Winter conditions are bound to push the limits of your compressed air system, especially if the compressor is exposed to the elements or in an unheated environment. When temperature differences become extreme, the moisture in your compressed air system will begin forming liquid condensate. If the external temperature is low enough, this condensate will freeze inside your air compressor system.
The ideal operational temperature for your air compressor is above 40° Fahrenheit. This keeps moisture from turning into condensation, prevents oil from thickening, and avoids the risk of damage caused by freezing. If the temperature drops below 40° Fahrenheit and your compressor is not in a heated environment, the freezing effects can be detrimental to your system in the short and long term.
Winterizing protects your system in multiple facets:
When the temperature outside drops, liquids and condensation in your compressed air system freeze. This can lead to problems in piping, connections, drains, tanks, and practically every aspect of your compressed air system. Freezing prevents the component from operating correctly if it can operate at all. When freezing occurs, it can cause a cascade of failures through your system.
When your compressed air lines freeze, impeding the flow of compressed air is only one potential issue. During a cold snap, pressure build-up in the piping can cause it to burst, increasing your downtime and repair costs.
Freezing temperatures also increase the viscosity of your oil, causing it to thicken and not operate properly. Improper lubrication of the equipment will, you guessed it, cause failures and reduce its efficiency.
Refrigerant dryers, on the other hand, can operate too efficiently in colder temperatures. When this occurs, increased quantities of moisture are pulled from the air; when that settles, it can freeze within the heat exchanger.
Not winterizing your compressed air equipment is likely to result in potential damage to your units and increased utility bills, especially if components are located outside of temperature-controlled areas. Although they can operate as expected in temperatures above 40° Fahrenheit, the ideal ambient temperature for most compressed air systems is around 75° Fahrenheit.
Winterizing your system is not as complex as you might think. Just a few simple checks and changes can transform it from cracking in the cold to reliable, efficient operation all winter long.
Regular maintenance might not be specific to winterization, but it is a necessary step in that direction. Oil is critical for the healthy operation of air compressors and their internal components. It lubricates the internal components and creates seals to improve compression efficiency.
Old oil will thicken up sooner than recently serviced oil. The faster it becomes viscous, the more likely you will have issues. Cold weather is known to impede the efficiency of your oil, so don’t push your luck.
During your system maintenance, check for any compressed air or heat leaks. If heat is escaping from your compressed air system, it increases the likelihood of system freezing. Proper insulation is essential to keeping the heat inside and the cold outside.
Recirculating the heat created during compression can help keep your compressed air equipment warmer during the colder months. By recycling the heat made from the compression process, you can reduce the likelihood of cold weather downtime.
Compressed air storage tanks often accumulate moisture as the air rests. This moisture can collect and freeze during winter temperatures. To avoid this, you need to drain your compressed air tanks routinely.
Monitoring the moisture content of your air storage will not only protect the tank but also give you an idea of any other problems that may be occurring in your compressed air system. Winter months create more opportunities for problems, so make sure you stay on top of draining excess moisture.
Consider using weather stripping and heat trace tape to protect your equipment from the weather and help keep the heat in. Weatherstripping is put in place to protect your equipment from the changes in weather. If you notice yours looks worn down or damaged, it should be replaced. Keep your system appropriately insulated during the winter months.
Heat trace tape is another way you can help keep your system insulated during cold snaps. Use it to protect your exposed piping and drains and keep them running. Properly installed heat trace tape will keep your equipment operating correctly and your ice buildup at bay.
Heat is a natural part of the compression process, and louvers can capture and recirculate it. Louvers allow you to pass air through while removing any particulate matter you want to keep out. You can recover the heat being outlet by the compressor and duct it to recirculate in the compressor room or nearby rooms.
Not only do they help with redistributing the heat being put off by your compressor, louvers also help minimize the amount of cold air being pulled into the inlet. Less cold air means proper lubrication and minimizes moisture content in the oil circuit.
Ideally, you will have thermostat-controlled louvers in place, which automatically adjust to achieve your desired internal air temperature. Otherwise, you will need to adjust them manually to control the air you are ducting.
Alongside getting your air compressor’s regularly scheduled maintenance done, you will want to check on the status of your other equipment as well. Make sure that your drains are functioning properly throughout the system. If a drain fails, it can send excess moisture downstream and lead to widespread issues.
Dryers, especially refrigerant dryers, can also be susceptible to issues during cold weather. If the air travels outside before it gets to the dryer, it can freeze before the dryer can remove moisture. If this sounds like your system, you should ensure that you have a solid regenerative dryer to handle the extreme temperatures. These dryers can achieve a dewpoint of -40° Fahrenheit.
Waiting till it gets to winter temperatures before you winterize can nullify your efforts. It is best to do it during the fall when the temperatures haven’t dropped below freezing. Winterizing your compressed air system gives it the edge it needs to tackle the winter months while maintaining effectiveness and efficiency.
Avoid pain points this winter, and be prepared for the cold weather. Benefits of winterizing your compressed air system:
It may not seem worth your time, but it is better to be safe than sorry with compressed air equipment. If you are curious to learn more about compressed air systems, check out our digital library.
The Words Warthog and the Stylized Warthog are Registered in U.S. Patent and Trademark Office. Reg. No. 7,109,357 and 7,109,356
