Air
Compressor Commissioning & Installation Services
The definition of Commissioning from Compressed Air Best Practice magazine, “Compressed air system commissioning is the
process for measuring, testing, adjusting, and documenting that the performance of an entire compressed air system achieves the target
system efficiencies (scfm/kW as a whole and for each piece of equipment) in all load regimes and potential failure modes.”
Proper compressor installation and commissioning helps ensure trouble-free startup and long-term reliability. Thorough inspection and
critical review during each phase of the installation process eliminates “built-in” deficiencies or problems which could later result in
equipment failures or poor performance.
Commissioning: Start with the Preparation
Checking your air compressor before the installation is critical to its' success. The checklists in the below sections are intended to aid
in this inspection/review process, but refer to your manufacturer's instruction manual for exact details.
Installation Checks
{"values":"Installation is per manufacturer's instructions "}
{"values":"Belt properly aligned "}
{"values":"Compressor turns freely"}
{"values":"Compressor in place and properly anchored"}
{"values":"Shipping pallets removed"}
{"values":"Power disconnect is located within site of the unit it controls and labeled"}
{"values":"All electric connections tight "}
{"values":"Safeties installed and operational "}
Reverse Rotation Check
This is probably the single most important startup item that should be conducted before starting the compressor.
The compressor should be “bump started” (i.e. control power de-energized immediately after startup) and the direction of the pressure gauge
movement should be checked to insure that the discharge pressure rises upon compressor start. If the compressor rotation is backwards the
discharge pressure will be pulled immediately into a vacuum, on a rotary unit this will starve the air-end of needed oil and cause air-end
damage within a seconds. If the rotation is backwards, the phasing of the compressor should be corrected (reversing any two leads will
change rotation) before attempting to re-start the compressor.
Some 3 phase units come with a piece of paper taped to the top of the cabinet. If the electrical phases are correct when started it will
blow the paper up revealing an OK on the bottom, this indicates the rotation is correct. In cases the phases are out of sequence when
started air will be pulled into the cabinet sucking the paper down, this would indicate incorrect phase sequence and wrong motor rotation
and would need corrected immediately before restarting.
Start-Up Of the Compressor
Great news, your pre-commissioning is all set. Now is time for installation and the next round of commissioning checklists. Below are a few
things to keep in mind during start up.
Startup Check List
{"values":"Pull disconnect and ‘lock out’ switch"}
{"values":"Activate disconnect switch"}
{"values":"Bump for proper rotation of motors"}
{"values":"Close receiver valve and start "}
{"values":"With valve closed let machine come up to pressure "}
{"values":"Check for proper cycling operation"}
{"values":"VFD interlocked to control system "}
{"values":"Open receiver valve"}
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Who we are and how Ash Air can help your business!
Ash Air has been around in New Zealand since 1979, and we’ve grown into a nationwide company with international support and a
reputation for quality and reliability.We look after all things compressed air for your business!
Reciprocating, Screw, air compressors
Vacuum pumps
Nitrogen
An extensive line of air treatment components
Ash Air's range of Chicago Pneumatic, Alup, Pneumatech, and Quincy compressors are used extensively around the world in industries
ranging from oil and gas to food, automotive and farming, and we bring you these world class compressors here in the land of the long white
cloud.Our technicians are compressed air equipment experts and are dedicated to addressing customer needs. Supported by a 13 locations
nationwide, Ash Air offers one of the widest selections of compressed air equipment and parts available today in New Zealand.
Reliability and Efficiency
With Ash Air compressors, you can count on reliability and high performance for even the most demanding applications. We focus our
efforts on the following:
A liquid ring vacuum pump is a powerful and steadfast piece of equipment that, if well maintained, can provide years of dependable
performance. Whether you purchase a large or small unit, you can rely on a vacuum pump for smooth, consistent and relatively quiet operation
for many months on end between each inspection.
Read More…
Just like any other equipment, a compressed air installation also requires the necessary maintenance work during its entire
lifespan. Even though maintenance costs are only about 5 to 10% of a machine's annual operating costs, failure to budget for
maintenance can have potentially disastrous consequences.
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The air dyer is one of the most ignored cooler in the system. A dirty condenser will cause water in the lines, or worse it will cause
complete dryer failure.
