Compressed Air Service Provider

How to select a compressed air system services provider

Compressed Air Service Provider

The biggest challenge any factory professional faces in Pakistan is finding the correct answer to the following question: “How do I know if the service provider I hired to evaluate compressed air systems has the necessary skills to do so?”

The production of compressed air is a dynamic system. Many factors affect its performance and reliability. Some of these factors may have nothing to do with the air compressor itself, or even with the compressor room. So the next time you are interested to contract a service provider, consider these set of guidelines to determine both the qualifications needed in a service provider and the scope of work level that will fit your needs best.

  1. Training

Ask the company to provide training documentation for their sales and service personnel. Technology advancements require constant training of any team dealing with compressed air systems. The company should share details of training institutes and certifications for every service engineer.

  1. Compressor knowledge and expertise

Does the service provider have the expertise to work on every compressor type in your facility? How much experience does the service technician have? How do they train? Do you participate in formal education? Knowledgeable service technicians deserve the high price they may need because they can troubleshoot and efficiently bring the device back online.

  1. Component controls knowledge and expertise

Handling, accessories and auxiliary equipment. Does the service provider have expertise in refrigeration and other work on dryers and related equipment? Is the service provider able to repair the type of filters, drains, distribution and point-of-use equipment in your facility?

System controls. Does the service provider have diagnostic and technical control functions to determine how to optimize the existing control configuration and suggest improvements? Can the service provider use the network compressor together or monitor it remotely as needed? Advanced controls can save energy and improve reliability by automatically starting and stopping, and turn off the compressor so that it can be used as a backup device. Early warning through remote monitoring can help you discover problems before they become serious downtime.

  1. Availability of compressed air system assessment services

Does the provider offer compressed air system analysis services? If yes, how well do they fit your needs? If no, can the provider outsource these services to an experienced system specialist? How experienced are the individuals who will be providing these services? Once a walk-through, assessment or audit is performed, what kind of follow-up services are available to ensure that recommendations are implemented properly and produce the desired results? Ask for client references, a sample of similar work that the provider has done for others and resumes of the personnel who will be performing the work. Please note that while leak detection is a useful element of a system assessment, a true system assessment includes much more.

  1. Company capabilities

Ask about the service provider’s standards of performance for:

  • Annual Service Contract
  • Emergency service response
  • Air-end Refurbishment
  • Parts shipments
  • Compressed Air Health-check services
  • Installation and Commissioning
  • Emergency Rental Fleet
  1. Service facilities

Visit the facilities of two or three service providers under consideration to see first-hand the type of repair shop and parts warehouse with which you will be dealing.

Sakoon Pneumatics (Pvt.) Ltd.

Sakoon Pneumatics is an Authorized Service Provider for Both CompAir and Gardner Denver  (Ingersoll Rand) Brand of Air Compressor and Associated Accessories in Pakistan.

We also provide Premium Screw Air Compressor Services and Spares for all types of other famous brands.

Experienced in Compressed Air Systems for 40 years, Sakoon Pneumatics is known for excellent services and after-sales support. Depending on Industrial needs, our team of qualified technicians schedule ideal maintenance plans for your compressed air system which lead to optimum machine performance, reduced downtime and increase productivity.

summer tips

Seven Tips for Summers for Your Air Compressor

Summer is almost there, which means that the temperature all around will rise. The high temperatures will put a lot of pressure on your air compressor. If the necessary precautions are not taken, it may cause production loss and machine failure. For industrial air compressors, extreme weather may play a key role in overall efficiency. Some of the most common problems we see when servicing equipment are air leaks, blocked drain pipes and dirty filter systems. To avoid some of these problems, we have organized 7 tips to help you prepare an air compressor for summers

Beat the Heat with Sakoon

  1. Check the Drains

When the temperature becomes higher, the level of condensation in the air compressor usually increases. This is problematic on many levels, because moisture can affect the performance of parts in pneumatic tools and air compressors.

If the drain fails and water starts to accumulate, it may disrupt production or cause the machine to shut down. Check the discharge port to ensure that once the temperature rises, the discharge port can work normally to cope with the increasing demand on the compressor. Make sure that no excess water passes through, and that the drain pipe can handle more water flow from the air compressor.

