air compressor pressure safety valve free sample

An OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES should be placed immediately after the air control shut off valve and before the hose on a compressor, and after each discharge port that a hose is connected to.

Before starting the compressor the air control valve should be closed completely. When the compressor unloads, open the air shut off control valve very slowly. Full port ball valves tend to work better than gate or butterfly type valves.

The air shut off control valve must be fully open for the OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES to work. Some portable air compressor manufacturers recommend start-up with the air control valve slightly open. In this case you may have to close the valve and reopen it slowly to the full open position, or wait for the safety shut-off valve to reset itself.

If the OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES fails to operate despite meeting all condi-tions, check the hose line for obstructions or a hose mender restricting normal air flow.

• Turn on air supply slowly (to avoid tripping OSHA safety valve). Prior to fully reaching operation conditions, the OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES should suddenly activate and stop air flow.

• If the OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVE is not activated the unit should be disconnected and the lower flow range OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES should be used. This means you need to use a different valve with a lower scfm range.

• At temperatures below 40°F ensure that OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES are not subject to icy conditions which may prevent proper functioning.

You may not worry often, if at all, about whether or not your air compressor is running safely. And you really don’t have to, because compressor manufacturers do. From the pressure rating on the air storage tank to emergency stop buttons, air compressors are designed with safety in mind.

But that doesn’t mean you should never think about your compressor’s safety features. In most cases, they need to be inspected regularly to make sure they’re working properly. One key safety feature that should be inspected regularly is the air pressure relief valve (PRV), sometimes called a safety relief valve.

The pressure relief valve is a safety valve that protects the compressor component that it’s attached to from being exposed to a pressure above its rated maximum operating pressure. This rating, called the maximum working pressure (MWP), is the pressure that the vessel has been certified to continuously operate at safely.

So when a compressor is running at or below its maximum working pressure—in other words, when it’s running “normally”—the relief valve doesn’t do anything.

However, when the air pressure inside a compressor exceeds its MWP, the pressure relief valve will activate to “blow off” the excessive pressure within the compressor. Without a relief valve, the storage tank could rupture from the excessive pressure, damaging the compressor itself, possibly other property near it, and even causing injuries (or worse) to anyone standing nearby.

Before we can talk about how the air pressure relief valve works, we first need to look at how air pressure inside a compressor is managed when everything is running normally.

Under normal circumstances, the air pressure in a compressor is controlled by a pressure switch in an electro/mechanical control system or, in the case of an electronic controller, a pressure transducer and controller settings. When the cut-out set pressure for the pressure switch is reached, the compressor will stop compressing air (unload) until the cut-in set pressure is reached, at which time it will start compressing air again (load). If the pressure switch fails, the compressor would not be able to start compressing air again, or potentially worse, not be able to stop. Most compressors also have a high-pressure safety switch that should stop the compressor if the pressure exceeds the unload set point.

A pressure relief valve is a straightforward safety backup to the pressure switch and high-pressure switch, or the controller set points, should any of these components fail with the compressor running. The safety relief valve is set above the high-pressure safety switch and generally at or below the vessel’s maximum operating pressure. Inside the valve is a spring, and the pressure created by the spring’s tension keeps the valve closed under normal operating conditions. However, as the air pressure increases in pressure vessels (like the storage tank), it eventually exceeds the rated pressure of the relief valve, causing the relief valve to open and the excess pressure to be “blown off” to the atmosphere.

If the pressure relief valve fails open, air will continually vent to the atmosphere, preventing the air stream from becoming fully pressurized. The compressor should be shut down and the relief valve replaced before the compressor is restarted. The open relief valve will likely cause a loss of production and possible danger to personnel as a result of the flow of high-pressure air with flying debris and an unsafe sound level.

A pressure relief valve failing closed presents a potentially more dangerous situation. As noted earlier, the relief valve exists to allow excessive pressure to be “blown off” so that the air pressure inside the compressor’s pressure vessels don’t exceed their rated specifications. If the valve fails closed, this pressure venting can’t happen. Unless compressed air demand matches the compressed air supply, the pressure inside the compressor will continue to build. Eventually, the pressure increase would cause the storage tank to rupture, damaging the compressor and possibly causing additional damage and injury to property and people nearby.

