Compressed air is a compelling investment for business. It has robust and steady forces, reliability and safety. Portable air compressor add more mobility to make the air system perfect. But one noticeable problem is that this system is easy to leak.
Since they’re often moved around, the portable air compressor is more vulnerable. A hit with rocks or a slip can lead to errors and holes. Business will suffer from leaking compressed air, in both financial and other aspects. To reach the peak of your profit and production rate, you have to tackle this leaking challenge.
1. Leakage is an all round loss
In fluid energy system, leaking is always a big concern. They cause a huge decline in company’s profit. As it’s fluid, when it leaks it can come out at a massive number. You can waste 20% to 30% of the energy used. In some cases, 50% of the power supply goes for nothing in return. Read more about 5 Tips Cooling Portable Air Compressor.
Besides, this phenomenon affects other different aspects:
– An increase in cost for maintenance alongside with power supply.
– More fixing means less durability. Your devices’ lifespan is much shorter than it should be.
– A longer downtime since work is always interrupted.
– And production rate will hit a low. Business can’t continue without machines.
– A cut in employees’ salaries and bonus. Their job status will be threatened as well
2. Portable air compressor and Causes of leaking
The very first thing you should do is to identify the causes of leakage. Leaking errors in an air system come from four primary sources: the compressor itself, their extra plug-ins, the pneumatic tools and the wrong way of using.
There are air hose’s worn couplings, open or broken blow-offs, valves and condensate traps, etc… The extra details and substances needed such as lubricators or filter are also the culprits. Out of date and damaged pneumatic tools result in wasting energy. And the wrong way of using compressed air also lead to terrible sequences.
There is a list of common reasons for leaking:
– Worn or damaged connections or couplings
– Loose or disconnected joints between parts
– Open blow-offs, valves and condensate traps
– Damaged or old seals, O-rings
– Incorrectly used or set up lubricators, filters
– Old or broken air tools
– Cooling or cleaning other devices with compressed air
– Using compressed air for another task that is not in its design
Almost these cause above are just minor mistakes. But the problems following are major threats to a company’s survival. You need to find them down right away.
3. Method of locating the leaks
To start repairing your system, you need to find out the leaking position. It’s fluid and you can’t easily see it by your eyes like oil or coal. But you still can recognize it by your bear ears.
When you poke a balloon, it will make a sibling sound. As well, leaks release noisy sound that can be easily heard. Just keep the place silence, step closer to the machines and listen. Make sure your employees join their hands, each person in each corner. This will increase the chance of success.
But there are more precise options: ultrasonic detectors. It can be more complex, though. You have to spend money for purchasing and training your employees. But instead, they’re powerful and excel at pointing out the exact location of the leakage. They can help stop wasting your valuable compressed air.
It’s easier if you know for sure the presence of leaking before searching. You can do that by some simple calculations. Measure and compare your compressor’s capacity before and after working. If there is a noticeable gap, there should be leakage somewhere.
4. Repairing leaks for portable air compressor
After locating them, you need to fix the leaks as soon as possible. But you need to pick out the most serious leaks first. Otherwise, you will waste time for an unworthy error.
The levels of priority are equal to the sizes of the leak. Bigger leaks are more dangerous and emergent. One 1/4” leak can cause more loss than 10 leaks of any other sizes. According to big rocks theory also, solving the biggest problem first can speed up the entire process. So you need to focus on the largest leaks in the beginning.
Based on the source of causes, there are different ways to repair your system. If it’s from loose couplings or joints, just tighten them. Pay more attention to these connections when you install the system. As portable air compressor is often moved and echoed, you have to use O-rings or seals to strengthen the joints.
Double check the blow-off and valves, as well as condensate traps. They play a crucial role in keeping your air inside the tank. If they are worn or damaged, replace them immediately.
If your air tools are out of date, they can waste the power of airflow. They can’t make use of all the energy provided. Grab some modern air blowguns or hammers. There will be a concern about the expensive cost. But in the long run, those innovative technologies are proved useful. And they guarantee a steady income flow for your company.
For the misuse of compressed air, you can’t fix it right away. You will need to develop some leaking prevention programs. You will need time and funds as well. But when your efforts come triggered, you will be paid. And this is the best way to say farewell to leakage.
5. Protect portable air compressor from leakage
Fixing can eliminate the leaks, but they still can occur again. So you must stop it before it happens. You need a strategy to stay away from it all the time. So a prevention program is a must. It has two parts: raising awareness and running regular maintenance.
You can raise employers’ awareness by sending them on a course. This course will be of the danger of leakage. It will also teach about how to anticipate leaking and how to prevent them. Workers will know that losses in business’ profit also affect their salary and job status. And if they know knowledge, they won’t use compressed air for incorrect tasks.
Replacing open blow-offs by nozzles to control and save compressed air. Purchasing cooler and more modern machines to prevent overheat. This will also increase the production rate. Lock down or turn off the airflow with valves when devices are not in use. These simple alternatives can minimize the incorrect use of compressed air.
Also, regular checking is essential. Ask your employers to monitor and detect leaking. They need to use lubricator and other required substances needed properly. They have to monitor and keep the machines at their best state.
With a portable air compressor, maintenance also includes reliable contacts with them. If the job needs to move around, make sure you don’t hit your tank with sharp objects. Check the status of the wheels and the quality of the desired destination. If it’s too rough, pulling your compressors slowly. Don’t make too many echoes and shocks, as it can break the connections.
Compressed air is capable of doing anything. It will give you a lift when working at its full strength. But leaking interrupt it, and your income flows as well. Follow these tips above; you can quickly take back your money and career. So now or never, find and fix the leaks.