Are you interested in learning more about agricultural compressors? Contact us today to secure an expert consultation!

The right site: Where to install a compressor and associated infrastructure

Optimising a compressed air system&#;s performance is not just about the compressor unit. Where it is installed and how the associated infrastructure is designed also has an impact on a system&#;s energy efficiency, how quickly a business will see a return on its capital investment, and in some cases, even its ability to comply with environmental controls. Martin Chitty, business development manager at Mattei UK, explains how to choose a suitable site to install a compressor.

Back in the day, air compressors were placed well away from the production area, often in a separate building due to noise. Whilst modern compressors are much quieter and can be installed on the same premises, the need to maximise energy efficiency and space utilisation, together with changes in production processes and environmental controls mean that there are now a whole host of factors to consider. So, what exactly should managers bear in mind when deciding on where to put an air compressor?

Particles and pollutants 

Many manufacturing environments are plagued by a high concentration of airborne, small sized particles that are a side effect of the actual manufacturing process itself. From cooking ingredients in a food processing environment, to oil mist which further attract other contaminants, they can adversely affect compressors even if equipped with high efficiency intake filters. These particles can block up vital parts of a compressor. Furthermore, the compression process also makes the impurities more concentrated, which can significantly reduce the quality of your compressed air.

Rotary vane compressors cope better than screw compressors in many aggressive environments due to a greater tolerance to contamination by airborne particles. Nevertheless, it is still best practice to avoid locations with excessive airborne pollutants, such as loading and unloading areas.

Adequate airflow

Air compressors move a considerable amount of air during their operation. A poorly ventilated area would cause a compressor to run unnecessarily hot, resulting in reduced efficiency, more frequent service intervals ultimately, shortening its life span. If the compressor needs to be housed in an enclosed area where the only way to get fresh air to the unit is to cut an opening in the wall, weather louvres should be considered to protect the compressor and the intake air from harsh weather. However, a larger intake will be required to compensate for the reduced surface area as a result of the louvres.

Climate control

In the winter during sub-zero temperatures, a compressor will not start if its oil temperature falls below the minimum threshold. So in addition to weather louvres, consideration should be given as to whether or not internal heaters should be installed if there is only one compressor, with no other form of maintaining a minimum temperature. Where there are multiple compressors, some of the waste heat could be redirected back into the compressor house rather than being expelled to atmosphere.

Cheap heat

Up to 95% of a compressor&#;s kilowattage is discharged as heat. Typically, 80% of this waste heat is recoverable. So as a minimum, it&#;s worth using it for space heating. For this to be an effective strategy, the compressor should be located near to where the heat is required without being too far from where it needs to be discharged in the summer.

Alternatively, waste heat from water-cooled compressors or those fitted with a heat exchanger can be used to provide hot water for the production process, heating or sanitary purposes. For example, a compressor can be located next to the factory&#;s boiler. Rather than using cold water as make-up water, it can be pre-heated using heat recovered from the compressor. One significant advantage is that hot water is needed year round. On the other hand, demand for space heating is seasonal which should be taken into account when calculating the value of this recoverable heat.

Considerate cooling

Whilst rotary vane compressors run significantly slower than screw compressors and produce less noise, it is still essential to ensure that any noise associated with the heat discharge process complies with local environmental controls. With this in mind, it is best practice to direct ducting used to expel heat away from noise-sensitive areas. Where this is not possible, noise attenuation measures within the ducting will be required.

A compressor&#;s cooling fan has a specified maximum loading which cannot be exceeded. This is why ducting for heat discharge needs to be correctly sized because restrictions can lead to excessive back pressure on the fan and damage the compressor&#;s cooling system.

Pipework pattern

The distance between the compressor and where the compressed air is used can have important implications in terms of system efficiency. Whilst it is preferable to locate a compressor as close as possible to where compressed air is used, this may be restricted by access to power supply as well as the other factors highlighted in this article. In many such instances, it is cheaper to install pipework to take compressed air from where it is generated to point of use, compared to the cost of installing copper cables.

However, pipework should be designed to ensure minimal pressure drop. Excessive lengths and bends lower efficiency, so pipe runs need to be suitably sized and laid out. Where bends areunavoidable, use swept bends and tees as these reduce pressure loss.

You can&#;t predict where compressor air is needed in the future. But you can design the associated pipework to accommodate changes to the factory floor layout in the future. Correctly designed ring mains can be used so that sections of the pipework can be isolated to make modifications without disrupting the whole system.

