Frequently Asked Questions

Experts have been discussing the most efficient compressed air treatment (purification) method for years. At the center of the topic, the following question comes to mind: Which system produces oil-free compressed air most economically and efficiently? If we set aside the statements of compressor manufacturers, it is undoubtedly a fact that oil-free and high-quality compressed air can be produced both with compressors using oil-free compression methods and with compressors using oil-lubricated compression methods. Therefore, the efficiency factor should be considered when deciding on system selection.

Atmospheric air contains more water vapor at high temperatures and less at low temperatures. This affects water concentration when air is compressed. For example, a compressor with an operating pressure of 7 bar and a capacity of 200 l/s, compressing air at 20˚C and 80% relative humidity, releases 10 liters of water per hour into the compressed air line. Problems and malfunctions may occur as a result of water precipitating in pipes and connected equipment. To avoid this, compressed air must be dried.

Atmospheric air always carries water; in other words, it always contains a certain amount of moisture. This humidity depends on the instant ambient temperature. Thus, air saturated with 100% water vapor at +25 C carries 23 grams per cubic meter.

The term “pressure dew point” (PDP) is used to describe the water content in compressed air. It is the temperature at which water vapor condenses into liquid water under the valid operating pressure. Low PDP values mean there is a small amount of water vapor in compressed air. When comparing different dryers, it should be remembered that atmospheric dew point cannot be compared with PDP. For example, a PDP value of +2˚C at 7 bar is equal to –23˚C at atmospheric pressure. Using a filter to remove moisture is not effective. There are five techniques to remove moisture from compressed air: cooling and separation, over-compression, membranes, absorption, and adsorption drying.

Formation of a significant amount of condensate is inevitable in compressed air production. Here, the definition of “condensate” may lead to misunderstandings. It is not only condensed water vapor that forms in this process. There is a very important point to consider. Every compressor is like a high-capacity vacuum cleaner. It draws in contaminants present in ambient air and continues to transfer them to the condensate through compressed air that has not yet been treated.

Heat recovery is a system that increases the efficiency of a compressed air system and at the same time does not harm the environment. The purchase cost is proportionally low. These systems, which pay back their investment in a very short time, need to be calculated precisely and planned as a project.

Master controllers coordinate the operating profiles of compressors in a compressed air system and ensure they operate in the most efficient way according to air demand.

Dirty environment, excessively hot environment, friction, high relative humidity, vibration, faulty manufacturing, failure to perform periodic maintenance on time.

To maintain machine performance and efficiency, and to prevent consumable materials affected by friction from causing greater damage.

It reduces bearing and seal life, shortens belt life, increases noise, increases the risk of screw seizure, reduces performance, and causes loosening in connection elements.

As a result of operating at high temperatures, the lifespan of materials such as oil, seals, and bearings decreases. Increased viscosity in extreme cold increases energy consumption and causes screw seizure.

A Maintenance (2000 H-3,000 H), B Maintenance (4000 H-6,000 H), C Maintenance (8000 H-12,000 H), D Maintenance (OVERHAUL) (18000 H-36000 H).

Machine performance and efficiency decrease, the risk of failures caused by consumable materials increases, and the customer’s energy cost increases.

Parts in all machines wear out and fail. Naturally, it is important to prevent malfunctions and problems from the very beginning. This allows the equipment to always operate in the best possible condition and have a long service life. This is exactly why periodic maintenance is extremely important.

Humidity, vibration, dust, temperature.

It keeps compressor efficiency at the highest level, provides better protection for screw block rotors, keeps compressor oil cleaner, increases separator efficiency and lifespan. It extends operating life.

It increases pressure drop, reduces compressor performance, increases your electricity bill and maintenance costs, shortens compressor operating life, and reduces the life of the oil and separator.

It provides appropriate viscosity for better lubrication. It ensures proper removal of heat and contaminants generated by compression. It prevents air leakage between rotors by providing sealing. The oil film formed prevents contact between the rotors.

Using the wrong type of oil, high operating temperature, dirty air intake, dust and particles, lack of maintenance, or delayed maintenance.

