With a proactive maintenance routine and high-quality lubricants from manufacturers like CPI Fluid Engineering, air compressors can operate at optimal performance with an extended life span.
However, a wide range of issues can lead to air compressor failure modes occurring like overheating, air leaks, electrical problems and abnormal pressure levels.
While problems are sometimes caused by electrical supply or poor maintenance, there are also many oil-related compressor failure modes. These can range from insufficient lubrication to air compressor oil carry over. Here, we outline some of the most common oil-related air compressor failure modes.
Overheating
A substantial cause of damage in air compressors, overheating is caused by a multitude of issues. These include fouled air filters, poor ventilation, blocked coolers and high ambient air temperatures.
When overheating is a regular occurrence, it prematurely wears seals, valves and compressor oils. When undetected, it affects the compressor’s performance and decreases its lifespan.
Insufficient oil levels or inferior oil quality leads to overheated compressors. Using non-recommended or poor-quality compressor oil is a false economy that always costs more in the long term.
Air leaks
An air leak results in lost pressure and decreased airflow within a compressed air system. Eventually, the high air pressure level locates the weakest part in the system. Consequently, leaks are often found at connection points at couplings, joints, hoses and valves.
Leaks produce substantial energy losses as compressors work harder and for longer to compensate, putting extra stress on components. In noisy work areas, it’s not always easy to hear air escaping, but its effects are visible through loss of system pressure.
Pressure issues
A wide range of issues result in insufficient airflow and air pressure. Air intake filters can become obstructed, stopping adequate ambient air from entering the compressor, airflow settings can be configured incorrectly, or regulators may fail.
Fluctuating air pressure causes damage to pneumatic air components and contributes to operational delays. Pressure switches can also become worn or malfunction, but both problems interrupt air compressor cycling processes running smoothly.
Electrical issues
Air compressor shutdowns because of electrical problems are a common occurrence. Causes include faulty wiring, damaged contactors and corroded fuses. Ensuing voltage irregularities and power surges can damage motors and control boards or shut compressors down completely.
Major electrical faults sometime have negative knock-on effects like internal component damage and overheated compressors. Overloaded motors often occur after a sudden restart or instant power loss.
Oil leaks
While not always easy to identify and isolate, air compressor oil leaks are a prevalent problem. It isn’t unusual to find oil leaking due to overfilling occurring during scheduled maintenance. Additionally, visible leaks at the oil seals, gaskets and drain valves are also a commonplace issue.
The only clear indicator of an air compressor oil leak can be a noticeable pool on the floor or a fall in compressor performance. Oils leaks are problematic; along with being a health and safety risk, they quickly attract a build-up of dust and grime that promotes accelerated wear and tear on all compressor components that contaminate the spilled oil.
Oil carry-over
The term oil carry-over refers to lubricant present in the compressed air leaving the system. Oil carry-over can significantly affect the air compressor’s performance as well as the downstream equipment. High levels of oil carry-over can lead to decreased efficiency and contamination of the system, and can cause mechanical harm to connected equipment.
Oil dilution
When air compressor oil becomes diluted, its capacity to lubricate and protect is significantly reduced, negatively impacting compressor operation. Loss of lubrication leads to greater friction, wear and tear and potential failure of the air compressor’s internal components.
Diluted oil can also result in the formation of sludge and varnish in the system, further impacting performance levels and causing further damage.
Vibration
Air compressor oils play a critical role in minimising friction and undue wear within compressors. Inadequate lubrication often directly leads to more vibration.
Moving compressor parts lacking sufficient lubrication experience more friction as they make direct contact, creating higher vibration levels that can potentially cause compressors to overheat. This may manifest as rust formation, bearing noise and can eventually lead to component failure.
Insufficient lubrication
Finally, using incorrect or inferior quality air compressor oils causes internal component failure. Operators must ensure they use a high-quality and compatible lubricant that matches the specifications of their application to avoid this compressor failure mode.