Maintenance and access

It might seem obvious, but ensuring that the compressor can be easily transported to where it needs to be installed is sometimes overlooked. It is not just a matter of measuring the footprint available for the compressor; any pinch points en route to its designated location need to be taken into account.

For example, will the compressor need to be manoeuvred through doorways and gaps? If the unit cannot fit though a doorway, and removing neither the doorframe nor even a wall can solve the problem, craneage will have to be considered and factored into the cost of installation.

It is preferable to install a compressor on the ground floor, with space allowed for expansion. Where this is not possible, careful planning will help to minimise headaches later down the line when your compressor arrives on site. Weather extremes can also influence the choice of location; compressor will need to be raised off the ground if it is going into a floodprone area. South-facing roof spaces are best avoided due to the possibility of excessive solar heat absorbed by steelsheeted roofs.

Once a compressor is fully operational, engineers will need ample space for maintenance and servicing. Siting the equipment in a suitable space will ensure that compressor doors can be opened and that engineers can safely lift components in and out. Each site is different and can present a wide range of challenges for managers to overcome. But by working with your compressor supplier and planning well in advance, a suitable site can be identified to ensure a smooth installation and optimal compressor performance thereafter.

For further information please visit: visit www.mattei.co.uk

You are logged in as a guest. ( logon

DaleD2

Posted 11/4/ 17:39 (#)
Subject: Where to put shop air compressor

Ont, Can

Any harm in locating a shop air compressor (horizontal tank) in cold dry storage and pipe air into heated part. Thought I could reduce noise and not use up scarce space in heated area by mounting it on brackets on wall (maybe 8 ft up) just to the other side of the insulated separating wall. Good idea or bad?
RickB

Posted 11/4/ 17:40 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Lincoln County. NC

Lincoln County. NC

A great idea absent ant issues with starting on your coldest days. Run the Lin downhill out of the tank into the heated area and put a drain inside at the low point.

Edited by RickB 11/4/ 17:41

gbenkfarm

Posted 11/4/ 17:44 (# - in reply to #)
Subject: RE: Where to put shop air compressor

SeMN

SeMN

Cold air will freeze up your impact or air tools, even at 32 degrees. Even my heated shop at 38 degrees my air sander would get ice in it. CMA

Posted 11/4/ 18:04 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Redickville, Ont

Our air compressor is inside the shop. Now it run humidifiers in potato storage so it runs a lot but it will actually hear the shop in November. How much do you use it greasegun

Posted 11/4/ 18:31 (# - in reply to #)
Subject: RE: Where to put shop air compressor

W.C. Mo.

I put a two stage compressor with an 80 gal horizontal tank in my shop loft. Set it on 2 heavy truck tires to reduce vibration in shop and I think it also reduces noise. Tank needs to be somewhere where moisture can be drained regularly- mine has a drain tube with a valve by my shop entrance door. redfarm

Posted 11/4/ 18:36 (# - in reply to #)
Subject: RE: Where to put shop air compressor

N. IL

Get one that has a RPM motor and not a RPM. It makes a difference in the noise. jedeka

Posted 11/4/ 18:49 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Boone, Iowa

I built an insulated room for my compressor. I used hockey pucks between the compressor feet and the concrete. I need to mount a couple of vents to suck cooler air in and push warm air out in the summer. That room gets warm when compressor runs in the summer. WTF

Posted 11/4/ 18:54 (# - in reply to #)
Subject: RE: Where to put shop air compressor

CIL

Thinking about putting ours in the ceiling above the finished shop with it's own insulation around it. Battery powered tools are making a large reserve of compressed air (large tank) obsolete. Most likely will buy or rent a portable 185 CFM air compressor for blasting.

Edited by WTF 11/4/ 18:54

ltct04

Posted 11/4/ 19:03 (# - in reply to #)
Subject: RE: Where to put shop air compressor

east central iowa

I put mine under the steps going up to the storage loft, enclosed it and put a door in to access it. Reduces the noise a lot but still easy to get to if need to tighten belts or service compressor. WTF

Posted 11/4/ 19:07 (# - in reply to #)
Subject: RE: Where to put shop air compressor

CIL

very good idea. Our shop won't have any stairs, but what you did will apply to more people than our situation.

Edited by WTF 11/4/ 19:09

jd

Posted 11/4/ 19:21 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Central ND

For more hydro compressorinformation, please contact us. We will provide professional answers.

