When you first get your industrial air compressor, it’s natural to wonder what having that piece of equipment will entail throughout its lifespan. What will the maintenance on the machine be like? How often can you expect to have to perform repairs? And what are the things you should be keeping an eye out for when it comes to repair work? Identifying and understanding issues within your system can allow you to quickly determine the repairs your system requires.
Why Industrial Air Compressor Maintenance is Important
Maintaining your system is one of the best ways to limit the repairs you must perform on your industrial air compressor. Maintenance helps you identify and address potential issues before they become significant, allowing your system to maintain smooth, steady production.
Creating an appropriate maintenance schedule is the best way to keep your system running right. With a predictable schedule, you won’t have to worry about when to check what areas of your system, and you’ll have a clear, detailed report of past maintenance actions and repairs. Maintenance schedules also help keep all employees on the same page regarding maintenance and repairs, eliminating the potential for confusion and communication issues along the way.
Common Industrial Air Compressor Repairs
Understanding the problem with your industrial air compressor system can help you find the solution. The overwhelming majority of industrial air compressor repairs have to do with the following issues:
- Compressor won’t start: If you’re pressing the start button on your unit and nothing is happening, first check the system’s pressure. The problem may lie in the electrical or mechanical system if that isn’t the issue.
- Low air pressure: If your system cannot maintain consistent pressure, the issue may lie within a blocked or closed valve, or there may be an air leak within the system. Check that your valves are in the correct position and operating properly, and inspect your system for the presence of any leaks.
- Air leaks: Air leaks are one of the most commonly overlooked issues within industrial air compressor systems, and they may also be one of the most costly. Leaks can result from a number of different sources, including worn or damaged seals or gaskets, the corrosion of metal parts, improperly sealed valves, cracks in hoses, or loose joints in piping.
- Inadequate cooling: If your air compressor is prone to overheating, you may need to consider checking the oil levels within your system. After checking the oil levels, check for a high ambient temperature, take a look at the heat exchanger to make sure it is functioning properly, and check for HVAC issues like clogged filters.
- Electrical Issues: There are a multitude of possible electrical issues that can occur within an industrial air compressor system. These issues range in severity from blown fuses to tripped breakers and malfunctioning starters. The answer to these problems can be similarly broad in nature, running from replacing an inexpensive fuse to much more costly solutions like replacing an entire motor. Operators less commonly note electrical issues during routine checks and may require the expertise of a professional compressor technician to properly identify and address them.
- Excessive oil consumption: If you find that your system is consuming an excess of oil or you have oil carryover into your compressed air, the problem is likely to do with your oil separator. Check the separator for leaks or malfunctions that could be causing the issue.
- Pressure fluctuations: Some pressure fluctuations are to be expected in any air compressor system. However, significant fluctuations can be an issue. Adjusting the parameters of your system to match air flow demands or replacing piping with something of a more appropriate size are the most common solutions for issues with pressure fluctuation.
- Pressure relief valve activation: The PRV is one of an industrial air compressor’s most important safety components. Activation of the pressure relief valve indicates that pressure within the system has exceeded safe limits. However, malfunctions with other aspects of the system, like the pressure sensor, inlet, or blowdown valves. Additionally, the PRV may activate simply due to the PRV itself weakening over time and being activated at lower pressures.
- Corrosion/Rust: Rust and corrosion are two of the most common issues you may run into with your industrial air compressor. If components of the system come into contact with water or excess moisture develops within the system, the functioning of the compressor can be compromised.
ESA for Your Industrial Air Compressor Needs
If you’re new to industrial air compressors or having difficulties determining the source of your air compressor issues, let the professionals at ESA step in. Our trained and experienced technicians can quickly pinpoint what common repairs are needed by identifying the cause of your compressor issue. Our team is available 24 hours a day, seven days a week, to answer your questions and address your concerns. Contact us today for a consultation.