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The Role of Air Compressors in the Industrial Sector and Essential Industries

For those that work in the industrial sector, the idea that compressed air has become the 4th utility has by now become somewhat of an overused—almost cliched— phrase. That doesn’t make it any less true.

Compressed air is vital to day-to-day operations in many industrial settings and manufacturing plants. For many manufacturing plants, maintaining a supply of compressed air is essential to perform some of the most vital tasks. 

For those not working in the industrial setting, this may not be obvious. So what is the role of air compressors in the world of manufacturing? Here’s a rundown. 

What is an Air Compressor and How Does It Work?

Most people have encountered an air compressor when their vehicle tires run a little flat. Most gas stations might have these compartmentalized machines off to the side. You throw a couple of quarters in (some are far more sophisticated now) and you inflate your tires using the nozzle. That pressurized air is needed to ensure the proper PSI of your tires. 

An industrial air compressor is one with over 1000 psi and 200 hp (horsepower). In other words, they pack a lot more pressure and power to deliver higher doses of compressed air. There are different types of industrial compressors that are used in different industries. 

Air Compressors and Their Role in Production Efficiency 

Industrial air compressors improve the efficiency of many tasks. The technology used today in compressed air combined with the precision of automated systems makes for a highly efficient process in industries that need to move through production quickly without any mistakes. The use of air compressors has reduced the need for human labor, maximizes efficiency, reduced human error, and improves safety. 

In industrial settings, it is common to find dual-stage air compressors. These types of compressors can compress air in two separate stages and are useful in powering air tools. The dual-stage refers to the number of times the air is compressed as it flows from one component (inlet valve) to the other component (tool nozzle). In order to achieve this action, these compressors need to have specified cylinders and the ability to cool the air to facilitate further compression.

How is PSI Measured? 

PSI measures the force per unit area and, in this case, the area is a square inch. This translates to the pressure that results from a force of one pound when applied to the area of one square inch. It is known by many as the way to gauge the required pressure on their tires. 

This measurement is conceptualized as relative to the atmospheric or ambient air pressure. This draws a distinction from the absolute pressure measurement. 

What are the Uses of Compressors in Manufacturing Applications?

 The manufacturing industry will have several essential tasks completed with the use of compressed air. Manufacturing plants will often use compressed air as readily as they use water and/or electricity. Most manufacturing processes will be powered through the use of pneumatic tools and use a combination of stamping, injection, cleaning, etc. 

In terms of general manufacturing, you’ll see these compressors used for:

  • Stamping
  • Clamping
  • Power tools
  • Tool cleaning
  • Controls and actuators 

In the manufacturing of furniture or other similar goods, you’ll see air compressors used for:

  • Air piston power
  • Power tools
  • Spraying 
  • Clamping 
  • actuators/controls

In the manufacturing of materials like plastics and silicone: 

  • Clamping
  • The use of power tools
  • Injection molding
  • Pressing power

What Other Industries Use Air Compressors? 

Air compressors are used across a wide range of industries and settings. The compressors used will vary in power, requirements, and demand. You’ll most likely see air compressors in some capacity or other in these industries: 

The Automotive Industry

As mentioned above, most people know air compressors as the way they inflate their tires, but the automotive industry truly does depend on compressors to accomplish a lot of work.  Compressed air is used when assembling vehicles, powering necessary tools, and when painting the vehicle. 

Railroad Industry 

Most of us don’t spend a lot of time thinking about trains, but they are still a very necessary part of transporting goods across the nation. The air compressors used in the railroad industry need to be specifically equipped to deal with dusty and unfavorable conditions. The suspension, brakes, and even the doors of the train require air-compressed components. 

Food Industry

The use of mechanized and automated applications has improved the production line of food products. Compressed air is a big part of moving those items quickly and is used through the assembly line system, assists with product packaging, and cools products down. 