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Using nitrogen is not about fully replacing CO2, but it can reduce their consumption of CO2 by close to 70%. Using nitrogen is about
sustainability. Creating your own nitrogen is easy and will reduce the use of a greenhouse gas, which is better for the environment. It will
also save you money as early as month one adding that savings to your bottom line.
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ICONS: Intelligent Connectivity System: The insight into your compressed air system, wherever you are. Learn More about ICONS in this article here!
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A question that is occasionally asked by our customers to Ash Air is 'what is the cost of compressed air?' This article looks at the
product costs involved with compressed air, as well as minimising the energy cost of compressors and cost allocation. When looking at these
factors, we need to realise what causes dropped efficiency of your compressor, leading to increased costs of compressed air.
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You may have great fall protection measures in place to keep employees safe when working at height, but what about their co-workers below?
Dropped tools and other falling objects are a major hazard – and one that isn’t always fully addressed.
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Providing a safe working environment for operators is essential, especially when using pneumatic tools and compressed air. If there is a
failure in the air network and the hose is not adequately clamped, the resulting whiplash could be devastating. Failure to follow best
practice can result in injuries, associated production downtime and decreased productivity.
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A common questions asked is why do I need an air dryer for my compressor? Typically, air compressors produce water, and although the
water can be drained, there can still be aerosol and vapour droplets that are present. This is because water cannoet be compressed. Water
can damage your compressor by corroding the valves, pipes and machinery controls, which will cost you time and money to resolve. In
the long run, the cost of a new compressor is a small price to pay compared to the loss of production that could potentially arise due
to water damage in your compressor.
Air compressors can fail for an assortment of different reasons: Normal wear and tear, lifespan and age of the unit, poor maintenance, power surge, install issues are just a few the come to mind. Check out this blog to find out our top 7 tips to ensure your compressor is looked
after!
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Air compressors use considerable volumes of energy during a typical work cycle. When you add up all the expenses of operating a facility,
any savings can help you boost your bottom line.
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If you have never bought a rotary screw air compressor before; do the following. Add up the air consumption of all the equipment at your
shop. That will be the amount of air your desired compressor should provide.
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Knowing the telltale signs of wear and tear, understanding your product’s specifications and usability guidelines, and knowing when it’s
prudent to call in repairs are skills that could save you a lot of time, effort, and money in the long term.
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That cold, rainy, and in some places icey New Zealand winter is upon us, and with the following air compressor tips, your air system will be
prepared with the preferred temperatures, despite the weather outside. Regardless of whether or not it actually snows or freezes up where
you live, most winterisation service recommendations are also basic, solid maintenance procedures that will help extend the life and
operational efficiencies of air compressors regardless of whether you live in Queenstown or Northland.
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If you're wondering what an air compressor actually is, you've come to the right place. Simply, air compressors convert power in to air that
is pressurised which is then used to power air tools such as spray guns. Air compressors are used in a wide range of applications, so
naturally if you want one that will be designed for spray painting your vehicle, you want a compressor specifically made for spray guns!
This way your compressor will be able to provide the right amount of power to perform the job.
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Compressed air plays a fundamental role in industrial activities. Depending on the type of application, the energy cost of producing
compressed air can be very high. Below are some tips to save on you compressor bill.
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Air Compressors are essential tools in a variety of industrial settings. No matter what industry you are in having a reliable air compressor
can be a crucial part of getting the job done efficiently. However, like an investment, air compressors require upkeep and maintenance, and
eventually will need to be upgraded. But how do you know when it’s time to upgrade your air compressor? Here are some things you need to
consider.
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When it comes to laser cutting and other industrial processes, the choice of assist gas is crucial in achieving optimal results. Nitrogen
and oxygen are commonly utilized as assist gases, each with its own unique properties and applications. Understanding the characteristics of
both gases, will help you to make an informed decision to ensure precision, efficiency, and cost-effectiveness in your operations.
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Mobile air compressors are portable, towable compressors particularly useful for applications that suit the construction and roading
industry! You'll often see a mobile compressor being used for sandblasting, irrigation blow-outs, and for quarrying tools such as pneumatic
block cutters and rock drills.
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Did you know that Chicago Pneumatic helped man land on the moon? Notice in this photo of the Apollo 11 landing what appear to be
"soccer balls" on top of the capsule. They were inflated through a compressor specially developed by Chicago Pneumatic for
NASA.
