Beyond Compression - An FS-Elliott University Podcast

In this episode of Beyond Compression, we explore how lubricant selection and maintenance affect centrifugal compressor reliability. Even in an oil-free compressor, lubricant has an essential job: protecting the gears, bearings, and other mechanical components while remaining separate from the compressed air path. Choosing a fluid that meets the compressor’s operating requirements can help reduce wear, deposits, and unplanned downtime.

We discuss what makes centrifugal compressor lubrication different, why fluid properties matter, and how heat, moisture, and contamination can affect lubricant performance over time. We also look at the value of proper storage, routine sampling, and fluid analysis in identifying potential issues before they interrupt production.

In this episode, you’ll learn:

• Why an oil-free centrifugal compressor still needs a carefully managed lubrication system
• What to consider when selecting a lubricant for centrifugal compressor operation
• How varnish, moisture, and fluid degradation can affect equipment reliability
• Why lubricant storage and sampling practices matter
• How routine fluid analysis can help maintenance teams spot developing problems
• Why lubricant selection and preventive maintenance should be considered together

Lubricant is a small part of a compressor system with a significant role in its long-term performance. Understanding what your equipment requires, and monitoring fluid condition throughout its service life, can help protect critical components and avoid preventable downtime.

To learn more, read our blog:
https://www.fs-elliott.com/blog/prevent-downtime-with-the-right-centrifugal-compressor-lubricant

Follow FS-Elliott on LinkedIn and Facebook for more insights from our engineering and service teams, and join us as we explore smarter, more reliable compressed air systems.

In this episode of Beyond Compression, we explore why a well-developed centrifugal compressor specification is critical to equipment reliability, energy efficiency, project costs, and long-term operational performance. The decisions made during the specification process influence nearly every aspect of a compressor package, from aerodynamic design and driver selection to controls, auxiliary systems, installation requirements, and lead times.

We discuss the process and site data needed to properly select a centrifugal compressor, including flow requirements, inlet conditions, gas properties, discharge pressure, ambient conditions, electrical requirements, and hazardous-area classifications. We also examine how industry standards such as API 617, API 672, API 614, and JIP 33 apply to different compressor applications—and how specifying unnecessary or conflicting requirements can increase costs and delay a project without improving reliability.

In this episode, you’ll learn:

• Why the compressor specification serves as the engineering foundation for the entire project
• What process, site, and operating data are required for proper compressor selection
• How to determine which industry standards apply to a particular application
• Why driver, electrical, controls, and hazardous-area requirements should be established early
• How incomplete information and late-stage changes can affect equipment design, costs, and project schedules
• Why early collaboration among the owner, EPC contractor, and compressor manufacturer can reduce risk and improve long-term performance

A centrifugal compressor specification is much more than a procurement document. When operating conditions and project requirements are clearly defined from the outset, project teams can avoid unnecessary scope creep, reduce engineering rework, improve equipment efficiency, and select a compressor package that meets the facility’s actual needs.

To learn more about developing an effective centrifugal compressor specification, read our blog:
https://www.fs-elliott.com/blog/how-to-specify-a-centrifugal-compressor-for-reliability-and-lower-lifecycle-costs

Follow FS-Elliott on LinkedIn and Facebook for more insights from our engineering and service teams, and join us as we explore smarter, more reliable compressed air systems.

In this episode of Beyond Compression, we explore the critical role compressed air plays in modern automotive manufacturing and why system design decisions can have a major impact on production uptime, product quality, energy consumption, and long-term operating costs. From robotic assembly and paint operations to EV battery manufacturing, compressed air supports some of the industry's most important processes.

We discuss the key factors manufacturers should consider when evaluating compressed air systems, including reliability, redundancy, scalability, air quality, energy efficiency, and lifecycle cost. We also examine common design mistakes that can limit performance and increase operating expenses, as well as strategies to help facilities improve reliability and prepare for future growth.

