SPECO Southern Parts and Engineering Company Compressed Air System Efficiency Factors: Routine Maintenance and Monitoring / Blog
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Compressed Air System Efficiency Factors: Routine Maintenance and Monitoring

Compressed air systems are essential to production machinery and processes in industrial facilities. Compressor inefficiency and downtime can mean costly energy consumption and decreased plant productivity. As a preventative solution to this, having sufficient knowledge on how compressed air systems are performing and addressing found issues right away should be put importance to. Routine maintenance and monitoring involving accurate measurement and tracking of pressures, temperatures, flow, power, and energy over time must be done.

A poor and ineffective compressed air system maintenance not only lower compression efficiency but also increase pressure variability or air leakage. It also pushes increased operating temperatures, weak moisture control, and equipment contamination. Regular system maintenance significantly reduces these issues, saves compressor energy, and most importantly improves system performance.


Good maintenance plans are reinforced by consistent monitoring supported by proper instrumentation. Investing on high-efficiency instruments including pressure gauges, temperature gauges, flow meters, dew point temperature gauges, and kWh meters & hours run meters is recommended for better compressor monitoring and maintenance.

Keeping an eye on system pressure involves using reliable pressure gauges. These can be set-up on each receiver or the main branch line and differential gauges across filters and dryers. To detect fouling and blockages as well as observe temperature, temperature gauges must be secured on the compressor and its cooling system. Quantity of air used can be measured with robust flow meters. Air dryer effectiveness can be monitored by dew point temperature gauges. kWh meters and hours run meters on the compressor drive are used to check on the amount of electric energy already consumed. These instruments help assess how the machine operates and provides a list of points to upgrade or fix, avoiding potential compressor downtime.

It is recommended to log data recorded from system monitoring as this can help develop a system baseline. This baseline is created from data collected over a period of time and can be used as a point of reference for future comparisons and improvement. A baseline can help right size a compressor and operate in the most efficient control mode, therefore minimizing power consumption.

Data logging also facilitates in monitoring system control, ensuring pressure stability, troubleshooting compressor problems, and sizing equipment. As compressed air systems are dynamic and conditions are continuously changing, it must be ensured that compressors work accordingly to maintain sufficient system pressure. With recorded information, responses of compressors to changes in pressure or how pressure responds to compressor changes can be determined. Other causes of system issues can be troubleshooted by reviewing logged parameter values as well.

With consistent maintenance and monitoring of compressed air systems, potential issues that affect compressor energy efficiency can be addressed immediately. Keep your compressors well-maintained and energy efficient with robust compressor parts. SPECO carries a comprehensive selection of OEM compressor parts and compressor parts replacements for uninterrupted and optimal operation of your compressed air systems. Browse our product offerings by visiting www.soparts.com/products. For additional product and service information, give us a call at 888-793-4988, today!