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Your company purchased an air dryer for your compressor, now where should you install it? One of the most common things we see in the
industry are air dryers being stored on top of the compressors. Seems like a wasted space not being used on top of the compressor, right?
Wrong.
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When using air compressors, there are many variables that are integral to the quality and effectiveness of your compressed air. When dryer
air is necessary, being able to constantly and accurately monitor dew points can be a critical factor to your operation.
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Compressed air plays an integral role in breweries both large and small around the world. From start to finish, all details in the brewing
process are managed in fine detail and having the right air compressor is no exception.
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We Kiwi's love our Coffee! Coffee, like all other food & beverage products, must go through a preservation process to keep the
beans fresh during storage and packaging before they reach the consumer. Coffee that is not properly stored after it is roasted will lose a
large amount of carbon dioxide, which lessens its' flavor and speeds up the staling process. One of the most common ways to preserve the
freshness of coffee is the use of nitrogen gas. Learn more here:
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Air compressors are helpful for an enormous range of applications such as air filling, packaging, tools, HVAC control, and more! One
possible drawback is the amount of electricity they use; air compressors can be a huge drain on energy if used inefficiency...
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Air compressors create the energy used by pneumatic tools and processes throughout your compressed air system. The component that connects
everything together is the piping. It is very important to choose the right compressed air pipe to avoid pressure
loss, rust and other problems.
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We get it, buying an air compressor is a big financial decision. And now we are suggesting that you need two air compressors, not just one.
Ask yourself one question- Can your business still run if your air compressor goes down?
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It’s no secret – air compressors are excellent sources of energy. Not only do they power essential manufacturing elements and applications, but the heat generated as a result of the compressed air processes can be used as a byproduct that offsets other energy costs. However,
there’s another form of energy that is also a consequence of the air compression process – sound.
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Maintenance is key to continuing the performance of your air compressor. Continue to read about maximising the performance and longevity of
your compressor and some air compressor maintenance tips!
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The emergency stop, "e-stop", is for true emergency situations only. When hitting the e-stop, all power is halted from the machine
and the unload process isn't achieved. The emergency stop button is intended to help with possibly hazardous situations that are developing.
Common conditions of having to use the e-stop is the misuse of the equipment in ways that weren’t intended, predictable failures not
addressed or failing to consider all the foreseeable uses of the compressor. Read More…
We've put together a list of tips for working safely with air compressors in your environment! We recommend that you always read owners
manual before running your compressor. The number one cause for repairs and personal injury is improper use. You've got to remember to use
eye protection and hearing protection when operating your air compressor and try to avoid using air compressors in a wet area.
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It's generally cost-effective to invest in an on-site industrial oxygen generator. If using bottled or liquid oxygen, you can save 50-90%
per unit of O2.
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Air Compressor Installation Tips
Installing Your Reliable Air Compressor
So, you've just bought an efficient and reliable ALUP air compressor? Welcome to the world of compressed air.
As your partners in compressed air, we will continue to assist you along your journey. We have provided air
compressor installation
tips to ensure you get the most out of your air compressor. Read More…
You may think you know pretty much everything there is to know about vacuums. You push one around your house to pick up dust on the floor
and that’s about all there is to it.
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What started as a family business has since grown into the world’s trusted expert in air treatment and industrial gas solutions. It’s a
success story we’re proud of, a true testament to the drive and entrepreneurial spirit of our entire team.
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Air dryers remove any condensation from the air compressed by your air compressor. Questions about them? Find answers to the most frequently
asked questions here.
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Power tools are a key to productivity in the oil & gas or the metal working industry. Maintenance and production tasks must be carried
out efficiently, however intensive use of vibrating power tools, such as grinders, can expose operators...
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Selective soldering with nitrogen is an essential process in the production of printed circuit boards (PCBs). It is used for bonding
components to PCBs that could otherwise be damaged if exposed to a lot of heat. Another area of application are mixed-technology circuit
boards with layout constraints.
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Hydrogen is becoming increasingly important as a promising clean energy carrier – especially with a view to a more climate-friendly future.
But have you ever wondered what hydrogen actually is and how it is produced? In this article, we look at the basics and technologies used to
produce hydrogen and what makes hydrogen a special element.
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