Compressor system upgrades tackle reliability and contamination risks head-on
Key takeaways
- Vibration and oil monitoring tools now offer real-time analytics, enabling early compressor failure detection and reducing maintenance risks.
- Hybrid acoustic and thermal cameras streamline leak detection, improving uptime and energy efficiency with faster, more accurate inspections.
- Redesigns of oil-free compressors boost energy efficiency, reliability, and safety with innovations in cooling, coatings, and drying systems.
- AI-powered mobile tools like Scout enhance field support by offering on-demand, equipment-specific diagnostics and troubleshooting help.
Optimization technologies for compressors and compressed air systems aim to increase performance and uptime, extend compressor life, and reduce maintenance intervals. Recent developments take on the challenge from different directions: equipment and oil monitoring, air and gas leak detection, compressor redesign, lubrication developments, and intelligent technical support.
Advanced compressor condition monitoring for predictive maintenance
For reciprocating compressors of all brands and manufacturers, the new UP! Detect condition monitoring system from Burckhardt Compression offers vibration monitoring with cloud-based analysis. It combines automated anomaly detection based on cylinder and crosshead vibration with real-time data analytics to deliver early failure detection and alerts to abnormal compressor behavior.
"Today, having data alone is not sufficient; the ability to interpret and analyze it is crucial,” observes Philipp Wolschner, digital product manager at Burckhardt Compression. “By combining 36-segment crank angle analysis and our advanced algorithms, UP! Detect can identify possible failures before they occur."
The Oil Check 500 measuring system from CS Instruments is designed to monitor oil vapors and oil carryover in compressed air and gas systems for contamination. It can measure down to parts per billion (PPB) for extraordinary accuracy, and false positives are reduced to a minimum with the company’s patented Forced Pressure Variation Method. Continuous monitoring and portable versions of the system are available.
One key innovation is its on-site sensor replacement feature, which “eliminates the need to purchase a backup unit during sensor calibration or service. This ensures uninterrupted monitoring and avoids the risk of losing visibility while the sensor is offline,” explains Martin Zeller, general manager at CS Instruments USA. “Oil Check 500 also comes with a standard eleven-point calibration, including multiple points within each ISO 8573 class.”
Next-gen leak detection tools for compressed air and gas systems
For compressed air and gas applications where it is critical to quickly and accurately pinpoint leaks, the novel V-MiX AcouTherm Camera from FOTRIC has the ability to simultaneously visualize sound and temperature. The hybrid, pistol-grip device for thermal imaging and acoustic detection is specifically engineered for industrial environments.
The added insight from combining acoustic and thermal imaging helps maintenance teams detect not only the presence of a leak but also assess its severity and surrounding conditions in real time, says FOTRIC Product Manager Evan Hartman. “In many cases, this dual-layered diagnostic capability streamlines workflows, reduces energy waste, and improves system uptime—benefits that far outweigh any learning curve associated with the technology.”
A new line of acoustic imagers from Fluke, the ii915, ii905, and ii500, detects compressed air, gas, steam, and vacuum system leaks while also capturing essential context such as issue prioritization and part availability—right at the point of inspection. By focusing not just on measurement accuracy, but on optimizing the entire workflow for users, the imagers require little to no training, allowing teams to be productive from day one.
“Features such as automatic Wi-Fi uploads to Fluke Connect, CO2 emission estimation, and tools like the SB-140 Sound Beacon accessory for non-pressurized environments all contribute to seamless integration across diverse industries like aviation, automotive, and construction—enhancing both regulatory compliance and quality control,” says Tako Feron, global product manager for industrial imaging at Fluke Corporation.
Compressor system upgrades boost energy efficiency and reliability
The redesigned CSG series of oil free screw compressors from Kaeser Compressors, including five fixed and four variable speed models, enhances energy performance and air quality for sensitive applications. A speed-controlled radial fan working in conjunction with the SIGMA CONTROL 2 regulates the fan speed. Airends have a new non-wearing triple-layer PEEK and nanoceramic coating that meets ISO 22000. Each model is available with a choice of integrated refrigeration or heat of compression (HOC) desiccant dryer. Service-side innovations include an improved water-jacket cooling design, more reliable condensate removal, automatic motor bearing regreasing, and more.
Werner Rauer, product manager for screw compressors at Kaeser Compressors, believes the CSG “really raises the bar” on oil free screw compressor design. “Its ground-up redesign is a great foundation to optimize air systems from multiple angles: energy, reliability, and consumer safety."
Lubrication advancements promote compressor reliability and efficiency. The recently expanded FSE-TurboCool range of premium lubricants and additives from FS-Elliott provides advanced protection against wear, oxidation, and varnish buildup to meet the evolving demands of industrial air systems. Formulated specifically for centrifugal compressors, TurboCool products are designed to meet specific industrial needs.
The expanded line, which includes advanced synthetic, eco-friendly, and NSF H-1-compliant options, “features a Gas-to-Liquids–derived base stock that delivers superior wear protection and exceptional stability under high thermal and oxidative stress. Compared to conventional hydrocarbon-based lubricants, TurboCool significantly extends service life and helps reduce unplanned downtime,” notes Roger Beavans, product manager at FS-Elliott.
Scout, a new AI-driven chatbot feature in Copeland’s mobile app, improves technical support and user productivity by providing personalized information about the company’s HVACR equipment on demand. Scout pulls troubleshooting and educational knowledge directly from the company’s published bulletins and product specifications, ensuring more timely, accurate, and relevant information for technicians on the go.
According to Jeff Kukert, senior technical trainer at Copeland, "The Scout AI chatbot feature in Copeland Mobile is a powerful tool that helps technicians determine whether their compressor is running at peak performance. Scout can also assist in diagnosing system or compressor issues, helping to reduce downtime."
