The Importance of Air Compressor Maintenance and Inspections
Air compressors are one of the hardest working pieces of equipment in industrial facilities; however, they require some TLC in order to continually provide the highest levels of performance and efficiency. For this reason, air compressor service that includes regular inspections and preventive maintenance is crucial if you expect to receive the optimal performance from your air compression unit.
This blog will provide information on inspection and maintenance activities, as well as an air compressor maintenance checklist, to help keep your air compressor running in good health throughout its lifetime.
The High Cost of Neglecting Air Compressor Maintenance
A well-maintained air compressor will provide years of trouble-free service, while a poorly maintained air compressor can end up costing big bucks in repairs and unplanned downtime.
Some of the costs associated with neglecting air compressor service activities include:
Reduced lifespan
Unnoticed and unattended wear and tear on air compressor components can significantly shorten the lifespan of the air compressor.
Emergency repair and replacement
When a small issue with an air compressor is neglected or unnoticed, it will eventually become a major problem that results in downtime and emergency air compressor maintenance. In addition to the cost of labor and replacement parts, there is also the cost of downtime, so emergency air compressor repairs can really add up. Therefore, performing major air compressor repairs (or replacement) is almost always more expensive than performing inspections and preventive maintenance on a regular basis.
Higher electric bills
Clogged filters, air leaks, inadequate lubrication and other issues can result in the air compressor working harder than is necessary, which leads to inefficient operation and higher costs for electricity.
Increased downtime
Neglecting to perform inspections and routine air compressor maintenance activities can lead to outages and unplanned shutdowns that can cost a company thousands of dollars per hour in lost production time.
Air Compressor Service Includes Performing Inspections
The first step in proper air compressor service includes frequent, if not daily, inspections that can help identify potential issues and permit scheduling of preventive maintenance activities before small problems become big ones that lead to major (and costly) emergency air compressor repairs.
On a daily or weekly basis, operators should visually inspect the air compressor and components. During each inspection, take note of:
- Control Panel: Check the control panel for any service indicators or fault alarms.
- Hoses, pipes, and fittings: Any detected air or oil leaks should be addressed as quickly as possible to avoid issues with operations or efficiency.
- Air intake: Ensure that the air intake is clear and free of obstructions.
- Filters: Examine the filters to see if debris has accumulated. If so, replace filters before contamination or blockages impede airflow as this can lead to inefficient operations.
- Oil levels: Proper lubrication is essential to a healthy air compressor. Check the oil levels with frequency and address the need for lubrication immediately to avoid damaging the air compressor. Remember that even oilless air compressors may require lubrication of parts outside the compressor chamber. Be sure to follow the manufacturer’s recommendations for oilless air compressor lubrication requirements.
- Temperatures: Track and document the running and cooling temperatures. Deviations from the norm indicate a problem that should be identified and addressed.
- Sounds: Unusual vibrations and/or knocking require attention to prevent downtime, so be aware of any unusual sounds.
- Valves: Check and adjust the valves and switches to ensure they are functional.
Air Compressor Maintenance Checklist
Regular inspections are integral to identifying and correcting potential air compressor repairs. However, even if inspections don’t reveal any underlying issues, performing preventive air compressor maintenance activities is essential to the health and longevity of your air compressor. Be sure to follow your specific compressors maintenance checklists and schedules as outlined in the manual.
Below you will find a general air compressor maintenance checklist with suggested activities and a timeline
| Daily Activities | – Check the oil level in the compressor pump and refill if it is low. – Listen for unusual noises or vibrations. – Inspect hoses, pipes and fittings for potential air leaks. – Drain any condensate from the air receiver. |
| Weekly | – Clean or replace air intake filters. – Inspect belts and pulleys and tighten as needed. – Inspect hoses and connections for signs of wear or leakage and correct ASAP. |
| Monthly | – Clean the compressor’s cooling system, radiator and fan. – Ensure that the pressure relief valve is functional. – Lubricate any moving parts according to manufacturer’s recommendations and instructions. |
| Quarterly | – Change oil and oil filters. (It is essential to follow manufacturer’s recommendations here as some compressors will need this done more frequently based on usage.) – Inspect the air compressor’s motor and electrical connections. – Calibrate pressure gauges. |
| Annually | – Replace any components that show signs of wear and tear. – Perform a tune-up or schedule a professional inspection and service company appointment as professionals may detect issues that in-house maintenance staff missed or are unable to repair. |
The key to getting top-notch performance from your air compressor is to perform regular inspections and preventive air compressor maintenance activities as listed above. While this air compressor maintenance checklist should serve as baseline guidance, it is crucial to follow manufacturer’s recommendations for lubrication, oil sample tests, and other necessary air compressor service activities and intervals. Doing so will help maintain the efficiency and effective operation of your air compressor for years to come. For more information on air compressor maintenance or to schedule an air compressor service call, please contact JHFOSTER.