Could Leak Detection Help You Cut Costs?

leak detection for air compressors

Compressed air leaks can be a huge energy drain on your business. They can sometimes be the difference between running your normal compressor system and being forced to turn on your backup. To really put this in perspective, consider that a ¼” air leak at 100 psig can waste as much as 104 CFM of compressed air. This is equivalent to a 25 HP compressor, and in energy dollars, can mean losing as much as $8,000 a year in power cost.

Benefits of Detecting and Repairing Compressed Air Leaks:

  • Reduce energy consumption and operating expenses
  • Identify equipment that is failing or not operating properly
  • Reduce the load on your compressed air equipment
  • Improve plant safety

Identifying Leaks Efficiently

There are two major ways to find leaks. The first is to turn off all production equipment, then walk the facility to mark and fix leaks. The second, more efficient option, is to use an ultrasonic leak detector to find the leaks while the facility is in production. Ultrasonic leak detection offers a simple, non-invasive way to quickly identify leaks that can be tagged and later repaired. This technology could help your operation identify costly issues and minimize waste. Think you might have a leak? Contact your local Lewis Systems for more details and pricing.

Gardner Denver RBS Blowers: Top 3 Design Advantages

Gardner Denver RBS positive displacement blowers and vacuum pumps bring incredible value to the industrial PD market. These robust tri-lobe pumps have a multitude of design advantages. Here are your top three:

  1. Durability
    • Piston Ring Air Seals – ensure oil-free air and last longer
    • Dual Splash Lube – dissipates heat and reduces maintenance intervals
    • Reinforced Bearings – 100,000-hour lifespan
    • High Strength Shafts – allow for higher overhung loads and eliminate the need for jack shafts or pillow blocks
  2. Efficiency
    • Tri-Lobe Rotors – greater performance and efficiencies than bi-lobe blowers reducing operating costs
    • Cylinder and Support Ribs – cast directly into the cylinder reducing deflections under heavy loads
  3. Sound Levels
    • Tri-Lobe Rotors – solid rotor design offers quieter operation reducing enclosure requirements
    • Helical Gears – provide smooth and quiet operation at all speedsadvantages of blowers and vacuum pumps

For more updates on the latest air compressor trends, follow us on LinkedIn. Or, if you need additional information or assistance with your air compressor system, contact us today.

Cold Weather and Compressed Air Systems – A Proactive Approach

It seems like September is a little early to be thinking about colder weather especially here in the South, but that’s exactly what we should be doing. Now is a great time to be proactive and get your compressed air system prepared for what is coming. My favorite definition of “Proactive” is acting before a situation becomes a source of confrontation or crisis. When cold weather hits, compressed air systems can struggle, and a variety of problems can arise.  Slow starting, line freeze problems, sensor malfunctions and equipment failure are all things our service department sees every winter. By taking a proactive approach and preparing your equipment for freezing temperatures you’ll be protecting yourself and your compressed air system from having to deal with a cold weather “crisis”.  Of course, you could just sit back, wait and take the reactive approach which usually consists of emergency service calls, air freighting parts and sometimes a rental compressor…

Here is a basic cold weather checklist:

  • If your equipment is outside, make sure you can air compressor winter tipsprotect it from the wind and use floodlights or heat lamps to keep your controls from freezing.
  • Check insulated areas and make sure the heat is staying inside and the cold is staying outside.
  • Also, check any weather stripping and replace areas that are worn out and not working properly.
  • Check condensate drains throughout your system for proper operation. Excess water in your lines and freezing temperatures are not a good mix. Install heat tape on anything that is exposed.
  • Check the intake for your air compressor. If it’s exposed to the outside elements, your inlet air filter can be damaged from ice and snow.
  • Compressed air receivers should be protected as well. If condensate collects at the bottom of the tank it can freeze.  Insulate any outside pipes feeding the tank as well as the condensate drain for the tank and make sure the drain is working properly.
  • Kind of a no-brainer here, but make sure your compressed air dryer and compressed air filters have been serviced and are operating correctly. Their job is to remove the condensate from your compressed air system.  The less condensate in the system the less there is to freeze and cause problems.