If the relief valve is opening because the air pressure in the compressor has exceeded the valve’s pressure set point, that means the valve is working and doing what it was designed to do. But because this indicates the MWP of the compressor has been exceeded, the condition that’s causing excessive pressure should be diagnosed and corrected.

If the relief valve opening wasn’t caused by excessive pressure inside the compressor, then the valve is most likely “failing open”. Most likely, this is because the valve has become “soft” over time, i.e. the valve spring is providing less counterpressure, so it’s opening at a lower pressure than it should.

Whether the valve opened because of excessive pressure in the compressor or because the valve is failing, you should have your local air compressor distributor inspect your compressor before running it again for two reasons:

First, your distributor can determine whether the valve opened due to a failing relief valve or excessive compressors pressure and perform any needed maintenance or service to get your compressor running efficiently and safely again.

Second, regardless of why the pressure relief valve opened, replacing it may be recommended to ensure safe compressor operation, depending on the valve manufacturer. (Replacement is recommended for Sullair compressors.)

Important: Running the compressor after the relief valve has opened, regardless of the reason why it opened, can put both your property at risk of damage and people at risk of injury (or worse). While this may be obvious if the compressor is building up excess pressure, it also applies if the valve failed open. As noted above, even a valve that fails open poses some risk, and next time it could fail closed.

Given how critical a working air pressure relief valve is to the safe and efficient operation of your air compressor, you may wonder whether you need to do any regular inspecting or testing of the valve to make sure it is working. Because this can vary by manufacturer, you should consult your owner’s manual or contact your local air compressor distributor for frequency and type of inspection needed. For most Sullair compressors, inspection for damage or leakage is recommended, but testing is not recommended, as doing so may compromise the valve’s performance.

However, one thing you should do is schedule regular maintenance with your local air compressor distributor. As part of regular maintenance, a service technician can inspect the PRV and let you know it’s at an age or in a condition at which the manufacturer recommends replacement. Also, problems with the compressor’s performance, e.g. not reaching normal operating pressure, may help the service technician identify a failing relief valve after ruling out other possible causes.

When a pressure vessel like a receiver, sump tank or other storage vessel is purchased separately from the compressor, it may not be supplied with a pressure relief valve. To ensure its safe operation, you should add a PRV.

When selecting a PRV to add to the pressure vessel, you must choose a valve with a pressure set point set at or below the maximum working pressure of the vessel. You will find the MWP (and other useful information) on a tag welded to the pressure vessel. Also, flow capacity of the PRV must meet or exceed the total compressed air supplied to the vessel.

For example, if you have two compressors with capacities of 500 and 750 cfm (14.2 and 21.2 m³/min), and a pressure vessel with a maximum working pressure of 200 psi (13.8 bar), the minimum settings for a pressure relief valve would be 1250 cfm (35.4 m³/min) and a set point 200 psi (13.8 bar) or less.

Finally, when attaching the valve to the vessel, the porting must not be reduced to a size less than the size of the inlet port of the pressure relief valve.

Because the pressure relief valve is critical to the safe operation of your compressed air system, if you’re not sure how to select the correct PRV and properly and safely add it to the pressure vessel, contact your local air compressor distributor. They have the experience and expertise to ensure that the PRV is sized and installed correctly.

Safety valves and pressure relief valves are crucial for one main reason: safety. This means safety for the plant and equipment as well as safety for plant personnel and the surrounding environment.

Safety valves and pressure relief valves protect vessels, piping systems, and equipment from overpressure, which, if unchecked, can not only damage a system but potentially cause an explosion. Because these valves play such an important role, it’s absolutely essential that the right valve is used every time.

The valve size must correspond to the size of the inlet and discharge piping. The National Board specifies that the both the inlet piping and the discharge piping connected to the valve must be at least as large as the inlet/discharge opening on the valve itself.

The connection types are also important. For example, is the connection male or female? Flanged? All of these factors help determine which valve to use.