Too many load/unload operations, poor quality or non-original oil use, dusty environment conditions, high ambient temperature, improper grounding connection, excessive relative humidity.

Water inside your compressed air pipes causes corrosion, may damage manufacturing machines, and there may be a risk of freezing. Note: Refrigerated dryers operate efficiently only at ambient temperatures down to 5 C. If your refrigerated dryer is located in a compressor room below 5 C, the dryer may not operate properly.

No power, main switch fault, low mains voltage, unbalanced supply or reversed phases, the compressor stopping due to any fault, or starting the compressor without releasing internal pressure may be the cause.

The scavenging line may be clogged, the separator element may be damaged, there may be an oil leak in the compressor body, low operating pressure, high ambient temperature, or failure to use the recommended oil and/or original separator filter.

The solenoid valve of the inlet valve may be faulty, the operating pressure setting may have changed, the separator filter may be clogged, or the safety valve may be faulty.

The idle waiting time is long, or the compressor switches to loaded operation mode before the preset time.

Mechanical connections may have loosened, there may be a problem in the main motor bearings or screw block bearings, a mechanical issue in the screw block, a balance problem in the fan motor or fan, or a manufacturing defect in the sheet metal panels.

The suction valve is faulty or the minimum pressure valve is faulty.

The air filter may be clogged, the motor may not be switching from star to delta, the inlet valve may be faulty, the minimum pressure valve may be faulty, the rapid discharge valve solenoid may be faulty, or the outlet valve may be closed.

Low supply voltage, the compressor exceeding its pressure settings, separator blockage, or a mechanical fault in the screw block may be the cause.

Low voltage or loosening of power supply terminal connections, the thermal switch not operating or the switch trip value being set incorrectly, or a mechanical problem related to the fan may be the cause.

There may be a mechanical problem in the motor or screw block, the cooling fan may be faulty or ambient temperature may be too high, currents may be too high due to low voltage, or the motor windings may be damaged.

The panel filter may be clogged. Clogging of this filter prevents sufficient cooling air intake, the compressor oil level may have dropped, the separator may be dirty, if the radiator is clogged internally it may obstruct oil circulation, or the thermostatic valve may be faulty. There may be a mechanical problem in the screw block unit; this problem causes the temperature to rise rapidly.

The operating pressure may exceed the high-pressure setting, the outlet valve may be closed, or the inlet valve may be clogged in the open position.

The internal pressure switch may be open, there may be high pressure in the separator tank, or the minimum pressure valve may not open fully or may open halfway.

Separators that should be grounded but are not properly grounded in the field may cause significant problems. Due to the centrifugal movement inside the oil separator tank, ignition may occur inside with the help of static electricity. The combination of high-temperature oil and static electricity may cause damage to the separator filter or a fire in the compressor.

Phase sequence is checked, rotation is checked using the arrow on the screw block unit, cooling fan rotation and load/unload control are checked according to blowing direction, and compressor operating temperature is checked after 10-15 minutes.

Using original parts and lubricants can ensure your compressor operates smoothly for a long time. All original spare parts are fit for purpose and manufactured according to original specifications.

The monthly energy loss of a 1 bar pressure loss in only 1 compressor; if the compressor power is 250 kW/hour, the additional energy consumption due to 1 bar pressure loss is +6% = 15 kW/hour; 1 month 10,800 kW/hour = 15,600 TL.

Service and maintenance expenses are less than 10% of the total lifetime cost; parts are 6% and labor is 4%. Energy cost accounts for at least 75% of the total lifetime cost.

For a 110 kW compressor at 7 bar, the electricity cost is 1.45 TL per kWh. The customer operates 4000 hours per year. Energy consumption for an additional 0.5 bar pressure drop; each pressure drop will cause a 7% energy loss. 0.5 bar will cause approximately 3.5% energy loss. Annual energy loss: 110 kW x 3.5% x 4000 h = 15400 kWh; 15400 x 1.45 TL = 22330 TL/Year.