Winter is coming… and colder temperatures that come with it. Equipment is built to be run within a given set of parameters, one of those being the temperature. A system that isn’t prepared for cold weather can suffer in efficiency, performance and reliability.

Here are 8 ways to combat the negative effects that winter weather can have on your compressed air system.

1. Control the Ambient Environment

If possible, place your system indoors so that it is under more standard and controllable conditions. A standard compressor shouldn’t be left in freezing conditions when it isn’t operating. Ideally, you should keep your compressor room’s ambient temperature at least 45° Fahrenheit. You might have to heat the compressor room, but you can also adjust your ventilation system.

During the hot months of summer, you may need the louvers in your compressor room to be fully open, increasing air flow.  During winter, adjust them to keep that warm air in the room. Look into implementing a heat recovery system to heat other areas in your facility and save on energy costs.

2. Weatherize Your Compressor

If you must put your compressor outside, weatherizing it is vital. This may involve adding weather stripping, insulation and even heaters inside of the compressor. Exposed parts should be well insulated or have heat trace to prevent damage from frozen condensate. A heater can also help keep your lubricant warm and limit the impacts of condensate. 

Insider Tip:Keeping a heat gun handy can be a big help if the lines in your compressor freeze. It’s not a permanent fix, but can get your compressor up and running in a bind.

3. Select the Correct Dryer Setup

Condensate remaining in your system during winter can freeze and cause numerous issues. Make sure that your dryer can handle the change in temperature or add additional dryers to mitigate the condensate

Desiccant dryers have much lower dew points than refrigerated dryers (as much as -100 °F). This means these dryers are best suited for conditions where the compressed air piping runs outside in environments that experience low temperatures, or for special applications that require very dry air.

Desiccant Vs. Refrigerated Dryers

Facilities typically use one of two types of dryers: refrigerated or desiccant-based regenerative.

A refrigerated dryer uses refrigerant to cool and dry the air coming from the compressor (and wet receiver tank). These dryers have a pressure dew point (PDP) between 37-42°F. The dried air leaving the dryer is then reheated to room temperature by the warm inlet air from the compressor. Refrigerated dryers have minimal dew point capacity, but can be a great option for facilities that don’t need extremely low dew points. The dryers can be cycling (turning on and off as needed), or non-cycling (running continuously).

Desiccant dryers remove moisture from the air using adsorption, a process where water sticks to the surface of a material; in this case, desiccant beads. Then the desiccant is regenerated with heat, running expanded dried air from the discharge (called purge) to be reused again. These dryers have very low dew points and are excellent for facilities needing to meet stringent ISO standards. They can have dew points as low as -100°F or lower and are an excellent choice for cold environments, as the air in the system will not contain water that can freeze. Desiccant dryers can purge the desiccant through purge air from the compressed air system itself, or from outside purge air that is heated externally.

RELATED:HOW TO SELECT THE RIGHT DRYER FOR YOUR AIR COMPRESSOR

4. Change Air and Oil Filters

Regularly check your air and oil filters to evaluate whether they are in good condition to perform as they should. Dirty filters can decrease the efficiency of your compressor quite a bit, so change them out regularly.

5. Check Compressor Oil

Lubricant can become thicker and be less effective in cold weather. Thick lubricant requires more power to rotate the pump, which can overload the motor and lead to premature wear on the compressor. To combat this, regularly check your lubricant pour point, and make sure that it remains fluid in the environment.

A factory service program can help take this item off your to-do list. While you’ll still need to check up on your compressed air system, regularly scheduled service appointments can eliminate unscheduled downtime at your plant. Based on your compressor specifications, a technician will come to you at systematic intervals, perform a check-up and report any issues they find. Think of it like taking your car for a routine oil change.

6. Clear Drains and Air Intake Openings

With the changing temperatures also come rain and snow. Check and clear your drains and intake openings regularly to limit the impact that blockages and other issues can have on your system.

7. Adjust Water Cooling System

In the cold months, you risk having the compressor’s cooling water pipes freeze. If this happens, even though it is cold outside, your compressor will overheat, and it could cause damage or down time. Check regularly to make sure that there is cooling water flowing through your system.

Monitoring your compressor’s temperature levels allows you to adjust water temperatures as needed. Look at your piping and make sure it is well insulated in areas exposed to cold temperatures.

8. Find and Fix Leaks

Leaks can be a huge drain on your compressed air system. If your company doesn’t have a leak prevention program, implementing one can save your facility thousands in energy costs. You can either do this yourself or hire outside experts to help you.

Performing an energy audit of your compressed air system can show you how much energy you are wasting in the different areas of your plant, including how much those leaks are costing your plant.

What is a Compressed Air Audit?

A detailed compressed air energy audit examines the function and energy performance of a compressed air system with data collection as a core feature. With some training and engineering experience, an individual can perform a compressed air audit. The existing system operation is examined and analyzed to create a system baseline. The baseline is the existing state of the system before any changes or upgrades are made.  A baseline for your New Year’s resolution to lose weight, for example, would be stepping on the scale on January 1^st.

After the baseline system analysis is complete, the data is analyzed using statistical computer models to simulate new operational setpoints to predict energy savings through equipment upgrades. Some energy savings prediction software is readily available. Many energy auditors have built their own proprietary simulation models, including our audit team at Rogers Machinery Company.

The data is typically compiled into a report with the proposed solutions, and energy incentives (if available) are estimated.

When the changes have been made and the upgrades installed, data is collected once again to tune the system and verify the accuracy of the predicted energy savings.

The final step is to set up periodic checks or have permanent sensors installed to ensure the system’s efficiency for years to come.

RELATED:BENEFITS OF AIR SYSTEM AUDITS: WHAT, WHEN & HOW

When cold weather threatens to compromise or shut down operations at your facility, taking these steps can help stop issues before they arise. By evaluating your compressed air system before the cold sets in, you’ll be able to ensure the best possible start to the winter season.