Wyler Industrial Services and Repairs Air Compressor

And just like any other essential component of a manufacturing plant, factory, or industrial plant, the air compressors should be serviced and kept in good conditions to ensure safety and efficiency. A faulty air compressor causes a myriad of problems. 

Wyler Industrial has years of experience working with various industries in servicing and repairing air compressors. Call us today and learn more about our services. 

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The Need for Pressure Vessel Inspection & Why They Matter 

Worker installs clamping ring on coated pipe

In any industrial setting, anything that is functioning or performing under high pressure is prone to cause serious damage if not working properly. Anything that is pressurized means that it is operating under very specific circumstances and requires every component to do its part. From industrial boilers to other pressure vessels, to your typical pressure washer or water tanks, the importance of maintaining and keeping these vessels secure is absolutely essential.  As certified inspectors of pressure vessels, we understand the necessity for quality upkeep and maintenance of these vessels. 

What is a Pressure Vessel?

To those that work in the industry, a pressure vessel is an everyday occurrence and necessity.  For others, it might sound very exotic but really it refers to any vessel that is operating under high pressures. Most pressure vessels are for industrial use like hot water storage tanks and dividing cylinders.  They can also be used to hold toxic and other non-toxic liquids. For this reason, these are carefully fabricated enclosed containers. They are primarily designed to hold gasses or liquids at high pressures or varying pressures.

These vessels serve a variety of purposes in industrial settings, factories, or installations. Because of the inherent dangers present in anything that involves contained and pressurized gas or liquids, there are stringent regulations and safety protocols that must be met. 

The most common shapes for pressure vessels include:

  • Spheres
  • Cones
  • Cylinders

How are Pressure Vessels Made? 

Because of the high pressure, they must withstand, these vessels will typically be fabricated out of different types of steel. Many will use carbon steel and stainless steel. When fabricating a cylindrical vessel, for example, different steel parts must be welded together to form the shape and ensure safety.

Subpar welding can lead to the compromise of quality, which means that precautions are necessary to ensure the parts are correct and properly installed. Only certain kinds of steel are appropriate for certain parts, as per regulations. Engineering standards require that only steel with high impact resistance should be used for pressure vessels. 

The bodies that establish these fabrication codes include ASME safety guidelines and the National Board of Boiler & Pressure Vessel Inspectors in the U.S. and the EU Pressure Equipment Directive in Europe. Other regulations around the fabrication of these vessels include the use of a load-bearing liner that helps withstand the pressure load. These will typically be composed of metal, ceramic, or polymer. 

What Happens When a Pressure Vessel Loses Integrity or is Cracked? 

If a vessel becomes cracked or damaged it can lead to rupture or leakage. None of these is good news. The potential health hazards that come with either of the above are serious and include poisonings, suffocations, fires, and even explosions. If the energy in the vessel expands and puts added pressure that the vessel is not able to withstand, it is a recipe for disaster.

What is an Industrial Pressure Vessel Inspection? 

Faulty pressure vessels lead to catastrophic consequences. This is why various governmental bodies have stepped in to ensure that there are frequent inspections that maintain the performance and integrity of these vessels. 

The inspection process will look at:

  • How well the vessels meet established industry standards
  • The vessel while empty and in operation
  • Several kinds of pressure tests will be conducted 

As mentioned above there are several ways that a pressure vessel can be inspected. The inspection must happen by someone that is certified through the Board. They might conduct a:

Internal inspection: This type of careful examination of the vessel happens when it is empty and not in operation. This inspection is used to identify internal damage, corrosion, worn-out components, etc. The welded seams will be looked at carefully, as well as other areas near welds and fittings. 

External inspection: This is a type of inspection that is done while the vessel is operational. External inspections are conducted on the outside of the vessel. These are important to catch malfunctioning external components like the piping, connections, and more. 

How Often are These Pressure Vessels Inspected? 

This might vary depending on the particular use for that vessel.  Pressure vessels that house toxic liquids, for example, will need more frequent inspections. Preventative maintenance is the best way to ensure successful inspections and avoid fines, loss time of operation, damage, and —most importantly— accidents and malfunctions. 

