One of the most commonly encountered issues with industrial compressed air systems is a reduction in pressure. Encountering pressure drop can be stressful, particularly if you don’t know the cause of the issue. Luckily, there are ways to troubleshoot the pressure drop within your system to determine its cause before calling the professionals.
Serious Causes of Pressure Drop
Several potential causes of pressure drop within your industrial compressed air system exist. The first thing to keep an eye out for is making sure your compressed air system is the proper size for your application. If your compressed air unit is too large for the output your application requires, there is the risk of losing pressure within your system. Additionally, oversized units consume more power and typically require more maintenance than smaller units.
Contamination is the other most common cause of pressure drop within an industrial compressed air system. There are a few common contaminants that you may encounter within your compressed air system, which impact air quality and can cause problems with the airflow within your system, resulting in pressure drop. Water vapor is one of the most common contaminants found in industrial compressed air systems. When water is introduced to the system, it can damage internal parts, encouraging the growth of bacteria and causing metal parts to develop rust. Make sure you are measuring the amount of water vapor within your system to avoid issues caused by this contaminant. Another common contaminant found in compressed air systems is oil. The presence of oil has the potential to clog the various piping systems within the unit and can cause the entire unit to overheat over time. Other fumes or gasses that come into contact with your compressed air system can also cause problems, either corroding the machine’s internal or external sections or impacting the system’s air output.
Finally, any obstruction within your compressed air system can cause resistance to airflow, decreasing the pressure within the system. Always ensure your compressed air unit is free from any obstructions to keep it performing at peak efficiency.
How to Reduce Pressure Drop
If you find that your industrial compressed air system is having difficulty maintaining the proper pressure for your application, there are steps you can take to try and identify and correct the problem. Here are some troubleshooting tips:
- Review Pressure Settings: One of the easiest troubleshooting actions you can take is simply reviewing the settings for your unit to ensure they are appropriate for the output your application requires. As with any business, your production’s needs and requirements will likely change over time. Whether your unit is set for production higher or lower than is required, correcting those settings to match the needs of your application can potentially help reduce the amount of pressure being lost within the system.
- Check for Leaks: After ensuring your compressor settings are correct, check your entire system for leaks. Common areas where leaks may occur include the compressor itself, hoses running from the compressor, fittings, valves that may come loose, and the other various connections within the system.
- Inspect valves: While looking at the valves on your compressed air system to check for leaks, ensure they remain free from blockage, as well as damage or wear, which can impact the integrity of the valves. If you encounter damage or wear on those valves, replace them as soon as possible and see if that takes care of the pressure drop issue.
- Check the Compressor Pump/Air End: Check to make sure there is no sign of damage or wear at the compressor pump/air end. Damage at this location can impact the compressor’s ability to pressurize air properly.
- Verify Lubrication: If your compressor is not properly lubricated or the lubricant is contaminated, consider adding or replacing the lubricant already in the system.
- Inspect Air Intake and Filters: If the air intake or filters are clogged or blocked, the pressure within the system is likely to drop incrementally over time. Clearing out blockages and replacing filters regularly is a good way to avoid this issue.
- Check the distribution system: Clogged filters, blockages in hoses or pipes, and too much friction due to long, narrow pipes or sharp bends can all reduce the pressure within your compressed air system.
ESA Can Help
If your attempts at troubleshooting your system show no solutions, don’t worry, we’ve got you covered. At ESA, our trained technicians have abundant knowledge about the potential causes of pressure drop, and we have decades of experience fixing air compressor system issues you may be encountering. If you’re unsure how to eliminate pressure drop issues within your application, call us today for a consultation. We’re available 24/7 and can come take a look at your system at a time that works for you!