Project Background
Arc Infrastructure manages Western Australia’s freight rail network, operating across thousands of kilometres and supporting critical supply chains throughout the state. Many of its operations rely on field-based infrastructure that requires off-grid power solutions, including generator-supplied compressed air.
Arc Infrastructure approached Air & Power with a specific operational challenge. They needed a compressor that could run smoothly off a generator, without constant start-stop cycling that causes voltage drops, overloads, or inconsistent air supply. The goal was simple: reduce generator strain and maintain reliable compressed air delivery on site.
The Problem
Standard compressors are designed to cycle on and off as pressure demand changes. While efficient in a mains-powered setting, this constant cycling creates sharp power draws, a problem when running on generator power. Every restart puts a heavy load on the generator, potentially causing power fluctuations or requiring oversizing of equipment.
Arc Infrastructure needed a compressor system that could:
- Run in continuous mode to minimise generator load variation
- Still provide flexibility to switch to standard cycling when needed
- Operate with reduced noise in an open-air or semi-enclosed field environment
The solution had to be reliable, power-conscious, and tailored to the customer’s specific generator setup.
The Solution
Air & Power supplied and customised a Pilot Air K30 piston compressor to meet Arc’s exact requirements. This was not an off-the-shelf install, every element was modified for performance, generator compatibility, and operational flexibility.
Key modifications included:
- Continuous running mode configuration: Allowed the compressor to stay running without shutting down between cycles, greatly reducing electrical demand spikes and maintaining smoother generator operation.
- Ball valve to pressure switch: Enabled operators to manually switch between continuous and standard running modes, depending on the power supply or job requirements.
- Installation of a muffler: Reduced operating noise, improving on-site working conditions for personnel nearby.
The modifications ensured that the compressor could run directly off Arc’s generator system with minimal impact, avoiding costly electrical redesign or system upgrades.
The Results
Arc Infrastructure conducted on-site testing using their own generator. The modified Pilot Air K30 compressor performed exactly as intended, running in continuous mode without triggering overloads or excessive draw.
The result:
- Stable generator load throughout operation
- No power fluctuation or fault cycling
- Reliable compressed air output in field conditions
- Improved on-site working environment due to reduced noise
This solution avoided the need to oversize the generator or compromise on air delivery, a practical fix that gave the team reliable performance without creating new problems elsewhere in the system.
Why It Worked
This project is a clear example of Air & Power’s technician-led approach in action. Rather than pushing a one-size-fits-all product, we listened to the operational needs, understood the electrical limitations, and delivered a tailored solution, tested, proven, and ready to work.
Our team knew exactly how to adapt the Pilot Air K30’s configuration to match the generator’s profile, reducing strain and maintaining air supply across all site conditions.
The inclusion of a pressure switch valve means the client isn’t locked into one operating mode. If circumstances change or the compressor is moved to a different site, it can be switched back to standard mode in minutes.
Lessons for Other Businesses
For operations relying on generators or off-grid power, compressed air can present a unique challenge. Standard start/stop compressor cycles often clash with generator limitations, leading to unstable performance or power management headaches.
This project shows that with the right advice and practical engineering, compressors can be adapted to run efficiently and reliably off generator systems, without needing to overspend on oversized power supply or industrial-scale compressors.
Air & Power continues to support Arc Infrastructure and other WA-based clients with custom solutions for specialised compressed air needs, backed by real-world experience and service that puts the technician first.