Get a Trusted Technician for Your Industrial Needs 

When it comes to industrial pressure vessels and other components, the consequences of malfunction or bad quality can be major. Here at Wyler Industrial, we have been providing quality services for generations. As a family-owned company, we have passed on our knowledge and understanding of the industry as we have grown and settled in the El Paso area. All of our technicians are certified and carefully trained. 

Need a pressure vessel inspection, maintenance, or service? Call Wyler Industrial today. 

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An Ode to Combustion and Why Combustion Control Matters

a close-up shot of an internal combustion engineOh where would we be without combustion? Well, life would surely have progressed differently. If you own a car that runs on gas or diesel, then the combustion engine has become part of your life. The engine is the heart of the vehicle, as it is what pumps the necessary fuel through the engine to get it up and going. Because it is now so ubiquitous, most people don’t think about the internal combustion engine even though it likely is responsible for their daily commute. And while most people know that the engine is vital, we might not understand just why this engine is the best type. This type of engine was really the beginning of a lot of key manufacturing processes, so we thought why not pay tribute to it. That’s because today many of our industrial boilers use this technological concept to produce steam or hot water for space heating or process heating. 

There are essentially two types of combustion engines: an internal and an external combustion engine. In the latter, the fuel source—usually coal— is burned outside the engine. Then, the burning fuel will give it the energy it needs to run. 

An internal combustion engine works a bit differently. Instead of heating the fuel on the outside, a mixture of fuel and oxygen is injected into the engine. From there, there is a spark that ignites the fuel that causes it to make tiny explosions. This is why, of course, spark plugs are quite important to the whole operation. 

Over 150 years, the design of the internal combustion engine has been worked on and perfected and is by far the most preferred way to power a vehicle. When it comes to vehicles, this brings an advantage in using petrol or diesel as its fuel source because it can last longer. 

The invention of this type of engine was almost reached by several people simultaneously. Like many great inventions in human history, it seems that several minds across the world often come to it around the same time. Ultimately it was a man named Jean Joseph Etienne Lenoir that patented the first combustion engine. Early iterations of the invention had only one cylinder. This often caused the engine to overheat, but it was able to power small vehicles. This was a huge milestone in the technology as there was an ability for it to run continuously. And then, thanks to several great scientific minds of the 19th and 20th century, the internal combustion engine was improved and became the most efficient engine. 

Combustion Systems in Boilers and Industrial Machinery 

After all, boilers use a lot of energy and take a lot of energy to run properly. They are made to produce hot water or steam through the combustion of a fuel. The combustion efficiency is important to consider for any business or commercial facility that utilizes these. There are more than 45,000 industrial and commercial boilers in the United States. These are boilers with a total fuel input capacity of 2.7 million MMBtu/hr. A combustion system for industrial boilers is a system designed to maintain a proper air/fuel mixture under varying load conditions and safe limits. 

Boilers can be categorized by water temperature and/or steam pressure. They can also be further classified by the type of metal they are constructed with. Typically, however, they will be built cast iron or welded steel. Boilers are rated in different ways and are measured with Btu/h or BTU per hour and MBtu/hr indicates the rate of input. 

 Many large commercial sites often wonder how they can increase the efficiency of their boiler function. There are essentially three ways to do this and they include replacing the boiler completely, replacement of the burner, or installation of a combustion control system. Having a combustion control system installed can help some facilities earn efficiency without having to spend the upfront costs of a full replacement. 

Combustion control systems work through continuous feedback from measurements of oxygen, carbon monoxide, and nitrogen oxide concentrations. This allows the combustion system to improve combustion efficiency while maintaining low carbon monoxide and nitrogen emissions. It also allows for continuous monitoring of boiler performance. 

A test conducted on the combustion control system in the Watervliet Arsenal in New York showed significant savings over the course of a year. The efficiency gain comes from various factors including the constant monitoring of carbon monoxide, which prevents inefficient and unsafe combustion to occur. 

