Regular inspections and maintenance are crucial to prevent air compressor failure. These important processes involve a variety of tasks ranging from cleaning and checking for oil leaks to draining excess moisture and replacing air filters, among many others.
Preventing air compressor failure also relies on being mindful of a compressor’s duty cycle and avoiding overloading it, while also using the correct components and lubricants that match the specifications of its make, model and operating conditions. Here, we break down the essential steps to mitigate air compressor failure.
Carry out compressor inspections
Regular inspections are vital to maintain the health and performance efficiency of air compressors. Your comprehensive checklist must involve visual checks for damage, wear and leaks; inspection of filters and air lines; monitoring air compressor oil condition and levels and making sure that electrical components and cooling systems are working properly.
Proactive routine inspections are important because they help you identify possible issues earlier, preventing expensive repairs and compressor downtime.
Professional compressor inspections are also required periodically. This is an in-depth examination of the air compressor system, performed by a qualified technician. It is designed to prevent potential problems, ensure peak performance and make certain compressors are compliant with safety regulations. Professional inspections usually include performance tests, visual checks and the specialised tools that identify signs of damage, leaks, wear and other issues
Conduct regular maintenance
Regular, ongoing maintenance of the compressor, its components and the lubricants it requires to run are key to preventing air compressor failure.
Lubrication
Maintenance teams must ensure they always lubricate the compressor effectively. Checking air compressor lubrication is critical for longevity and proper functionality. This process involves being sure to routinely check oil levels, inspecting for oil leaks, and changing both the oil and oil filter at required intervals. Correct lubrication effectively reduces friction and wear and prevents overheating while maintaining the compressor efficiency.
The compressor oil must be replaced according to original equipment manufacturer (OEM) recommendations to prevent any component damage.
Drain condensate
Compressor maintenance also requires condensate draining to stop moisture-related issues and facilitate optimal operational efficiency. Condensate is defined as a mixture of water with other contaminants and forms when air is compressed. It must be removed from the air compressor system.
Inspect belts and hoses
Routine inspection of hoses and belts is also an essential air compressor maintenance practice. Check for leaks, wear, fraying and cracks. Replace any damaged hoses and belts immediately to prevent more damage and to help maintain maximum performance.
Filter maintenance
Air filters also require attention. Filters should be cleaned or replaced as required to ensure sufficient airflow and prevent blockages. All maintenance checks should also involve inspection of the pressure relief valve to make sure it functions properly.
Store properly
After maintenance, the compressor must be correctly stored when not in active use. Choose a dry and temperature-controlled area indoors. Make sure the compressor is completely clean and cover it with breathable material to stop dust accumulation. Routinely check for any signs of rust or damage during storage.
Address leaks promptly
It’s crucial to check for and efficiently repair leaks found in the compressor to prevent it overworking. Identify the source of the leak and depressurise the system. Then, repair or replace faulty parts, tighten loose connections, reassemble and clean. The system should then be tested to ensure the leak is fixed.
Use correct parts
When any compressor parts are damaged and require replacement, they should only be switched out with OEM approved components. Using the wrong parts during air compressor maintenance leads to negative consequence like reduced performance, wear and tear, and damage. It also voids warranties.
Monitoring for warning signs
During operation, air compressor failure is prevented by monitoring for indicators of issues. These include reduced compressor performance and unusual noises like rattling and whistling.
Adopt best operating practices
Proper usage is also vital to prevent air compressor failure. Avoid overloading the air compressor by running it according to the right duty cycle and by adjusting the load. Prevent overheating by maintaining proper ventilation, and make sure the cooling system is clean and operating properly.
Using high-quality lubricants
Correct lubrication is essential for compressors to work properly and remain protected from friction, wear and corrosion. Always use high quality air compressor oil from trusted brands like Mobil, Fuchs and CPI Fluid Engineering.
Following these key processes, you can substantially reduce the risks of air compressor failure.
