The most common compressor problems and how to avoid them

Compressors are the heart of many industrial installations - from garages to large manufacturing plants. However, even the best compressor can fail if it is not properly operated and serviced. In this article we discuss the most common compressor problems and we suggest how to prevent them effectively.

1. compressor overheating

Symptoms:

• frequent emergency shutdown,
• high housing temperature,
• performance loss.

Causes:

• dirty air filter,
• insufficient ventilation of the room,
• oil pressure too low or oil contamination.

How to avoid it?

• Clean and replace filters regularly,
• ensure adequate air flow around the compressor,
• check the oil level and quality.

2. Pressure drop in the system

Symptoms:

• compressor works longer than usual,
• pneumatic tools lose power,
• air noise can be heard in the installation.

Causes:

• leaks in the pipes,
• worn valves or seals,
• Incorrectly sized cables.

How to avoid it?

• perform periodic leakage tests,
• use good quality cables and connectors,
• match the diameter of the pipes to the capacity of the compressor.

3. excessive oil consumption

Symptoms:

• frequent topping up of oil,
• oil in the condensate,
• dirty installation components.

Causes:

• leaks in the lubrication system,
• worn seals,
• unsuitable oil type.

How to avoid it?

• use the oil recommended by the manufacturer,
• monitor the condition of the oil-air separator,
• react to the first signs of increased wear.

4. high noise and vibration levels

Symptoms:

• noisier than usual,
• vibrations transmitted to the ground,
• faster bearing wear.

Causes:

• loose fasteners,
• damaged bearings,
• unbalanced rotating components.

How to avoid it?

• check the tightness of bolts and fixings,
• carry out regular inspections of the bearings,
• use vibration dampers and anti-vibration mats.

5. too much condensate in the system

Symptoms:

• water in pipes and tools,
• corrosion of plant components,
• decline in air quality.

Causes:

• missing or faulty dehumidification system,
• ineffective condensate drain,
• poorly matched oil/water separator.

How to avoid it?

• install compressed air dryer appropriate to the compressor performance,
• Check dehydrators regularly,
• use separators as required by the installation.

Summary

Compressor failure does not only mean repair costs, but also downtime for the entire plant. That is why it is worth knowing the most common compressor problems and eliminate them at an early stage. Regular maintenance, the correct choice of accessories and a rapid response to the first signs of irregularity can significantly extend the life of a compressor.

👉 Contact the experts at Marani - we can advise you on how to choose a compressor and air treatment system so that your installation will run trouble-free for years.