Is Your Compressor Ready for the Summer?

Summer is a just around the corner and for those who work in a compressor room, they understand that high temperatures can affect the performance of the equipment. 

Most compressor manufacturers rate their equipment at 60° inlet and ambient room conditions. If you have 95° F ambient in the room, the compressor should run okay if properly ventilated, but will lose approximately 8% of its capacity. As the temperature increases beyond 95° F, you lose even more capacity and could start damaging the compressor.

If the coolers are not cleaned, the inlet filter has not been changed, and/or the condensers on the refrigerated air dryers are dirty, you may have operational problems and possible shutdown when the outside thermometer reaches 85° F.

Here is some advice on what you can do:

• Prepare your compressor for the summer by reading the operator’s manual and perform the indicated service needed for high temperatures.
  
• Put a thermometer in your compressor room to monitor the room temperatures. (Anything above 100° F could be damaging for your equipment).
  
• Take a look at current room temperatures and compare it to the operating temperatures of the compressor and the refrigerated air dryer. (If there is more than a 15° F difference from the room temperature on the air dryer inlet air you have a problem with the coolers).
  
• Increase the room ventilation to make sure that you can match outside air temperatures even in the hottest weather. You should move air through the room at least one time every 2 minutes. 

Key Temperatures to Watch: 

• The room temperature should be no greater than 10° F more than the outdoor temperature.
  
• Rotary screw compressors should not operate above 210° F
  (Most shutdown at 215/220° F. Normal operating temp in a 70° F room is 190° F).
  
• The dryer inlet should be no more than 15° above room temperature.
  (95° F room = 110° dryer inlet air). 

If you operate your compressor and dryer over the design temperature you will shorten the life substantially and create wet /oily air. If you have current issues with your compressor, it would be wise to have it serviced now because it will only get worse in the hot weather. If you need assistance please contact Frank Lederer at 508-351-1817 or by email. (FLederer@hopeair.com).

What is a Cycling Dryer and Why Would You Want One?

Most plants currently have a dryer that continuously runs and uses a component called a hot gas bypass valve to keep the unit above 38° F and prevent it from freezing up. But, there are many different types of cycling dryers that accomplish the same result without the dryer constantly running.

• Cycling type with a thermal mass is cooled down to the required temperature and the compressor shuts off – this works much like your refrigerator – if no load, the unit does not come back on until required – very effective and the most reliable
  
• VFD cycling uses a variable speed drive on the refrigeration compressor that varies the amount of power/refrigeration used based on the temperature of the air – operates much like a variable speed air compressor – most have a range of 100% to 30% – not good in low range applications – fairly complicated electronically
  
• Load/unload cycling compressors – works much like larger refrigeration systems and can be effective when they are fairly steady medium loads – can short cycle with low loads – sometimes not as power cost effective as a true cycling dryer

With that being said, if you purchase a 500 CFM dryer ($8,000) for your plant and left it on while your compressor is running (or maybe you forget to shut it off at the end of the second shift), it would use 2.5 HP continuously. If you purchase the same 500 CFM thermal mass cycling dryer ($10,200) for the same application, it would require 2.7 HP. But, in an average plant it would be on only 20-25% of the time. The cost difference between the two is $2,200 and the savings is $1,490 for $6,000 a year at $.15 a KW. Using simple math, the ROI is 1.5 years.

Other advantages of using a cycling dryer are:

• You do not have to remember to turn the dryer off when you turn the compressor off as it shuts down
  
• Potential freeze up at low load conditions almost eliminated
  
• It can be used with lower CFM compressors while maintaining the same dew point
  
• It will tolerate higher ambient/higher inlet temperature conditions more readily over standard dryer.

Remember all dryers are rated at 100 PSI/100° F inlet air/100° F ambient temperature. If you increase the air pressure dryer performance gets better. If the ambient air temperature or the inlet air temperature gets above 115° F your dryer could be in big trouble and moisture will soon be invading your system.

If you would like to know more about how a cycling dryer would be a better fit for you than what you have we be happy to help or if you have any moisture issues let us know. Contact Frank Lederer: flederer@hopeair.com.

Rotary Screw and Piston Compressors On Display at No. Haven Parker Store

Jeff Haynosch
Sales Engineer


It’s exciting that in addition to the fluid power products we have been representing at Connecticut Fluid Power over the years, our joining up with The Hope Group last year has meant that we have expanded our product offering to include fluid connectors, and now, compressed air systems and service.

At the Open House and Technology Seminars on May 10, 2017, at our new Parker Store in North Haven, we will have a display as part of the Trade Show of Kaeser rotary screw compressors and Hope Air Systems’ own brand of piston compressors. Our customers always need a power source, whether it’s a generator, a hydraulic power unit, or an air compressor, and so it’s great to introduce this new line of products to the North Haven area.

You can learn more about the Technology Seminars and the Open House by visiting the website.

Don’t Leave Fluid Analysis Until It’s Too Late

Henry St. John
Parts Mgr, Hope Air Systems


Without proper preventive maintenance, your system could experience failures ranging from small to fatal. Routine fluid analysis is important and should be conducted on a schedule to monitor wear, determine potential failures in process, and to schedule fluid changes accurately.