The set pressure of the valve must not exceed the maximum allowable working pressure (MAWP) of the boiler or other vessel. What this means is that the valve must open at or below the MAWP of the equipment. In turn, the MAWP of the equipment should be at least 10% greater than the highest expected operating pressure under normal circumstances.

Temperature affects the volume and viscosity of the gas or liquid flowing through the system. Temperature also helps determine the ideal material of construction for the valve. For example, steel valves can handle higher operating temperatures than valves made of either bronze or iron. Both the operating and the relieving temperature must be taken into account.

Back pressure, which may be constant or variable, is pressure on the outlet side of the pressure relief valve as a result of the pressure in the discharge system. It can affect the set pressure of the upstream valve and cause it to pop open repeatedly, which can damage the valve.

For installations with variable back pressure, valves should be selected so that the back pressure doesn’t exceed 10% of the valve set pressure. For installations with high levels of constant back pressure, a bellows-sealed valve or pilot-operated valve may be required.

Different types of service (steam, air, gas, etc.) require different valves. In addition, the valve material of construction needs to be appropriate for the service. For example, valves made of stainless steel are preferable for corrosive media.

Safety valves and relief valves must be able to relieve pressure at a certain capacity. The required capacity is determined by several factors including the geometry of the valve, the temperature of the media, and the relief discharge area.

These are just the basic factors that must be considered when selecting and sizing safety valves and relief valves. You must also consider the physical dimensions of the equipment and the plant, as well as other factors related to the environment in which the valve will operate.

We are a leading manufacturer of high quality valves serving the compressed air, pressure washer, automotive, fluid power, fire protection, specialty gas, and pneumatic industries.

The Model “ST” safety valve is our standard safety valve for small air compressor systems and related applications. Even though the size is compact, flow capacities are high.

Resilient rubber pad, offered in silicone or flourocarbon, insures valve is bubble-tight to within 10% of set pressure. Three inlet sizes are available: 1/8″ NPT, 1/4″ NPT, and 3/8″ NPT.

All brass construction with zinc-plated music wire spring. Stamped with “UV” and “NB” symbols. Available set pressure range 25 PSI to 250 PSI. Set pressure tolerance +3% of set pressure. 250°F max. temperature.

Stamped with “UV” and “NB” symbols. Available set pressure range 50 PSI to 350 PSI. Set pressure tolerance +3% of set pressure. 350°F max. temperature.

Model “SV” ASME safety valves are designed for systems where large flow capacities are needed. Resilient pad insures valve is bubble-tight to within 10% of set pressure. Inlet size: 1/2″ NPT.

All brass construction with zinc-plated music wire spring and a rubber seal, offered in silicone or flourocarbon. Stamped with “UV” and “NB” symbols. Set pressure tolerance +3% of set pressure. 250°F max. temperature.

All brass construction with stainless steel spring and stainless steel ball seating on brass seat. Inlet size: 1/2″ NPT. Stamped with “UV” and “NB” symbols. Available set pressure range 50 PSI to 350 PSI. Set pressure tolerance +3% of set pressure. 350°F max. temperature.

Model “SB” safety valves offer Control Devices value to users of high capacity ASME safety valves. Unique O-ring seal insures valve is bubble-tight to within 10% of set pressure. 1/2″ NPT and 3/4″ NPT inlets available.

All brass construction with stainless steel springs. O-ring seal available in silicone or fluorocarbon rubber. Available set pressure range 25 PSI to 300 PSI. Set pressure tolerance + 3% of set pressure. 250°F max. temperature.

The model “SW” valve is our highest capacity ASME safety valve. Unique O-ring seal insures valve is bubble-tight to within 10% of set pressure. 1″ NPT and 1¼” NPT inlets available.

All brass construction with stainless steel springs. O-ring seal available in silicone or fluorocarbon rubber. Stamped with “UV” and “NB” symbols. Available set pressure range 25 PSI to 300 PSI. Set pressure tolerance +3% of set pressure. 250°F max. temperature.

The Super-Chek® design has been proven over the last 15 years to be the standard for air compressor in-tank check valves. One-piece brass bodies, stainless steel springs, and glass-filled fluoropolymer poppets all add up to long term reliability, while the eight discharge holes insure quiet operation.

