotary screw compressors are a good choice for intermittent use. They are robust and powerful. For constant use, we recommend Atlas Copco’s range of variable-speed drives. These respond to changes in demand instantly, keeping energy consumption as low as possible.
Planning your installation
We install systems in all types of businesses, and every installation is unique, catering to their demands, locations, and operations. Some general rules should be considered when determining your compressor’s location.
- Ventilation: compressors, like any machinery, work best when well-ventilated and in stable conditions. This is particularly important for an air compressor that relies on air intake. While filters can help, dusty or polluted environments will impact performance and require 20 – 30% more maintenance.
- A firm foundation: air compressors need a stable, flat base to cope with their weight and vibration during operation.
- Power supply: you will need a sufficient power supply – and emergency power-off switches – at the compressor’s installation point.
Elements of a compressed air system
The air compressor may be the heart of your system, but every part of it will fulfil a critical function.
- Air intake: the intake filters remove fine particles and pollutants. It should be positioned to receive the cleanest air possible.
- Air dryers: as compressed air cools, condensation forms. Dryers remove almost all the water vapour, reducing the risk of corrosion and making the air suitable for a wider range of uses.
- Oil separators: minuscule amounts of oil can get into your compressed air unless you have an oil-free compressor. If purity is important, separators can catch this.Air receivers: variable-speed compressors can help manage and smooth out demand surges and stabilise pressure, increasing your system's efficiency.
- Pipework: a well-designed network makes a huge difference in getting compressed air to where it needs to be. A looped layout can reduce pressure drops by as much as 20%, while using a material like aluminium can decrease them by as much as 50%.
Safety equipment
Your installation will include a range of safety features to help meet statutory and regulatory standards. While each component will feature safety elements, those that you might see within your system will include:
- Pressure relief valves: these are designed to release excess pressure; this avoids the risk of damage to equipment or even injury.
- Safety interlocks: these monitor system health, initiating a shutdown of the entire system in case of a critical fault.
Maintain optimal performance
There is no reason for a compressed air system not to provide decades of service. However, that requires care and attention. Your initial installation will include a thorough check to ensure the system is calibrated and functions as expected. Regular maintenance will keep it that way. We can always advise on a suitable frequency for various checks, but a rigorous maintenance regime will include the following:
- Leak tests: leaks are inevitable, but regular ultrasonic testing can identify leaks even while your operations continue, providing you with a prioritised list so you can maximise efficiency.
- Routine inspections: daily checks for changes in operation, vibrations, or build-ups can alert you to issues. You should also check filters and oil levels regularly.
- Remote monitoring: modern systems often include remote monitoring options, giving you real-time information on performance, and alerting you to changes.
- Regular servicing: your entire system needs regular servicing. We offer comprehensive fixed-price plans that can cover everything you – and your system – would need.
Common design and installation problems
Occasionally, we see installations that were not well designed or that have not kept pace with changes in operations:
- Poor ventilation: we always stress the importance of adequate ventilation for an air compressor. However, as your business changes, further installations impact it; be careful not to add polluting equipment near your air intake.
- Inappropriate sizing: it is critical to get the right size of compressor. Too small or too large a compressor creates problems, stressing your system and/or wasting energy. Review your needs regularly, especially after any major business change.
- Poor pipework: direct and shorter routes work best for compressed air. Ensure your initial installation does not have unnecessary bends, and monitor adaptations to ensure they do not introduce inefficient routes.
Get a Great Air Compressor Installation
A poor installation will let down the best air compressor.
At Anglian Compressors, we combine decades of experience with the latest air compressor system design knowledge.
Our range of serving options supports this, giving you confidence that you have the best possible system from day one and every day thereafter.
Contact us today to arrange a consultation. We can demonstrate how an Anglian Compressor installation can power your business and its profits.