  1. Clean Air and Oil Filters

Filtration plays a huge role in improving the efficiency of the air compressor. As long as the air and oil are sufficiently filtered in a given entire cycle, it can be expected that the air compressor will produce a constant volume of cold air, and the overall performance of the machine is stable. However, if the filter is clogged with dust, the pressure may drop, forcing the air compressor to work harder to perform only basic functions. In essence, energy is consumed during this process, and parts wear faster.

If dust is allowed to accumulate in a few seasons, the decline in air quality may be a warning sign that road costs will be higher in the future. To avoid these problems, please check the filter regularly and clean it if necessary.

  1. Clean the Coolers

During summers, the surrounding air is hotter than normal, it will affect the performance of pneumatic tools and machines. It is essential that the air compressor itself maintains a stable temperature throughout the year, including the hot summer season when the outdoor temperature soars above 30 degrees Celsius.

To prevent the air compressor from becoming hot in summer, the cooler must be cleaned every year when the temperature starts to rise. If the cooler is blocked, it may hinder its ability to keep the compressed air system functioning properly. To prevent this from happening, please perform the following steps later in the spring:

  • Check the cooler for dirt, debris or mist residue
  • Remove any dirt deposits present on the cooler
  1. Check the Ventilation

Just as you put the air filter and oil filter in the air compressor, you must also check the ventilation of the room where the machine is located. To prevent the ambient air from becoming too crowded, please perform the following steps regularly:

  • Check the ventilation holes for dust deposits
  • Remove dust accumulation on the vent
  • Check the HVAC system for dust accumulation and defects
  1. Adjust the Water Cooling System

When you cool the air system with water, the water itself must be cool to achieve the desired effect. When the weather gets warmer, the incoming water should be colder. Like air coolers, water-cooled air compressors also require enough cold water to offset the warmer months of the environment.

To ensure that the water maintains a sufficient temperature, perform the following steps before each wet work cycle:

  • Check water temperature
  • When the ambient temperature rises, adjust the water temperature if necessary
  1. Identify and Fix Air Leaks

Regardless of the season or outside temperature, air leakage is the ultimate enemy of compressed air systems. Summers happened to see more leakages though. Air compressors can have a fully functional filtration system without condensate and flowing oil, but if air leaks occur anywhere between the machines itself, in piping system or at pneumatic tool, performance will still lag.

When a leak is formed along the compressed air system, the performance of the tool will decrease and the operating efficiency will also decrease. If the operator does not know the source of the problem, the first solution usually thought of is to simply increase the system capacity to compensate for the lagging power which leads to increased capital and electricity costs.

  1. Change the lubricant

Summers bring high heat and humidity which can shorten the life of the oil by as much as half. Changing lubricant regularly is must as it several key functions:

  • Lubricated bearings
  • Absorption / removal of compression heat
  • Form a liquid seal on the air end to effectively compress
  • Prevent contact between metals
  • Removes particulate contaminants

Air-End Refurbishment – The Open Heart Surgery of Air Compressors

Compressed Air is the lifeline of your manufacturing facility. At the heart of all rotary screw compressors is the air-end. Normally, little is done to protect one of the compressor’s most critical components before the compressor goes offline. Mechanical components of air-end has a specific life after which they deteriorate.

  • Typical oil lubricated screw compressor bearing life is the 24,000-40,000 hour range or 6 years, whichever comes first.

During operation, the air-end’s critical components such as bearings and seals can become worn or damaged and can lead to reduced efficiency or even failure. It might be like cardiac arrest for your company as you will face production downtime and capital cost for its replacement.

AirEnd Refurbishment Timeline

  • As soon as air-end reaches specified hours, you must call Sakoon compressed air expert for technical evaluation.
  • Place your order for air-end refurbishment.
  • Let us know in advance if you need a rental air-end during refurbishment time.
  • After you place your order, you’ll skid your air-end and ship it per our instructions.
  • Air-end arrives at our repair center. The air-end is inspected and enters our rebuild process.
  • Air-end rebuild is completed in 5 to 7 business days.
  • Unit is skidded and packaged appropriately and shipped back to your location.