Valves may be disassembled for cleaning or repair. Valves are 100% tested for backflow leakage performance. 450 PSI max pressure, 400 deg. F max temperature.

These cast-brass check valves have been specifically designed for installation into air compressor discharge lines. Extra-heavy walled cast brass bodies, glass-filled fluoropolymer poppets, and stainless springs resist corrosion and insure long life.

In order to ensure that the maximum allowable accumulation pressure of any system or apparatus protected by a safety valve is never exceeded, careful consideration of the safety valve’s position in the system has to be made. As there is such a wide range of applications, there is no absolute rule as to where the valve should be positioned and therefore, every application needs to be treated separately.

A common steam application for a safety valve is to protect process equipment supplied from a pressure reducing station. Two possible arrangements are shown in Figure 9.3.3.

The safety valve can be fitted within the pressure reducing station itself, that is, before the downstream stop valve, as in Figure 9.3.3 (a), or further downstream, nearer the apparatus as in Figure 9.3.3 (b). Fitting the safety valve before the downstream stop valve has the following advantages:

• The safety valve can be tested in-line by shutting down the downstream stop valve without the chance of downstream apparatus being over pressurised, should the safety valve fail under test.

• When setting the PRV under no-load conditions, the operation of the safety valve can be observed, as this condition is most likely to cause ‘simmer’. If this should occur, the PRV pressure can be adjusted to below the safety valve reseat pressure.

Indeed, a separate safety valve may have to be fitted on the inlet to each downstream piece of apparatus, when the PRV supplies several such pieces of apparatus.

• If supplying one piece of apparatus, which has a MAWP pressure less than the PRV supply pressure, the apparatus must be fitted with a safety valve, preferably close-coupled to its steam inlet connection.

• If a PRV is supplying more than one apparatus and the MAWP of any item is less than the PRV supply pressure, either the PRV station must be fitted with a safety valve set at the lowest possible MAWP of the connected apparatus, or each item of affected apparatus must be fitted with a safety valve.

• The safety valve must be located so that the pressure cannot accumulate in the apparatus viaanother route, for example, from a separate steam line or a bypass line.

It could be argued that every installation deserves special consideration when it comes to safety, but the following applications and situations are a little unusual and worth considering:

• Fire - Any pressure vessel should be protected from overpressure in the event of fire. Although a safety valve mounted for operational protection may also offer protection under fire conditions,such cases require special consideration, which is beyond the scope of this text.

• Exothermic applications - These must be fitted with a safety valve close-coupled to the apparatus steam inlet or the body direct. No alternative applies.

• Safety valves used as warning devices - Sometimes, safety valves are fitted to systems as warning devices. They are not required to relieve fault loads but to warn of pressures increasing above normal working pressures for operational reasons only. In these instances, safety valves are set at the warning pressure and only need to be of minimum size. If there is any danger of systems fitted with such a safety valve exceeding their maximum allowable working pressure, they must be protected by additional safety valves in the usual way.

In order to illustrate the importance of the positioning of a safety valve, consider an automatic pump trap (see Block 14) used to remove condensate from a heating vessel. The automatic pump trap (APT), incorporates a mechanical type pump, which uses the motive force of steam to pump the condensate through the return system. The position of the safety valve will depend on the MAWP of the APT and its required motive inlet pressure.

This arrangement is suitable if the pump-trap motive pressure is less than 1.6 bar g (safety valve set pressure of 2 bar g less 0.3 bar blowdown and a 0.1 bar shut-off margin). Since the MAWP of both the APT and the vessel are greater than the safety valve set pressure, a single safety valve would provide suitable protection for the system.

However, if the pump-trap motive pressure had to be greater than 1.6 bar g, the APT supply would have to be taken from the high pressure side of the PRV, and reduced to a more appropriate pressure, but still less than the 4.5 bar g MAWP of the APT. The arrangement shown in Figure 9.3.5 would be suitable in this situation.

Here, two separate PRV stations are used each with its own safety valve. If the APT internals failed and steam at 4 bar g passed through the APT and into the vessel, safety valve ‘A’ would relieve this pressure and protect the vessel. Safety valve ‘B’ would not lift as the pressure in the APT is still acceptable and below its set pressure.