In this episode, you'll learn:

•  Why compressed air is considered a production-critical utility in automotive manufacturing 
•  How reliability, redundancy, and advanced controls help reduce downtime risk 
•  The importance of planning compressed air systems for future facility growth and automation 
•  Why air quality matters in paint operations, EV battery manufacturing, and other sensitive applications 
•  How compressor selection and system optimization can reduce energy consumption and lifecycle costs 

As automotive manufacturers continue investing in automation, electrification, and production efficiency, compressed air systems must do more than simply supply air. A properly designed system can help improve product quality, support reliable operation, reduce energy costs, and provide the flexibility needed to meet future production demands.

To learn more about compressed air system design considerations for automotive manufacturing, read our blog:
How Compressed Air Impacts Product Quality and Efficiency in Automotive Manufacturing

Follow FS-Elliott on LinkedIn and Facebook for more insights from our engineering and service teams, and join us as we explore smarter, more reliable compressed air systems.

In this episode of Beyond Compression, we cover why compressed air quality matters more than many facilities realize, and how oil-free compressor technology can help reduce contamination risk, improve reliability, and support long-term operational performance. From ISO 8573-1 Class 0 standards to the hidden costs of oil carryover, we explore how air quality directly impacts manufacturing efficiency, product integrity, and maintenance requirements across a wide range of industries.

We also discuss the differences between oil-free centrifugal compressors and oil-lubricated technologies, why understanding ISO classifications is important when evaluating compressed air systems, and how facilities can simplify maintenance while protecting sensitive operations.

In this episode, you’ll learn:

• How ISO 8573-1 defines compressed air quality and what Class 0 really means
•  Why oil contamination can create hidden risks for manufacturing operations
•  The differences between oil-free centrifugal compressors and oil-lubricated technologies
•  How oil-free systems can help reduce maintenance, improve reliability, and lower lifecycle costs
•  Which industries benefit most from clean, oil-free compressed air applications

Compressed air is often called the fourth utility, but in many facilities, it also plays a direct role in product quality, operational efficiency, and regulatory compliance. Understanding air quality standards and compressor technology selection can help manufacturers reduce risk while supporting cleaner, more reliable operations.

Learn more about ISO 8573-1 Class 0 oil-free compressed air by reading our blog: https://www.fs-elliott.com/blog/benefits-of-iso-8573-1-class-0-oil-free-compressed-air-systems

Follow FS-Elliott on LinkedIn and Facebook for more insights from our engineering and service teams, and join us as we explore smarter, cleaner, more reliable compressed air systems.

In this episode of Beyond Compression, we share a combined perspective from the compressed air experts at FS-Elliott and FS-Curtis on how seasonal temperature changes impact compressor performance, efficiency, and reliability. From summer heat and humidity to winter cold and condensation risks, we explore how shifting ambient conditions influence both centrifugal and rotary screw compressors—and what operators can do to stay ahead of them.

We also discuss why following a structured, OEM-recommended maintenance approach is critical to maintaining performance year-round, and how proactive preparation helps reduce risk, extend equipment life, and avoid unplanned downtime.

In this episode, you’ll learn:

•  How temperature and humidity changes affect compressor performance and system stability 
•  The four critical factors that influence reliability: cooling, lubrication, filtration, and moisture management 
•  Key maintenance practices to prepare for both summer and winter operating conditions 
•  Why seasonal challenges are predictable—and how to prevent them before they impact your operation 

Depending on your location, you may be preparing for peak summer heat or transitioning into colder winter conditions. In either case, your compressed air system is facing known challenges that require attention.

👉 Learn more about seasonal compressor maintenance by reading our blog: https://www.fs-elliott.com/blog/seasonal-maintenance-for-centrifugal-and-rotary-screw-compressors

Follow FS-Elliott on LinkedIn and Facebook for more insights from our engineering and service teams, and join us as we explore smarter, cleaner, more reliable compressed air systems.

In this episode of Beyond Compression, we explore how site conditions like temperature, humidity, elevation, cooling water, and demand profile influence compressor design, efficiency, and long-term operating costs. We also discuss why compressors designed around actual operating conditions perform more efficiently, operate more reliably, and provide better long-term value than standardized designs.

From aerodynamic stage design to control strategies and system coordination, this episode explains how compressor performance is engineered rather than selected. 

