The air compressor is a fundamental component in many industrial operations. Its proper functioning is essential to ensure the efficiency and continuity of production processes. However, like any mechanical equipment, it requires regular maintenance to prevent costly and unexpected failures.
Below, we present 5 warning signs that indicate your compressor needs urgent maintenance, along with some preventive recommendations to extend its service life.
1. Increase in Amperage Consumption
Symptoms
- Increase in energy consumption without a proportional increase in compressed air output.
- Fluctuations in the motor’s electrical current.
- Motor overheating or unexpected shutdowns.
Possible Causes
- Clogged air filters, causing the motor to work harder.
- Lack of lubrication in mechanical components.
- Electrical system issues or unstable power supply.
2. High Oil Consumption
Symptoms
- Rapid drop in oil level.
- Visible oil leakage in piping or connection points.
- Compressed air contamination with oil residues.
Possible Causes
- Leaks in the lubrication circuit.
- Worn out or saturated oil separators.
- Use of improper or low-quality oil.
3. Temperature Alarm and Equipment Shutdown
Symptoms
- The compressor generates more heat than usual.
- Alarms appear in the control system.
- Unexpected shutdown of the equipment as a safety measure.
Possible Causes
- Insufficient ventilation or clogged radiators.
- Low level or degradation of the lubricating oil.
- Faulty temperature sensors or cooling system failure.
4. High Pressure Differential
Symptoms
- Significant pressure drops between the compressor and the point of use.
- Variations in compressed air flow.
- Pressure alarm activation on the controller.
Possible Causes
- Saturated air or oil filters.
- Leaks in the compressed air distribution system.
- Faulty valves or regulators.
5. Warning Messages on the Controller
Symptoms
- Frequent warning messages on the control panel.
- Changes in system configuration without human intervention.
- Intermittent failures in compressor operation.
Possible Causes
- Miscalibrated or faulty sensors.
- Software or control system errors.
- Electrical issues in the control unit.
Recommendations to Avoid Major Failures
To reduce the risk of compressor failures and extend its service life, it is essential to implement preventive actions. At Saving with Energy México, we offer a specialized strategy called the “Always-On-Time Maintenance Plan (PMST)” to ensure your equipment operates efficiently through a plan tailored to your needs.
1. Schedule Predictive and Preventive Maintenance
- Implement a maintenance plan based on operational data analysis.
- Conduct regular inspections and replace worn-out components on time.
- Use monitoring technology to detect potential failures before they occur.
Our Always-On-Time Maintenance Plan (PMST) allows you to carry out scheduled inspections to avoid costly repairs.
2. Comply with Service Intervals
- Follow the manufacturer’s recommendations regarding service intervals.
- Keep a detailed maintenance record for each piece of equipment.
- Use original spare parts and consumables to prevent premature damage.
3. Remote Monitoring for Real-Time Supervision
- Implement remote monitoring systems to receive immediate alerts.
- Analyze operational trends to anticipate possible failures.
- Connect the compressor to a centralized management system to optimize performance.
With Cloudview, our remote monitoring system, you can supervise the condition of your compressors in real time and make timely decisions to prevent failures.
CONCLUSION
A poorly maintained air compressor can lead to high repair costs and costly downtime. Staying alert to warning signs and taking preventive action is the best strategy to ensure efficient operation and avoid production interruptions. By implementing proper maintenance, you can maximize the efficiency of your compressed air system and reduce operational costs.