It should be noted that safety valve ‘A’ is positioned on the downstream side of the temperature control valve; this is done for both safety and operational reasons:

Operation - There is less chance of safety valve ‘A’ simmering during operation in this position,as the pressure is typically lower after the control valve than before it.

Also, note that if the MAWP of the pump-trap were greater than the pressure upstream of PRV ‘A’, it would be permissible to omit safety valve ‘B’ from the system, but safety valve ‘A’ must be sized to take into account the total fault flow through PRV ‘B’ as well as through PRV ‘A’.

A pharmaceutical factory has twelve jacketed pans on the same production floor, all rated with the same MAWP. Where would the safety valve be positioned?

One solution would be to install a safety valve on the inlet to each pan (Figure 9.3.6). In this instance, each safety valve would have to be sized to pass the entire load, in case the PRV failed open whilst the other eleven pans were shut down.

If additional apparatus with a lower MAWP than the pans (for example, a shell and tube heat exchanger) were to be included in the system, it would be necessary to fit an additional safety valve. This safety valve would be set to an appropriate lower set pressure and sized to pass the fault flow through the temperature control valve (see Figure 9.3.8).

A safety valve must always be sized and able to vent any source of steam so that the pressure within the protected apparatus cannot exceed the maximum allowable accumulated pressure (MAAP). This not only means that the valve has to be positioned correctly, but that it is also correctly set. The safety valve must then also be sized correctly, enabling it to pass the required amount of steam at the required pressure under all possible fault conditions.

Once the type of safety valve has been established, along with its set pressure and its position in the system, it is necessary to calculate the required discharge capacity of the valve. Once this is known, the required orifice area and nominal size can be determined using the manufacturer’s specifications.

In order to establish the maximum capacity required, the potential flow through all the relevant branches, upstream of the valve, need to be considered.

In applications where there is more than one possible flow path, the sizing of the safety valve becomes more complicated, as there may be a number of alternative methods of determining its size. Where more than one potential flow path exists, the following alternatives should be considered:

This choice is determined by the risk of two or more devices failing simultaneously. If there is the slightest chance that this may occur, the valve must be sized to allow the combined flows of the failed devices to be discharged. However, where the risk is negligible, cost advantages may dictate that the valve should only be sized on the highest fault flow. The choice of method ultimately lies with the company responsible for insuring the plant.

For example, consider the pressure vessel and automatic pump-trap (APT) system as shown in Figure 9.4.1. The unlikely situation is that both the APT and pressure reducing valve (PRV ‘A’) could fail simultaneously. The discharge capacity of safety valve ‘A’ would either be the fault load of the largest PRV, or alternatively, the combined fault load of both the APT and PRV ‘A’.

This document recommends that where multiple flow paths exist, any relevant safety valve should, at all times, be sized on the possibility that relevant upstream pressure control valves may fail simultaneously.

The supply pressure of this system (Figure 9.4.2) is limited by an upstream safety valve with a set pressure of 11.6 bar g. The fault flow through the PRV can be determined using the steam mass flow equation (Equation 3.21.2):

Once the fault load has been determined, it is usually sufficient to size the safety valve using the manufacturer’s capacity charts. A typical example of a capacity chart is shown in Figure 9.4.3. By knowing the required set pressure and discharge capacity, it is possible to select a suitable nominal size. In this example, the set pressure is 4 bar g and the fault flow is 953 kg/h. A DN32/50 safety valve is required with a capacity of 1 284 kg/h.

Where sizing charts are not available or do not cater for particular fluids or conditions, such as backpressure, high viscosity or two-phase flow, it may be necessary to calculate the minimum required orifice area. Methods for doing this are outlined in the appropriate governing standards, such as:

Coefficients of discharge are specific to any particular safety valve range and will be approved by the manufacturer. If the valve is independently approved, it is given a ‘certified coefficient of discharge’.

This figure is often derated by further multiplying it by a safety factor 0.9, to give a derated coefficient of discharge. Derated coefficient of discharge is termed Kdr= Kd x 0.9

Critical and sub-critical flow - the flow of gas or vapour through an orifice, such as the flow area of a safety valve, increases as the downstream pressure is decreased. This holds true until the critical pressure is reached, and critical flow is achieved. At this point, any further decrease in the downstream pressure will not result in any further increase in flow.

