How to Solve Air Leakage and Pressure Drop in Air Compressors?

I. Air Leakage in Pipes, Hoses, and Connections (Most Common)

1. Causes

• Seals (O-rings, flat gaskets) for pipe/hose connections are aged, cracked, or not properly compressed during installation;
• Steel pipe/hose connections are loose (thread loosening caused by vibration), or hoses are aged, damaged, or have cracked interfaces.

2. Solutions

• Apply soapy water to the connection area; bubbling areas indicate leak points;
• For loose connections: First relieve pressure, then tighten with a wrench. If leakage persists, replace the seals;
• For damaged hoses: Directly replace with high-pressure hoses of the same specification (ensure pressure rating matches, e.g., 1.6MPa and above);
• For leaking steel pipe interfaces: Check if threads are stripped. If stripped, replace the connector, wrap PTFE tape (thread seal tape) again, and reinstall.

II. Air Leakage in Valves

1. Causes

• The valve core of the safety valve is worn, jammed by impurities, or the spring is failed, resulting in poor sealing;
• The sealing surface of the valve core in pressure switch valves or check valves is worn, or the valve is blocked by carbon deposits, preventing complete closure.

2. Solutions

• For leaking safety valves: First relieve pressure, disassemble the valve to clean the valve core. If wear is severe, replace with a safety valve of the same model (regular calibration is required to ensure the set pressure complies with regulations);
• For leaking pressure switch valves/check valves: Disassemble the valve, polish the sealing surface with fine sandpaper, and remove carbon deposits. If leakage persists, replace the valve core or the entire valve.

III. Air Leakage in Air Receivers

1. Causes

• Corrosion occurs at the welds of the air receiver (long-term failure to drain water leads to rust caused by moisture);
• The seal of the bottom drain valve of the air receiver is aged, or the valve is not fully closed.

2. Solutions

• For leaking welds: If the leak point is small, temporarily repair it with epoxy resin; if corrosion is severe, replace with a compliant air receiver (do not continue using the old one to avoid explosion risks);
• For leaking drain valves: Close the main valve to relieve pressure, then tighten the valve or replace the drain valve gasket. Drain water 1-2 times a week regularly to reduce moisture accumulation.

IV. Air Leakage in the Air Compressor Body Seals

1. Causes

• The gasket between the cylinder head and cylinder block is aged or damaged, causing compressed air to leak through the gap;
• The piston rings are worn or broken, or the cylinder wall is scratched, leading to air leakage through the gap between the piston and the cylinder wall.

2. Solutions

• For leaking cylinder head gaskets: Cut off power and relieve pressure, then disassemble the cylinder head, replace with a high-temperature resistant gasket of the same specification, and tighten the bolts evenly during reinstallation;
• For leaking piston rings/cylinder walls: Disassemble the air compressor body and check the wear of the piston rings (replace if the opening gap exceeds 0.5mm). If the cylinder wall is scratched, bore the cylinder or replace the cylinder liner. Professional technicians are recommended for this repair.

Precautions for Leakage Inspection

1. Before inspection, must turn off the air compressor power and open the pressure relief valve to empty the air in the receiver to avoid high-pressure injury;
2. Prioritize using the “soapy water test method” to locate leak points, as it is accurate and efficient;
3. Inspect the tightness of pipes and valves regularly (monthly), and replace vulnerable seals quarterly to reduce leakage losses (air leakage will cause the air compressor to load frequently, increasing energy consumption).