Why to prefer Sakoon European Certified Facility

State-of-the-art design and significant engineered parts are what make screw compressors most effective. To deal with such top-notch technology, one must consider certified compressed air experts. Our Sakoon air-end refurbishment facility is European certified and offers warranty for rebuilds. Unlike local market, Sakoon take serious concerns for complexities of air-end and its components. As air-end is almost 30% of compressor’s total cost, we make sure it is rebuild and tested to same designed efficiency. Sakoon offers following features for air-end refurbishment:

  • European Standard Facility
  • German Certified Engineers
  • 6 months warranty
  • Restored air-end to original performance
  • Delivery within one week
  • Rental air-end for all frames

Contact Us if your air-end is about to complete time mentioned above.

Compressed-air

Is Compressed Air a Potential Source of the Corona Virus? – The Use of Compressed Air

Important Information Regarding Coronavirus COVID-19 & The Use of Compressed Air

Currently there is information circulating claiming that compressed air is a potential source of Corona virus COVID-19, requiring the installation of sterile air filters (or more frequent filter sterilisations and element changes) to prevent the contamination of food, beverage or pharmaceutical products.

The World Health Organisation (WHO) has been very clear that Coronavirus COVID-19 is not an airborne virus.

Coronavirus COVID-19 is spread from human to human by droplet dispersion (from coughs and sneezes) and by contact between humans and surfaces contaminated with the droplets from coughs and sneezes.

Currently , WHO is investigating the rare possibility that when an aerosol- generating procedure, such as that carried out in a medical care facility is undertaken, particles can become aerosolised, meaning that they can remain airborne for a little bit longer. There is a recommendation that health-care workers take additional precautions when they are working on patients and carrying out these procedures.

Dr Maria Van Kerkhove, head of WHO’s emerging diseases and zoonosis unit, told reporters during a virtual news conference on Monday. “In health-care facilities, we make sure health-care workers use standard droplet precautions with the exception … that they’re doing an aerosol-generating procedure, … we are confident that the guidance that we have is appropriate,” she added.

It is important to understand that while airborne viruses do exist, and these viruses, if drawn into an air compressor intake, have the potential to multiply in warm, wet, under-treated compressed air, Coronavirus COVID-19 has not demonstrated these behaviours. In addition, the location of these aerosol- generating procedures is not located typically near a compressor intake.

There is no scientific evidence to support the claims that compressed air is another potential source of Coronavirus COVID-19 or that compressed air used in the manufacturing of food, beverage or pharmaceutical products can contaminate these products with the virus.

Please Contact Us for further assistance Contact Us

Source: British Compressed Air Society

rent-a-compressor

Rent A Compressor – Air For Hire

rent-a-compressor

Renting an air compressor is the best way to address your temporary air compression needs during this shutdown /Lock down Situation Due to CORONA VIRUS (Covid-19). Industrial air compressor rental is also a great option if you have an existing system that requires repairs or maintenance and you don’t want to fall behind your work orders. Industrial air compressor CompAir rental machines are available in different sizes, capabilities, and mobility types. You need to choose the model that matches your tools and the requirements for your specific projects.

Reasons why companies rent air compressor equipment

  1. Unexpected equipment failure

It is always wise to expect the unexpected. Emergencies inevitably happen like Corona Virus Spreads in the whole world, whether they come from a natural disaster, human error, or from equipment failure. Ensuring production lines are continuously running with clean and reliable compressed air is absolutely critical. Compressed air equipment breakdowns can have serious consequences, and minimizing the costs and delays caused by unscheduled repairs is a priority.

When an air compressor stops working, every minute production is down creating a loss of money and time, and increases stress and frustration. To reduce the risk of financial and productivity loss, a rental will maintain the air capacity needed to keep a process operational while issues with the current system are being addressed.

  1. Planned outages and maintenance

When facility changes are underway, the last thing needed is for product quality and productivity to be at risk. During plant upgrades, renovations, or routine maintenance, temporary compressed air solutions facilitate continuous operations, keeping production running at peak efficiency. When planning for facility changes, air compressor rentals can sustain critical processes while new equipment and other changes are being adopted.

