As a key power equipment in industrial production, the stable operation of air compressors directly affects production efficiency and costs. Timely identification of when equipment needs repair can effectively avoid shutdown losses caused by sudden failures. Below is a summary of criteria for judging air compressor repairs from multiple dimensions to assist enterprises in efficient operation and maintenance.
1. Abnormal Operating Sounds: Alert for Internal Faults
Metallic friction noises
Sharp, harsh metallic friction sounds during operation may result from rotor-housing wear, bearing damage, or poor gear meshing. For example, excessive clearance between male and female rotors in screw compressors causes obvious impact noises, requiring immediate shutdown for inspection.
Abnormal vibration and noise
Increased overall vibration during operation, accompanied by periodic “clacking” sounds, may indicate loose anchor bolts, unbalanced pulleys, or loose internal components. Delayed handling accelerates component wear and even risks equipment tipping.
2. Performance Decline: A Key Signal of Insufficient Efficiency
Unstable discharge pressure
Sustained discharge pressure below set values or frequent fluctuations may stem from intake valve failure, internal rotor leakage, or a clogged oil-gas separator. For instance, a clogged intake filter restricts air intake, preventing pressure from reaching standards.
Insufficient air output
Significant reduction in exhaust volume under the same conditions may be caused by rotor wear, loose belts (belt-driven models), or solenoid valve faults. Untreated, this affects the normal operation of pneumatic equipment on production lines.
Excessively high oil temperature
Normal operating oil temperature is generally 60-85°C. Sustained temperatures exceeding 90°C with no improvement may result from a clogged oil cooler, failed temperature control valve, or deteriorated lubricating oil. Long-term high temperatures accelerate oil oxidation, leading to severe faults like coking or seizing.
3. Abnormal Appearance and Oil Condition: Intuitive Judgment Bases
Oil or air leaks
Visible oil stains on equipment surfaces or hissing air leak sounds may indicate aging seals, damaged pipelines, or loose joints. For example, oil leaks at oil separator tank welds require checks for welding quality or corrosion; air leaks at connections waste compressed air and increase operating costs.
Deteriorated oil condition
Regular oil inspections: if oil turns black, turbid, has a pungent odor, or shows emulsification (moisture mixed in oil), it indicates severe oil deterioration. Immediate replacement is needed, along with checks for internal component wear or cooler leaks.
4. Abnormal Instrument Data: Early Warnings from Monitoring
Excessive current fluctuations
Current exceeding rated values or frequent fluctuations may result from motor failure, unstable power supply voltage, or overload. Long-term overload operation can burn out the motor, requiring prompt root cause detection.
Pressure and temperature sensor alarms
Modern compressors feature intelligent monitoring systems. Persistent sensor alarms, even if the equipment still runs, demand immediate shutdown checks to avoid real faults being masked by false alarms.
5. Maintenance Cycles and Historical Faults: References for Preventive Repair
Overdue maintenance
Failure to replace key components (e.g., air filter element, oil filter, oil-gas separator) at specified intervals (e.g., every 2000 hours) or neglecting oil replenishment/replacement accelerates equipment aging. Even without obvious faults, comprehensive maintenance is needed promptly.
Recurring similar faults
Frequent failures of components (e.g., intake valves, temperature control valves) may indicate improper selection, incorrect installation, or systemic issues. In-depth analysis of root causes is required to avoid superficial fixes.
Summary
Judging if an air compressor needs repair requires comprehensive observation of operating sounds, performance indicators, appearance, instrument data, and maintenance records. Enterprises can establish an equipment inspection checklist, record key parameters daily, and combine regular inspections by professionals to detect and address faults early. If in doubt about equipment condition, contact professional air compressor repair teams for comprehensive testing to ensure safe and efficient operation.
Post time: Jul-16-2025