We have never had a compressor in the heated part of our shop, 3 different shops and the compressor has always been in the cold storeage side, we did put lighter synthetic oil in the compressor for easier startup but we have never had an issue of any kind Lookingglass

Posted 11/4/ 19:36 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Southwest Illinois

We put it in cold storage but for us only during the coldest part of winter does our cold storage get much below 32. We have a 2 stage with automatic condensation dump and a water filter on the warm side. Lil' Hoss

Posted 11/4/ 19:46 (# - in reply to #)
Subject: RE: Where to put shop air compressor

NESD

Mine has been in a small un-insulated storage building about 30 ft from the shop for 20+ years now with the air line under ground, had it freeze up underground once from condensation, some airline anti-freeze poured down the line thawed it out in about 20 minutes. Would never have a air compressor in the shop again. no lost space and best of all, no noise. 

TGUY

Posted 11/4/ 19:52 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Put mine in the corner of shop between overhead door and corner in its own little room with big swinging door. Left compressor on pallet that in came on. If it needs to come out for major service or replacement just grab it with forklift. Cut two big holes in lower door and two on top for better air circulation. Room has insulation for less noise in shop. Can store items on top of room also. SLC

Posted 11/4/ 20:04 (# - in reply to #)
Subject: RE: Where to put shop air compressor

38 degrees?? Heated shop? Not on my place. It would be 50 gbenkfarm

Posted 11/4/ 20:06 (# - in reply to #)
Subject: RE: Where to put shop air compressor

SeMN

SeMN

Usually at 50 but I noticed the ice in my tools at 38. gbenkfarm

Posted 11/4/ 20:10 (# - in reply to #)
Subject: RE: Where to put shop air compressor

SeMN

SeMN

Ok , so a few of you guys have them in cold storage, how do you handle the high air volume tools that get so cold from the cold supply air. I suppose an air dryer would help with the ice, but I have had my impact get so cold sometimes I could hardly hang onto it. bleedred

Posted 11/4/ 20:12 (# - in reply to #)
Subject: RE: Where to put shop air compressor

East Central Ia

East Central Ia

Ours has been in the cold side of my shop/storage building for five years with no issues.

I wouldn&#;t even consider it inside my shop!

I just make sure to work my safety pop off valves every now again and spray with penetrating oil so they don&#;t freeze up if needed. jd

Posted 11/4/ 20:14 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Central ND

We have honestly never had a problem with our 3/4"-1" impact wrenches, we do all our own truck/tractor tire repair/replacing so they get used alot...... 4WD

Posted 11/4/ 20:24 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Between Omaha and Des Moines, 7 miles South of I80

ltct04 - 11/4/ 19:03 I

put mine under the steps going up to the storage loft, enclosed it and put a door in to access it.

Reduces the noise a lot but still easy to get to if need to tighten belts or service compressor.

 

I hope you put the shop toilet, right next to the back wall of that air compressor room = should give a nice surprise, when it kicks ON, for anyone "doing their business" in the bathroom. LOL

 

{I guess, I always envisioned that under the loft stairs, might be a good place for a small bathroom}

ronm

Posted 11/4/ 21:01 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Fruita CO

I used to work in a shop a lot that had the compressor on top of the restroom. Only possible worse idea would be to have it on top of the office... John.jr

Posted 11/4/ 21:13 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Fancy prairie, Illinois

Fancy prairie, Illinois

Dad put the big noisy compressor out in an old building 60 feet away close to 20 years ago. No issues at all. I recently bought an ultra quiet ingersoll screw compressor that's quieter than a washing machine and mounted it in the main shop. AR Plowboy

Posted 11/4/ 22:28 (# - in reply to #)
Subject: RE: Where to put shop air compressor

East Central Arkansas

East Central Arkansas

We built a stand for the air compressor in our shop that picked the bottom on the tank up to about six foot. It sure makes less noise in the shop now when it's running and I have storage under it. My reason for raising it up was to have one less heavy thing that needed moving when we have floods but the extra room and noise reduction was a good thing.

rank

Posted 11/4/ 22:35 (# - in reply to #)
Subject: RE: Where to put shop air compressor

SEON

Put it as far away from the office as you can get
. Lone Wolf Picker

Posted 11/4/ 23:56 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Black Hawk County, IA

John.jr - 11/4/ 20:13

Dad put the big noisy compressor out in an old building 60 feet away close to 20 years ago. No issues at all. I recently bought an ultra quiet ingersoll screw compressor that's quieter than a washing machine and mounted it in the main shop.

john jr. , what model did you get ? I've been looking at new compressors, and IR's are on my list.
TIA J mmaddox

Posted 11/5/ 01:41 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Our little unit, 10 hp, 80 gallons, is in loft above bathroom, on rubber and the shipping platform. Bigger unit, 25 hp, 129 gallon tank is on castors to be able ton move to work on from under steps. Have auto moisture ejectors. Moisture rquires they be in a warm area. Ron..NE ILL..10/48

Posted 11/5/ 07:55 (# - in reply to #)
Subject: RE: Where to put shop air compressor...been that way a LONG time

Chebanse, IL.....