  1. Save on capital expenses

The first reason to consider renting an air compressor is simply a matter of finance. Compressors don’t exactly come off the line at a low price. This means a company would need a fair capital budget to get the equipment up and running. Renting tends to be more affordable. While renting the air compressor, companies are able to pay it out through an operating budget, allowing them to keep up with operating and uptimes. On the note of expenses, this could save on maintenance as well, since most rental agreements come with support services on these air compressors.

  1. Personalized productivity

Often when inheriting a compressor or purchasing a new one, they must be adapted to current systems. Because of this, renting can be a choice of convenience as well. Since the rented compressor is often a temporary device, it is easier to get more specific with system needs. Adjust the compressor to the facility’s system and if things change, rent a different one. This adaptability can additionally save costs and optimize productivity in different ways. A compressor fitted to the company’s specifications means optimal compressed air quality, exact pressure levels, and reduced waste.

  1. Compressed air on demand

Sometimes renting an air compressor is necessary for addition to the compressor currently in use. Seasonal demand can be a large variable for a company to consider. Spikes like these can be met with additional compressors that can facilitate the additional compressed air necessary to keep up with seasonal order periods. Outside of the seasonal nature of the sales cycle, it is also important to consider seasonal weather conditions. Some compressors’ performance can suffer from the natural conditions they are subjected to and the support of an additional compressor can help productivity from falling out of optimization.

Why Rent?

  • Monthly payment – no unexpected bills
  • Less admin processing invoices for engineer visits or parts
  • Rapid emergency response in case of break down
  • Peace of mind for compliance
  • Less downtime
  • We will simply swap machine if it can’t be fixed quickly
  • Minimum service contract length 1 year
  • Priority service desk support
  • Simple pricing structure with no hidden extras

Will Renting Help to Save Money?

In most cases, renting is a much better deal than buying. It can be an especially good deal if you only need an air compressor for certain tasks or for a limited time.

For example, you can rent one of these machines for under $200 per day. In contrast, owning an air compressor can cost $5,000 to $50,000 or more with interest fees and insurance costs.

No matter how long you need an air compressor, Sakoon Pneumatics can help you do the job right the first time. With day-, week-, and month-long rentals across the country, we’re at your service for big and small jobs alike.

From compact air compressors to some of the biggest models on the market, we have the power you need. Reserve your air rental compressor online or contact us

Production Downtime – Shut Down & Start up your Compressor Do’s & Dont’s

If you have to reduce or stop production, please remember that switching off a compressor requires a certain procedure. To maintain the working conditions of the equipment when a COVID-19 related shutdown has passed us, please follow the following instructions or contact our technical support team for assistance.

We are here to assist you with technical advice on how to safely shutdown your equipment to avoid future problems or warranty disputes.

Taking Your Compressed Air Equipment Out of Service

DO’S

  • Bring any alternative equipment on line first
  • Shut down all equipment using the stop button
  • Open any manual condensate drains
  • Isolate from air mains
  • Isolate from any water supplies
  • Ensure any receiver tanks are drained
  • Ensure lock off and tag procedure is used
  • Ensure all internal air pressure is vented
  • Ensure to comply with long term storage guidelines if the shutdown period is over 1 month

DONT’S

  • Do not press the emergency stop button to shut down any equipment
  • Do not leave any water supply on to any equipment
  • Do not rely on non-return valves to isolate from any pressurised systems

Putting Your Compressed Air Equipment Back Into Service

DO’S

  • Restore power to the equipment
  • Remove any isolations that were placed and close and manual condensate drains
  • Ensure all ancillary equipment such as water pumps are working
  • On oil-free screw machines check for free rotation by hand before attempting to start
  • Follow all guidelines for start-up in the user manual
  • Check all temperatures and pressures
  • Ensure any service due is done ASAP

DONT’S

  • Do not try to start equipment with isolations in place
  • Do not start equipment without water supply fully functioning
  • Do not rely on non-return valves to isolate from any pressurised system

Feel Free to contact us anytime for your compressor needs

piece-of-mind

Annual Service Contracts for Your Compressors

Improved Efficiency, Performance and Pricing

There are many benefits to having a service agreement with Sakoon Pneumatics for your compressed air equipment. These benefits come to you on many fronts.