A relationship (called the critical pressure ratio) exists between the critical pressure and the actual relieving pressure, and, for gases flowing through safety valves, is shown by Equation 9.4.2.

For gases, with similar properties to an ideal gas, ‘k’ is the ratio of specific heat of constant pressure (cp) to constant volume (cv), i.e. cp : cv. ‘k’ is always greater than unity, and typically between 1 and 1.4 (see Table 9.4.8).

For steam, although ‘k’ is an isentropic coefficient, it is not actually the ratio of cp : c. As an approximation for saturated steam, ‘k’ can be taken as 1.135, and superheated steam, as 1.3. As a guide, for saturated steam, critical pressure is taken as 58% of accumulated inlet pressure in absolute terms.

Overpressure - Before sizing, the design overpressure of the valve must be established. It is not permitted to calculate the capacity of the valve at a lower overpressure than that at which the coefficient of discharge was established. It is however, permitted to use a higher overpressure (see Table 9.2.1, Module 9.2, for typical overpressure values). For DIN type full lift (Vollhub) valves, the design lift must be achieved at 5% overpressure, but for sizing purposes, an overpressure value of 10% may be used.

For liquid applications, the overpressure is 10% according to AD-Merkblatt A2, DIN 3320, TRD 421 and ASME, but for non-certified ASME valves, it is quite common for a figure of 25% to be used.

Backpressure - The sizing calculations in the AD-Merkblatt A2, DIN 3320 and TRD 421 standards account for backpressure in the outflow function,(Ψ), which includes a backpressure correction.

The ASME/API RP 520 and EN ISO 4126 standards, however, require an additional backpressure correction factor to be determined and then incorporated in the relevant equation.

Two-phase flow - When sizing safety valves for boiling liquids (e.g. hot water) consideration must be given to vaporisation (flashing) during discharge. It is assumed that the medium is in liquid state when the safety valve is closed and that, when the safety valve opens, part of the liquid vaporises due to the drop in pressure through the safety valve. The resulting flow is referred to as two-phase flow.

The required flow area has to be calculated for the liquid and vapour components of the discharged fluid. The sum of these two areas is then used to select the appropriate orifice size from the chosen valve range. (see Example 9.4.3)

When you use an industrial air compressor, making sure it has the right air pressure is critical. Some operators believe running a compressor at relatively high pressure improves performance, but the opposite is true. Operating an air compressor at an air pressure above your performance requirements guzzles power, makes your compressor less efficient, decreases productivity and can degrade the compressor’s internal systems.

If performance is flagging and you find yourself asking what’s wrong with your air compressor, take a few minutes to inspect for signs that the air pressure is too high or too low. Addressing any pressure issues you find, no matter how slight, can go a long way toward ensuring your compressor’s reliability and high performance.

One of the common high-pressure air compressor signs is the occurrence of high-pressure fluctuations. If you notice these fluctuations, your air compressor’s pressure is probably too high for your performance needs. High-pressure fluctuations tend to result from poor pressure control on the machine. Inadequate pressure control can lead to excessive pressure and variations in that pressure, especially when the user does not monitor the pressure carefully.

If your air compressor is experiencing pressure restrictions, the air pressure is probably too high. Pressure restrictions often result from improper attachments or faulty machine piping. Defective piping and attachments are common in components like hoses, filters and end-use connectors, and they can cause overcompensation in the air compressor. When restrictions occur in these components, the operator must raise the air compressor’s air pressure to compensate, resulting in excessive pressure throughout the compressor.

If your air compressor is creating artificial storage with increased pressure, its air pressure is probably too high. Excessive pressure in an air compressor often leads to a shortage of storage, especially when the machine has poor pressure control. The shortage of storage causes the compressor to create artificial storage with increased pressure. A related issue is that the air compressor sometimes lacks adequate storage receiver capacity. This scenario causes poor compressor control, and necessitates pressure increases to create artificial storage.

