Did you know that 76% of the cost of running your air compressor goes to electricity? This leaves you with 12% for equipment and maintenance.
Consider the fact that most industrial air compressors only have 10-15% efficiency. That means you can't afford for your compressor's performance to fail. Your costs will rise in both operation and production if your compressor starts to fail.
What steps can you take to avoid this? Keep an eye out for these signs that your air compressor is failing.
1. HIGH OPERATING TEMPERATURE
Heat is a constant opponent for all air compressors. The physical act of compressing air molecules generates enormous amounts of heat (known as "compression heat"), and effective heat dissipation is critical for safe and reliable compressor operation. A sudden or unexplained increase in compressor operating temperature is a clear sign that a problem is on the way. Any maintenance program should include regular cleaning of a compressor's coolers. Additionally, the condition of a compressor’s lubricant can greatly affect the machine’s ability to operate at a safe temperature. Closely monitoring lubricant conditions through a formal oil sampling program is a good strategy for preventing compressor failure and downtime.
2. INCREASED NOISE
Many industrial air compressors, especially older models, produce a lot of noise while operating. While advances in technology have enabled many compressor OEMs to reduce overall operating noise in newer models, air compressor users should be familiar with their compressors' typical operating noise under normal conditions. Any increase in operating noise should be investigated as soon as possible. Bearing noise should always be addressed as soon as possible, and any unexplained clicks, rattles, or rumbles can indicate the presence of a larger problem. Call a professional service company for troubleshooting and repair if a specific noise cannot be identified or corrected.
3. MOTOR OVERLOAD OR TRIPPED BREAKERS
Most industrial air compressors have a safety shutdown that will automatically shut down the unit if the motor amperage exceeds the acceptable range. If a compressor shuts down as a result of this problem, the root cause should be investigated as soon as possible. An accredited professional may be able to quickly resolve the problem by making a minor adjustment. A motor overload or tripped breaker, on the other hand, can often indicate more serious issues, such as electrical system flaws or increased mechanical friction in the air compressor. Regardless of the potential cause, an electrical overload should always be taken seriously and addressed immediately for the sake of safety.
4. LOW FLOW OR PRESSURE
A properly designed compressed air system should provide enough airflow and pressure to meet the application's necessities. When a compressed air system fails to maintain adequate pressure for no apparent reason, the consequences can be disastrous for a company's bottom line. Poor product quality, downtime at the facility, and decreased safety can all eat into a company's profits. As a result, air compressor users should be constantly aware of system performance in order to minimize the impact of a compressed air supply shortage.
The potential causes of reduced pressure or flow are varied – and can manifest in both the compressor room or in a facility’s air piping. Leaking pipes, open valves and stuck drains can all cause pressure to fall. However, sometimes the control system of the air compressor can be the culprit. If the cause of sudden pressure loss cannot be identified immediately, call a trusted compressed air technician for assistance.
5. INCREASED OR EXCESS MOISTURE
Condensation occurs in every compressed air system. Users of air compressors must deal with this natural byproduct of the compression process on a daily basis. The presence of liquid water in a facility's compressed air supply, on the other hand, can have a negative impact on quality, productivity, and dependability. As a result, most end users remove condensation from their air systems using air treatment equipment like dryers, filters, and mist eliminators. An air treatment problem is usually to blame when the amount of condensation in a compressed air system suddenly increases.
When do you need industrial compressor repairs?
Industrial air compressors only last for so long. That lifespan gets shorter as you put them through more use. If you are starting to see the signs of problems with your air compressor then it is time to take action.
All Air Compressors specialises in compressed air servicing and repairs, air piping installation and line filter installation. Our mobile technicians are available for scheduled servicing and 24-hour breakdowns and repairs throughout NSW. Contact us today so we can help you to have long-lasting, durable industrial air compressors, so allow us to service and maintain them so you can enjoy years of service.