In this episode, you’ll learn:

•  How real-world operating conditions affect compressor performance and efficiency
• How design and controls work together to improve reliability and energy use
• Why application-specific compressor design leads to better long-term performance

If your compressors weren’t designed around your actual operating conditions, your system may not be operating as efficiently as it could.

👉 Learn more about custom aerodynamic compressor design by reading our blog https://www.fs-elliott.com/blog/custom-aerodynamics-centrifugal-compressors or listening to Episode 4 of the Beyond Compression podcast.

Follow FS-Elliott on LinkedIn and Facebook for more insights from our engineering and service teams, and join us as we explore smarter, cleaner, more reliable compressed air systems. 

Compressed air powers nearly every industrial facility, but it’s often one of the most underestimated operating costs.

In this episode of Beyond Compression, we explore why compressed air costs more than most organizations realize and how system-level inefficiencies quietly drive energy, maintenance, and reliability expenses over time.

Through a real-world case study, we share how a compressed air audit uncovered hidden costs across excess pressure, leakage, and inefficient loading. With data in hand, the facility prioritized targeted improvements that reduced operating expense and strengthened system reliability.

In this episode, you’ll learn:

• Why most compressed air costs occur after installation
• How small pressure and control decisions compound into a major energy expense
• What system audits reveal that daily operation often hides
• How monitoring and data improve efficiency and uptime
• Why compressed air should be managed as a system, not just equipment

If compressed air feels like a fixed cost, this episode shows how much control you actually have.

 👉 Download our white paper to learn more: https://www.fs-curtis.fs-elliott.com/hidden-costs-air-compressor-operation

Follow FS-Elliott on LinkedIn and Facebook for more insights from our engineering and service teams, and join us as we explore smarter, cleaner, more reliable compressed air systems. 

OEM and Non-OEM parts may look the same—but do they really perform the same?

In this episode of Beyond Compression, host Pam Wasielewski sits down with Dave Sleeman, a seasoned service expert, to break down one of the most common—and costly—assumptions in industrial maintenance: that OEM and non-OEM parts are interchangeable.

From reverse engineering and material selection to micron ratings, tolerances, and long-term performance, this conversation pulls back the curtain on what manufacturers see that others don’t. Dave shares real-world field experience, including a case where a seemingly harmless non-OEM air filter led to reduced efficiency, vibration alarms, impeller damage, and nearly $50,000 in unplanned costs.

In this episode, you’ll learn:

• Why “looks the same” doesn’t mean “performs the same.”
• What’s lost when parts are reverse-engineered without original design data
• How non-OEM components contribute to early-life failures
• The hidden costs of downtime, efficiency loss, and secondary damage
• What OEM parts protect beyond performance—warranty, safety, and compliance

If you’ve ever considered saving a few dollars on replacement parts, this episode explains why the real cost often shows up later.

👉 Full case study:
https://www.fs-elliott.com/blog/oem-vs-non-oem-parts-explained-what-manufacturers-see-that-others-dont

Follow FS-Elliott on LinkedIn and Facebook for more insights from our engineering and service teams, and join us as we explore smarter, cleaner, more reliable compressed air systems.

In this episode of Beyond Compression - An FS-Elliott University Podcast, we explore one of the most misunderstood and undervalued components of your compressed air system: the control panel.

From outdated manual switches to modern, intelligent controllers, we explore why upgrading your compressor control system isn’t just a “nice-to-have,” but a critical step toward achieving higher efficiency, greater reliability, and next-level visibility in your plant operations.

Join our host, Barbara Myers, and guest Tom Nist, as they break down:

• A brief evolution of compressor control systems
• The hidden costs and risks of running outdated controls
• How modern controllers unlock higher performance and real energy savings
• The top warning signs your compressor controls are overdue for an upgrade
• The game-changing impact of data, automation, and remote monitoring on air system efficiency

Whether you're working with aging infrastructure or planning your next system upgrade, this episode will arm you with practical insights on bringing your compressed air controls into the future, without breaking the bank.

Because better control doesn’t just optimize your air, it transforms your bottom line.