  • Improved Pricing: Annual Service Contracts work is performed at a discount from our standard labor rate.
  • Flexibility in Type: We have four levels of service coverage to choose from.
  • Flexibility in Payment: Agreements can be paid for as the work is done, or in flat monthly or annual payments (discounts for up front annual payments).
  • Resource Utilization: Let a compressed air equipment specialist maintain your compressed air equipment, so that your plant staff can focus on your production equipment.
  • Improved Performance: Sakoon Service Engineers are trained on the systems approach, so that machines are set to work at peak energy saving performance.
  • Less Downtime: Equipment that is properly maintained is less likely to fail, reducing the chance of costly unscheduled downtime.
  • Predictive Maintenance: IoT enabled services are part of our service agreement offering which predicts problem before hand
  • Warranty: Service Agreements can help you stay within the terms of manufacturer warranties

Benefit to Customers

It is that we have a base amount of work that we know is going to happen in the next few months. This allows us to schedule work more efficiently and predict our parts purchases to keep a proper inventory level. Because of this we are able to perform the preventive maintenance work at a lower price to the customer than our unscheduled or emergency service work.

The Mutual Benefit

Over time we have proven that customers that keep their equipment on a Service Agreement with Sakoon Pneumatics spend less money to operate and maintain their equipment than if they do not maintain a Service agreement with us. They also have significantly less unscheduled downtime; this is where the greatest savings occur.

Our goal is to have a satisfied customer that continues use Sakoon Pneumatics for their compressed air needs.

For more information please visit Sakoon Contracts

compressed-air-costs

Compressed Air Costs

7 Expenses That Every Manufacturer Should Track

A common mistake when purchasing an air compressor is making a selection based on capital cost alone rather than reviewing the total equipment ownership costs. Since energy consumption and equipment maintenance can quickly drive up ownership costs, it is critical to understand what contributes to these expenses at your facility. To get started in your cost savings journey this year, you must first identify the following costs associated with your system.

Energy Costs

According to Energy Star, 76% of compressor ownership costs go towards the electricity required for operation. This paired with the rising cost of energy means the goal at your facility should be delivering the required demand of air with the lowest amount of energy possible. To calculate compressed air energy costs, you must first track rated power, motor efficiency, service factor, running hours, and energy rate.

  1. Power & Motor Efficiency
    The percentage of electrical input that the motor uses to power the air compressor is referred to as the efficiency rating. Although there is a large range of efficiencies, generally the older and smaller the compressor motor is, the less efficient it is. As an example, a 100 HP premium efficiency motor typically has a motor efficiency rating at around 96%. Review your motor manufacturer’s datasheet to find this efficiency rating.
  2. Service Factor
    Service factor is a rating applied to a motor that determines how far it can operate over the rated horsepower without damaging the motor. For example, a service factor of 1.15 means the motor can operate at 15% over the rated horsepower, 1.20 equates to 20% over, and so on. It is not a good practice and potentially damaging to continuously operate motors above the rated load in the service factor area. When reviewing compressor capacities, bear in mind some manufacturers promote a full load that utilizes a portion of the service factor.
  3. Running Hours 
    The running hours of your unit is the amount of time it is operating at a given power value, usually on a per year basis. This assessment tends to be grouped by labor shifts due to air demand changes between shifts. Continuous running machines typically operate 8,000 hours per year.
  4. Energy Rate
    The energy rate for your area may be obtained from your local power company. For reference, the average power cost per kW is PKR 12 in the Pakistan.

Maintenance Costs

Even the most reliable machinery requires maintenance to keep functioning at maximum efficiency. Since maintenance requirements vary between compressor technologies, it is essential to have a firm understanding of what you are spending on consumable products, condensate removal, and AirEnd replacement.