If imperceptible technical issues are occurring and the compressor operator raises the pressure to compensate for them, the air pressure is probably too high. One typical example occurs when the air compressor has tiny leaks. The leaks reduce pressure in the air compressor, so without noticing the leaks, the operator is likely to raise the pressure to compensate. Doing so can cause excessive air pressure overall.

These unobserved leaks are costly. The Compressed Air and Gas Institute reports that at 100 pounds per square inch (psi), a quarter-inch air leak can cost a company more than $2,500 annually. To avoid this unwanted effect, air compressor operators should take care to check for technical causes of low air pressure before raising the pressure excessively.

If your air compressor experiences too much oil carryover, its air pressure is likely too low. Every air compressor that uses oil or lubricant has a small amount of oil carryover. But an excessive amount of oil lingering in the air tank often indicates insufficient air pressure. This is because a compressor operating at low pressure is less efficient and leaves more oil in the tank, preventing the tank from building up a sufficient amount of pressure. When this happens, the pressure in the air compressor will run low almost all the time.

One of the most common low-pressure air compressor signs is a failure to reach the standard cut-out pressure. If you notice your air compressor running for extended periods without attaining its cut-out pressure — the pressure at which the pressurization stops — the air pressure is likely too low.

Monitoring air compressors allows you to pick up on changes resulting from high or low pressure or underlying problems with the equipment. Below are a few tips for air compressor troubleshooting and monitoring:

To address insufficient pressure in an air compressor, you can try checking the inlet and drain valves to ensure they are not leaking. You should also ensure the safety valve is not leaking. The safety valve is particularly important because if the pressure switch fails to turn off the pressure once the compressor has reached its cut-out pressure, the safety valve steps in as a backup to release excess pressure. If the safety valve is leaking, it may be releasing pressure all the time.

You should also check the reed valve. A faulty reed valve can remove air from the air inlet as exhaust. On a two-stage piston compressor, a defective reed valve can also diminish pressure by sending air out through the intercooler safety valve instead of through the intercooler and piston and out the appropriate discharge.

If leaking valves are not the culprits in an air compressor’s low pressure, you can try checking the belt if your compressor operates on a belt drive. You might also evaluate the pump rings, motor capacitors, air demand and filters to check for leaks and debris buildup.

When you need to address excessive pressure in an air compressor, the best thing to do is to check the air pressure regularly. If you keep an eye on your pressure gauges and notice the psi has gone up substantially, you’ll want to investigate to determine what unobserved technical issues have caused the increase in pressure.

Look for hidden air leaks and piping and filtration defects, and check hoses and attachment valves. You might also want to assess the tools you’re using. If your pneumatic tools call for excessive psi, their taxing requirements may cause performance issues in the compressor.

Although you can give your air compressor a rudimentary assessment, we recommend professional analysis for a more thorough evaluation. For routine air compressor monitoring and analysis, partner with a professional air compressor service like The Titus Company. We offer comprehensive system analyses that can give you basic data and analysis about your air compressor or go into more depth with energy efficiency and implementation recommendations.

To see the benefits of a well-designed and well-maintained air compressor in your operations, contact The Titus Company. Our quality products and superior system design means you’ll get the air compressor that’s right for your unique industrial needs. We also offer the best customer service and after-the-sale support available, so you’ll have someone to go to with questions or for help with technical issues. While located in Pennsylvania, our air compressor sales and service experts extend preventative maintenance and emergency service in Delaware, Maryland, Northern Virginia & New Jersey areas.

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An air compressor check valve is a device that allows fluid or air to flow in only one direction. When your compressor reaches the unload pressure, the check valves closes to prevent backflow of the air from the tank to the compressor head.

A quick note on check valves: Many times people will find air leaking from the pressure switch. When this occurs, they immediately purchase and install a new pressure switch. Because air still leaks, they call and state that the switch is defective.

If air is leaking consistently, the problem is not the pressure switch - it is the check valve. More than likely it is filled with debris and is not sealing. When this occurs the check valve either needs to be cleaned or replaced.

Any place that you would have high pressure, you will also need a pressure relief valve (also known as a safety valve). A pressure relief valve releases air smoothly and consistently into the atmosphere from the compressor tank if the air pressure becomes too much.