Chebanse, IL.....

I've posted this many times. Haven't read other responses to you yet, but here's ours.

About 20 yrs ago I got tired of hearing our 5 hp compressor hammer away in the corner of our shop. Back then, if we got a call (land line) in the shop, you had to quick run over & kill power to the compressor so you could hear the call. Our was 45' away from compressor.

We have a quonset tool shed (built in '55) about 100' away from the shop containing compressor. Brother & I got 100' of 180# test, 1" black plastic water pipe. Actually got 2 of them & stuffed them inside a 3" (maybe 4"?) plastic drain tile. Backhoed a trench about 4' deep from quonset to shop. Moved compressor to corner of quonset & connected via the plastic water pipe. Ball valves at compressor and at inlet to heated shop. We kill the air supply to the shop at the end of the day. Though, the underground pipe is pressurized. Unbelievable success!!! If you stand in our old heated shop, you can not tell me if our compressor is running or not. I think I asked about doing this way back when in the early days of AgTalk. Some responders were concerned about winter time start-up of the compressor. Probably the coldest actual indicated temp I've seen since then is about -25F. No problem ever on start-up. I'd estimate our compressor run 350 days per year.

Fast forward about 15 yrs to . We built a new shed/shop on the other side of the farmstead. Quonset & heated shop remain in place. Needed air supply in 80x80 new heated shop. Went to the compressor in the unheated quonset & removed a pipe bung from the 60 gal supply tank, added another ball valve & bought some more 1" plastic pipe & borrowed a trencher this time. Ran the air over to the new 80x80 shop. This was about an 80' run. Again, ball valve inside the shop shuts off air at night. Again, 100% success. We have one compressor nearing 40 yrs old that supplies 2 shops. We use a LOT of air, I think. Restoring old tractors/implements means countless hours in a blast cabinet. Air tools, etc etc.

I personally question why people would install a compressor inside a shop any more. Another side benefit was the power load. The old quonset now powers the compressor, so that freed up a 40 amp 220v circuit in the shop. Another benefit was we now have air supply to the quonset to power air tools/jacks/etc there. Our remote installation has been a 100% success. Though a cold day in winter ( 0 or below),  you can feel the cold air in hand tools, it has never-ever been a problem....ever!!!! Keep in mind the compressor usually heats the air, so it's warming it somewhat from ambient.

I'm guessing that a 1" smooth wall line will carry all the air you'll ever need for a farm shop.

ronm

Posted 11/5/ 08:49 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Fruita CO

+1-I've always wondered why half the farmers here put up a shop & the first thing they put in was a compressor, the second thing was a , right on top of the compressor! John.jr

Posted 11/5/ 09:16 (# - in reply to #)
Subject: RE: Where to put shop air compressor

Fancy prairie, Illinois

Fancy prairie, Illinois

It's an ingersoll up6-5-125 I purchased used, the only advantage in seeing with it is the quietness. I talked to a dealer about turning the pressure up to 150psi and apparently everything for it is extremely expensive. The parts to turn up the pressure were about $. The 3 filters and oil to service it are over $800 for genuine IR parts. So buyer beware. School Of Hard Knock

Posted 11/5/ 10:09 (# - in reply to #)
Subject: RE: Where to put shop air compressor

just a tish NE of central ND

SLC - 11/4/ 19:04

38 degrees?? Heated shop? Not on my place. It would be 50

Its 17 degreese out here........ 38 sound nice....(: just push the thermostate up when you need to work in the shop.
Down when its just for storing stuff ......
ltct04

Posted 11/16/ 17:01 (# - in reply to #)
Subject: RE: Where to put shop air compressor

east central iowa

If you want to learn more, please visit our website china screw blower suppliers.

It actually is against the wall in the bathroom but it is not loud enough to even startle the dog who likes to sleep on the floor in there so I don't think we could have any fun with anybody new using the restroom lol