  1. Consumables
    Consumable products include anything that needs to be replaced at regular intervals such as filters, separators, and oil. The rate at which these need serviced varies wildly based on the type of compressor you use. For compressors that are not oil-free, it is important to understand the downstream filter replacement costs as they can quickly add up over time and result in pressure drops that require additional energy to overcome. Oil-flooded machines also require oil to be changed every 6-12 months, while oil-free compressors can last 2-3 years on the minimal oil they need to operate. For operators looking to extend the time between changes, full synthetic oil is an ideal solution and offers less downtime and maintenance costs.
  2. Condensate Removal
    While both oil-flooded and oil-free compressors produce condensate, that of oil-flooded units makes a water/oil mixture which either must be properly disposed of or use a filtration system to separate the oil from the water. Proper condensate disposal could result in costs of $50,000 per year and is something to take in consideration when making a compressor decision.
  3. Airend Replacement / Refurbishment
    As compressors age, replacing the Airend is often an option to improve overall performance. Depending on the technology, some Airends are designed to last 3-5 years while others are rated for 20 years of continuous operation. This replacement cost may be upwards of 70% of the original equipment price, so it is important to get a professional opinion and to weigh your options. Instead of replacing an Airend, it is more economical to get it refurbished.

Collecting and tracking these figures may seem at first a daunting task. However, once you present to management the thousands of rupees a year you are saving on compressed air alone the initial work will be well worth it and contribute to a healthy bottom line at your company.

rotary-screw

Rotary Screw Compressor Troubleshooting

Problem Possible Causes Solutions
Compressor Will Not Start
  1. No power
  2. Fuse blown in control circuit
  3. Motor overloads not tripped or nor reset
  4. Loose incoming or power connection wires
  5. Low voltage to unit
  6. Faulty temperature switch
  7. Temperature switch tripped
  8. High pressure switch tripped
  1. Check power supply for adequate voltage
  2. Check fuses
  3. Make sure all power wires are tight at connections
  4. Check voltage supply to make sure it is high enough to run the electric system
  5. Check temperature switch for proper operation
  6. Check system pressure
Unit starts-them immediately stalls
  1. Pressure switch out of adjustment
  2. Temperature switch activated
  3. Loose electrical supply wires
  4. Motor overloads tripped
  5. Low voltage
  6. Incorrect compressor rotation
  1. Check compressor power supply for adequate breaker and wire size
  2. Inspect check valve for proper operation
  3. Tighten belts
  4. Check compressor for proper oil level
Low Discharge Pressure
  1. Plugged separator
  2. Plugged oil cooler
  3. Improper pressure switch setting
  4. Low incoming power voltage
  5. Electrical phase imbalance
  6. Possible airend or motor failure
  1. Tighten compressor belts to recommended specifications
  2. Check compressor voltage supply
Compressor does not build up to pressure
  1. Air leaks in shop
  2. Inlet valve malfunction
  3. Compressor belts slipping
  4. Air demand exceeds compressor output
  5. Pressure switch set to low
  6. Solenoid valve malfunction
  7. Compressor rotors damaged
  1. Find and fix shop air leaks
  2. Check inlet valve for proper function
  3. Check air usage requirements on machinery and check for shop air leaks
  4. Check pressure switch for proper setting
  5. Check solenoid for proper function
Compressor will not load to compress air
  1. Pressure switch set to high
  2. Inlet valve malfunction
  3. Faulty solenoid
  1. Check pressure switch for proper setting
  2. Check inlet valve for proper function
  3. Check solenoid for proper function
cfm Flow (air flow) seems low
  1. Restricted air intake filter
  2. Inlet valve partially closed
  3. Air pressure set to high
  4. Insufficient oil flow
  5. Solenoid valve malfunction
Excessive oil consumption
  1. Over filled sump
  2. Broken oil line
  3. Plugged oil return line
  4. Damaged or dirty separator
  5. Excessive unloaded compressor run time
  1. Check sump for proper oil level
  2. Check all lines for cracks
  3. Replace separator
  4. Add a timer to the system
High temperature shutdown
  1. High ambient air temperature around compressor
  2. Low oil level in compressor
  3. Plugged oil filter
  4. Restricted air flow over cooler
  5. Thermal by pass leaking
  6. Faulty temperature switch
  1. Lower ambient temperature around compressor
  2. Check unit for proper oil level
  3. Replace oil filter
  4. Clean oil cooler
  5. Check thermal bypass for proper operation
  6. Check temperature switch for proper operation.
High amperage draw
  1. Restricted air intake filter
  2. Inlet valve partially closed
  3. Air pressure set to high
  4. Insufficient oil flow
  5. Solenoid valve malfunction
  1. Change separator
  2. Clean oil cooler
  3. Check pressure switch
  4. Check incoming voltage
  5. Check air end and motor for proper function