Fluid analysis should not be an optional procedure left to whenever you “get around to it”. It must be routinely conducted by engineers and technicians as a tool to measure and monitor principal fluid characteristics that include metal content, water content, and viscosity.

Hope Air Systems’ engineers and technicians are ready to help with a fluid analysis to prevent costly failures and breakdowns. If you have any questions, please contact me at 508-351-1827 or by email (hstjohn@hopeair.com).

How to Save Energy/Money By Controlling Your Air Compressors

We recently released our monthly eNewsletter. It contained two important topics about your air compressors that I would like to share with you.

The first article deals with properly controlling your air compressors to save energy and money. Unfortunately, electrical costs are not going down and it is important that one person is responsible for conserving energy in your plant. There are some simple things that you can do to ensure you are controlling your systems properly. To learn more, read the entire article titled: Turn It Off (Your Air Compressor)

Avoid Filter Confusion
The second article talks about avoiding filter confusion. Are you selecting the correct filter? How many filters do you actually need? When tackling this topic, I discuss a basic filter that every system needs down to a filter that may be used in breathing air or biotech firms. To learn more, read the entire article titled: Filters - How Many and What Do I Need

If you didn’t already know, Hope Air Systems releases a monthly eNewsletter on a wide range of informational topics, such as these, that can help you in your compressor room. If you would like more information on these topics, or would like to receive the newsletter, please contact Frank Lederer at 508-351-1817 or by email (flederer@hopeair.com) and he would be happy to assist you.

New Reciprocating Compressors Added to Hope Air Product Line

Henry St. John

Parts Mgr, Hope Air Systems

As you know, Hope Air Systems is a proud distributor of Kaeser and Champion Air Compressors. I am excited to announce we are launching our own line of industrial-grade reciprocating air compressors to add to our product line.

The new Hope Air Systems’ stationary vertical or horizontal electric two-stage, belt-driven compressors deliver up to 33.6 CFM at a maximum pressure of 175 PSI and 35.0 CFM at 100 PSI. They are built for commercial and industrial applications and are equipped with an electric Baldor Motor (single phase and 3 phase available), magnetic starters, and cast iron pumps. The patented pump design provides for a cooler running pump. We are also offering gas engine (powered by Honda) and portable compressors.

You can view our brochure (PDF) for details and pricing. Or, if you have any questions call me at 508-351-1827 or email me (hstjohn@hopeair.com). 

In the meantime, take a look at all our reciprocating compressors on our website!

Hope Air Systems V-120 Compressor now displayed in our Northborough showroom

Why Blow Offs Are The Newest Secret Saver

We all know that a pinched copper tube blowing onto a product is a really inefficient way of using compressed air. 

How bad is it? A 1/8 inch hole will flow 26 CFM at 100 psi, which uses at least 6 HP on your air compressor. If you run three shifts five days per week and pay $0.10 per KW, that little piece of copper blow off tube probably cost you around $2900 per year. Many blow offs have smaller openings than 1/8 inch.

There are really three solutions out there to save energy and costs associated with air blow offs.

#1 is to convert to a blower, which may not be feasible in some applications. 

#2 is to put a nozzle on the end of the tube to reduce the flow and the sound level, which works just fine but many of the nozzles disappear after period of time.

#3 is to reduce the amount of air by changing or and inserting a control valve.

Solution #3 is the direction that Parker's Air Saver Unit has taken. It is a valve that converts a continuous air blow to a pulsed air blow without the need for any other external control. Air is blown with a series of ON and OFF pulses. When the blow is OFF, there is no air consumption. By using switching valve technology the Air Saver Unit can reduce air consumption by up to 50%, which translates into:

• Large reductions in air consumption.
• Savings in compressor power consumption.
• Reduction in plant CO2 emissions.
• Big contribution to energy-saving activities.
• Improved efficiency.

When you consider that air blowing accounts for up to half of all compressed air used in plants, the potential energy and cost savings is considerable. In the example outline below, the application of Air Saver Unit valve on four nozzles with a one minute below per four minute cycle operating for three shifts, five days per week saved plant operators $3,500 annually.

Sample Application	—›	4 nozzles 6 mm dia.	+	$0.10/ kWh	+	1 min blow per 4 min cycle	+	3 shifts 5 days/ week	=
Air Saver Unit Valve Calculator Summary Sheet
VALUE IMPACT SUMMARY
Reduced Total Annual Air Discharge per Blowing Nozzle (cfm) by:							3,232,005
Reduced Annual CO2 Emissions Generated (per Blowing Nozzle, in tons) by:							5.77 tons
Reduced Annual Air Generating Costs Per Blowing Bozzle by::							$892.03
Quantity of Air Blowing Nozzles with Same Application Specifications:							4
Reduced Annual Air Generating Costs For All Nozzles by:							$3,568.13
Reduced Annual CO2 Emissions Generated (For All Blowing Nozzles) by:							23.07

This is the only the tip of the iceberg for air conservation. To find out more about how to properly use this Air Saver valve and other energy conservation components click on the link below to register for the Introduction to Industrial Pneumatics seminar being held from 8:30AM to 12PM on October 20 at the Parker Store in Lewiston, Maine.

www.TheHopeGroup.com/workshops

Need a system engineer to look at specific air use problem in your plant? Please call Frank Lederer at 508-351-1817 or email: Frank Lederer at FLederer@HopeAir.com.