Complete blockages that can cause plant down time

Partial blockages or accumulated ice will increase pressure drop, leading to less air at the point-of-use while reducing compressor performance & efficiency

Malfunction of components and the processes they control

Increased chance of tank or component failure

A properly selected and sized air dryer is the #1 best defense against condensate, and will create clean, dry air that removes condensate before it has a chance to create problems!

• In general, dryers should be specified for a dew point 20°F below the lowest ambient temperature encountered.
• For air systems in unheated or outdoor environments, this will generally require desiccant air dryers, which can achieve dew points of -40°F (or even -100°F for some Ingersoll Rand desiccant dryers!)
• Because unheated or outdoor environments often have ambient winter temperatures below the Dew Point rating of most refrigerated dryers (often ~38°F), most are inadequate for these applications and will not remove enough condensate.
• “In almost every operation, clean, dry compressed air will result in lower operating costs” – from  Compressed air and gas drying, Compressed Air and Gas Institute (CAGI)

Use heat trace tape and pipe insulation to winterize exposed piping, condensate drain lines and drip legs, and drain bowls. Regularly check that drains are working properly – a frozen drain can cause condensate to build-up significantly and create problems!

Reduced lubricity and increased drag on motor, which can lead to breakers tripping, increased power consumption, and higher operating expenses

Cold starts can also cause wear and tear on the motor and airend, leading to catastrophic and/or premature failures in some cases

Use a full synthetic or blended synthetic air compressor oil, which will maintain the proper viscosity throughout a greater temperature range. Plus, this also allows a longer interval between oil changes!

Modifications like sump or crankcase heaters can keep lubricant warm

BONUS TIP: Regularly check that there are no signs of condensate in the oil, which will make it appear milky or light brown. Identifying this as early as possible can make a significant difference, possibly preventing huge damages!

• Diagnostic tools like oil analysis can also provide early warnings of issues that could be related to the effects of cold temperatures, and is standard with all our Preventative Maintenance service.

Weatherproof the Compressor Room:

• Repair weather stripping and replace worn areas
• Use cabinet or ambient heaters. If already installed, ensure they are working properly and set to the correct temperature
• Compressor rooms don’t need to be room-temp – even increasing the ambient temp to just 45°F will help significantly!

Ensure Proper Ventilation:

• Adjust louvers to minimize cold air and/or use automatic thermostatically controlled louvers.
• If possible, consider installing a heat recovery system that harnesses compressor heat and ducts it into the building during cold months. 80-93% of the energy used by a compressor is usually wasted as heat, but this will capture and reuse it for space heating, process heating, water heating, make-up air heating, boiler water pre-heating, and more! Learn more with this article on the “Heat-Reclaim Economics of Air and Water-cooler Air Compressors” from Compressed Air Best Practices