Contact us today if you need any help with addressing your cold weather vulnerabilities. Taking these proactive steps now, can help prevent some major problems once it turns cold outside.

Lewis Systems & Service Co., Inc. Adds Territory in Eastern Virginia

Best-In-Class Compressed Air System Reliability Requires the Right Partner

Lewis Systems & Service Company expands

After an extensive review by Gardner Denver, Lewis Systems has been selected as the new Authorized Distributor in the Eastern and Tidewater areas of Virginia.  But, we are not new to Gardner Denver nor to Virginia.  As their compressed air and compressed air treatment distributor in North Carolina and Central Virginia for the last 30 years, Lewis Systems has the service expertise and dependability to help you maintain your Gardner Denver product warranty while maximizing the efficiency and productivity of your entire compressed air system.gardner denver compressor repair

Lewis Systems & Service Company has been building and sustaining Gardner Denver compressors and compressed air systems for decades. Lewis Systems will leverage its vast industry experience and knowledge to be your local resource for everything related to compressed air systems – from service to a complete system design and installation that takes advantage of Gardner Denver’s broad array of reliable products and technologies.

Lewis Systems is headquartered in Greensboro, NC with branches in Lynchburg, VA, Rocky Mount, NC, and Charlotte, NC. Lewis Systems provides 24-hour, 7 days a week emergency service to compressed air customers. Their team is ready to assist with your sales, service, and technical support needs. The new area, in particular, will be served through their locations in Lynchburg, VA. Lewis Systems can be reached using the following contact information:

Lewis Systems & Service Company

126 Bradley Drive

Lynchburg, VA 24501

434-455-0361 or 877-855-6830

Or visit our homepage for more information.

Treating Oil and Water Condensate in a Compressed Air System

How to Treat Condensate in a Compressed Air SystemWe recently did a blog post on Summer Preventative Maintenance, (check it out here). One of the key points listed in that post was making sure your oil/water separators are operating properly. So let’s take a look at what an oil/water separator is and why it is so important.

A typical compressed air and gas system can produce a tremendous amount of condensate each year so it’s important to know how to treat oil or water condensate in a compressed air system. This condensate is usually a mixture of condensed water and hydrocarbon vapors. It’s extracted from your compressed air system at various points. The compressor aftercooler, compressed air receiver, compressed air dryer and various line filters. So what do you do with all of this “stuff”? You need to either collect it and pay someone to haul it off or you can treat it and dispose of it properly. Since over 98% of the condensate is pure water it makes sense financially to separate the lubricant from the condensate then dispose of it properly. An Oil/Water Separator will do that for you.

Traditional oil/water separators operate on the basis of using a settling tank and gravity to do the bulk of the separation. Oil is skimmed off the surface and discharged into a separate container for proper disposal and the rest of the condensate, up to 98% of it is sent through a filtration process, usually a bed of carbon.  The carbon bag/filter has to be maintained on a regular basis to ensure your discharge water is meeting government regulations in your area. The “settling” tank has to be emptied and cleaned and the carbon bags have to be pre-soaked with water before you install them. Proper sizing is key here due to the variety of synthetic lubricants on the market and fluctuating humidity levels.  If a system is not sized correctly, media life is shortened and system back up can occur, spilling oil and making a general mess.

Newer designs of oil-water separators have been coming out recently to make the separation process more environmentally friendly and easier to maintain. Our friends at nano Purification Solutions have a great product that addresses the pain points of a traditional setup.  Their design utilizes a unique filtration media that not only outperforms carbon technologies but is also made out of environmentally recycled materials.  It’s so efficient that there is no need for oil skimming and collecting. The media is very light and there is no pre-soaking before installing it. You have one discharge port with clean water, down to 5 ppmw or less.

Important Points to Remember:

  • Proper disposal of oil/water condensate is required by law
  • Separating and treating it on site results in considerable savings
  • Employing the latest technology from nano and Lewis Systems gives you peace of mind. (you don’t want the EPA knocking on your door).