Generally a relief valve will have male threads on one end, with a ring on the other end (as displayed in the photo). By pulling the ring, you are releasing compressed air into the atmosphere in a safe manner. It is pretty rare that you will ever have to use a PRV, but it is necessary to ensure safety.

An air compressor pressure switch is an instrument which senses a change in pressure and automatically adds or decreases air in the tank. Most homeowners simply know the pressure switch as the device that contains the on/off lever.

Certain air compressors have specific pressure switches that are designed specifically for the machine. Campbell Hausfeld is one company that makes uses a specific switch for each of their compressors. The CW301300AJ kit is by far the most popular.

There are also more generic pressure switches that vary depending on what your cut-in and cut-out pressure is. The photo to the right displays a typical pressure switch that is common on many homeowner style compressors. The small red piece at the top is the on/off switch for the machine.

Depending on the type of compressor you have, an air compressor belt is an essential component of your machine. Most homeowner and smaller handcarry compressors do not use a belt. When you get involved with wheelbarrow or stationary compressors, belts become necessary (especially with virtually all Ingersoll Rand air compressors).A belt works with the pump to help spin the motor to the correct horse power.

Sizes and styles vary across the board. Everything from grooves, length, and width will change depending on the type of compressor that you have. To help find the correct belt for your compressor, we recommend finding you model number and giving us a call.

Generally, most air compressors come complete with two pressure gauges. Most will have one gauge near the pressure switch to display thepressure setting, and another gauge to indicate the air pressure in the tank.

Although an air gauge may not seem like an extremely important part - it is. Having a broken or non functioning gauge means that you will not know the pressure setting at your application, which can result in the incorrect use of your tools.

Simply put, the unloader valve unloads air when the receiver reaches its set point. Most of the time an unloader valve is located at ornear the pressure switch, and when the switch is turned either on or off, the unloader valve is either opened or closed.

There are many different varieties of unloaders available. They will vary by the type of compressor as well as the manufacturer. By givingus a call at 1-866-208-2797, we can generally let you know what type of valve is necessary.

Intake filters are pretty much self explanatory. They filter the air for the first time as it is brought into the system. These are very important to your compressor system, and the operator needs to ensure that they are clean and free from debris.

In-line filters are placed throughout the piping system to ensure that clean air is reaching the end product. It is pretty rare for homeowners and people with small consumer grade compressors to use an in-line filter. In industrial applications they become much more common. Using an in-line filter will make sure that the end line is free from particles and debris,which will ensure that your compressor tools and attachments will last for many years to come.

Generally this will only apply if you have an industrial or stationary compressor. Homeowner and small contractor compressors do not have auto-drains available, as they are all manualdrains. There is a drain on the bottom of the compressor, which should be opened every two days at a minimum (generally once a day is a good idea). this drain helps to remove any waterfrom the compressor tank. If water is left for long periods of time, rust will start to accumulate in the tank.

An auto drain eliminates the need to manually drain the tank every day. It is equipped with a timer that automatically opens the drain at a set time each day. Lets face it, people can forget and mistakes can be made. Therefore, an auto drain is almost always recommended for applications that require consistent air. It makes life easier and helps to prevent mishaps from occurring.

There are various types of gaskets that are used on compressors depending on what type of compressor that you have. Industrial compressors may have head gaskets, cylinder gaskets, etc, while homeowner compressors may use none at all. These gaskets help create a seal when two items are placed together, such as sealing the cylinder head to the valve plate assembly. Many times these are all combined together in one gasket kit.

Each type of gasket will vary depending on the model and manufacturer of the compressor that you have. One of the best resources that you can find with the correct gasket that you need would be the owners manual of your compressor. Of course, you can always call 1-866-208-2797 with your serial and model number, and we can find the correct part for your compressor.

Vibration pads are pretty self explanatory and simple. These pads are small pieces that are made out of various materials (often cork), which are placed under each foot on the air compressor. They are then screwed into the ground with the air compressor, and helps to reduce the amount of vibration and rattling that occurs. It reduces the amount of contact that the compressor has with the ground, and depending on the surface it will reduce noise and lengthen the compressor"s life.