Here at Wyler Industrial, we perform boiler maintenance and repair for small and large industrial or commercial facilities. If you’re looking to improve the efficiency of your boiler, call us today. We’re here for all your industrial needs. 

 

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Boiler Disasters: What Can Go Wrong if You Don’t Hire Professional Help

We all love our boilers, even if you don’t fully understand what they do. Boilers are especially pertinent during the winter months. They stop your home’s pipes from freezing, after all! It’s easy to take boilers for granted. The moment these pieces of equipment cease to work, it’s as if the entire world stops. And what are you to do? Before you go fetch the toolbox, remember that boilers are complex and require professional maintenance in order to avoid any issues. If you’re ready for high-quality service, choose Wyler Industrial. In the meantime, take a look at these common nightmare scenarios that may have occurred if you decided to fix your boiler on your own.

Annual Tune-Ups and Inspections are a Must

In order to avoid expensive repairs in the future, make sure your boiler is inspected and tuned up by a professional once per year. Through regular inspections, your boiler will be able to receive any repairs it may need now rather than having to repair or replace a more substantial aspect (or the entire boiler itself) in the near future. By preparing preemptively to face any repair or mishap, you won’t have to suffer in the cold winter months or pay exorbitant amounts of money when the time for maintenance comes around. If large-scale repairs are necessary, don’t put them off! Taking care of boiler repair can cost a pretty penny but if you put it off, it’ll be much pricier in the future. Avoid any future complications and have your boiler taken care of, today.

Choose a Reputable Team to Take Care of Your Boiler

Your boiler deserves the best help it can get. Don’t cut corners when it comes to boiler repair. Instead, make sure to hire a team who understands boilers, inside and out. With Wyler Industrial’s help, your boiler will be up and running in no time. We’ve been serving the El Paso area for decades and decades. Throughout our time, we’ve seen every single boiler issue imaginable and we’ve been able to use this knowledge and expertise to fix whatever may be ailing your unit. Give us a call today to learn more about what we can do for you. Sure, winter might’ve just ended but that doesn’t mean your boiler should be forgotten about until next October. We’re ready to help!

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The Benefits of Choosing Mechanical Repair in El Paso

a mechanic working on a machineNo matter how high the quality of a machine, there will come a time when it needs repairs, or at the very least some maintenance. When your machine needs a little love and care, you do not want to let just anybody work with it. You want service you can trust, with experience and dedication to getting our machine on track. Wyler Industrial is one such machine shop. We have served businesses in the El Paso area with pride and care for many, many years.

Every Machine Needs Repairs

Even the toughest machines will need repairs every once in a while. It is not a matter of the machine being faulty or old, it is simply a fact of life. Having an experienced machine shop take care of your machine is one of the best ways to ensure it continues to work.

Routine Repairs

One way to avoid a machine break down is to have routine repairs done. Just as you should take in your car for regular oil changes, so too should you have our machine looked at. Whether the machine is big, like an air conditioning unit, or smaller, like a portable HVAC, it will need some care now and then. For example, an air conditioning unit needs to be checked at least once a year for dust build up, and to have its vents cleaned. An HVAC system, especially one that’s used often, needs to have its internal fan and vacuum checked. This is to avoid blockages occurring and to see if any parts need replacing. Many different machines require different kinds of maintenance.

Emergency Repairs

Now, what happens if your machine malfunctions during a crucial time? Well, if you have a machine shop you trust on standby, then you take care of the problem quickly. Having quality service on your side will help make even the most difficult situations a little less stressful.

Finding the Right Shop

You know that having a good machine shop in your contact lists is very beneficial for your peace of mind, but how do you pick the right one? Look for a team that has the experience and expertise you require. As such, Wyler Industrial is ready to help. We understand that Your machines help keep your business running smoothly. So when something goes wrong you need to turn to the qualified people at Wyler Industrial. Give us a call today to learn more about what we have to offer.