Ignoring any of the design fundamentals listed above would be a mistake when assembling your compressed air system. There are a lot of additional things that can go wrong both during and after the design process that might cause problems. Here are a handful of the most significant ones:
- Using a low-cost compressor. You get what you pay for, so purchase the greatest compressor you can afford. You might as well invest in a decent compressor from the start, because you’ll more than likely end up paying up the difference in annoyance and maintenance in the end.
- The header piping is too small. We’ve discussed the importance of pipe in terms of materials, but size is also important. There are several aspects to consider when deciding the size of your pipes, ranging from air velocity and pressure to friction loss and future demands. Make certain that your plumbing meets your capacity.
- The failure to keep the air pure. Plant air should be filtered, oil-free (for most uses), and dry. Failure to achieve any of these requirements can have serious consequences for your system and process. Make certain that your system meets all three criteria at all times.
- Failure to include surge tanks. Surge capacity is critical in your system, yet far too many systems are installed without them. It may be a risky error. You’re not going to make it.
- Ignoring routine maintenance. A compressed air system contains enough parts, controls, devices, and switches to assure that something will go wrong. However, these issues may not have to be unavoidable. Regular and preventative maintenance, such as oil changes, are critical to keeping your system (and your process) operational. Make a maintenance plan and stick to it. In fact, before you make a buying choice, find out where your local service representative is located. Having them close may be your best defence against extended downtime.
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