To maximize operational effectiveness and energy efficiency while protecting your compressor from damage, have your compressor cleaned, checked and/or repaired on a regular schedule. With proper maintenance, compressors operate smoothly for years but, like all equipment, there can be the occasional problem. Knowing how to troubleshoot your compressor is an essential skill.
What is a Compressor?
In the oil and gas industry, a compressor is a mechanical device that reduces the volume of a liquid or gas to increase its pressure. It’s used at processing plants, field nodes and inlets of the pipeline. Hydraulic compressors are powerful and lightweight deck-mounted compressors used for low volume and high differential pressure applications such as vapour recovery, gas well boosting and casing gas. Reciprocating compressors are widely used in the chemical, oil, and gas industries for moving compressible fluids reliably. Rotary vane compressors serve in a variety of welding operations, in the use of air-operated metal and woodworking tools, in cylinders used in paper pressing, in many industrial cooling operations, in the agricultural industry, in material handling operations, in printing pumps/equipment and more.
Troubleshooting rotary vane compressors:
Keep in mind that isolating the cause of a complex system failure in a rotary vane compressor may require professional assessment and assistance. However, the following guide may help with common operational problems.
- Problem: Your compressor won’t start.
- Solution: Check the power supply and check the compressor display to see if there is an error code. Make sure the emergency stop function is not activated. Check to see if the system pressure is above the cut-in point on the pressure switch. Ensure both oil volume and temperature are at appropriate levels by checking safety switches and oil levels.
- Problem: Your compressor shuts down unexpectedly.
- Solution: Unexpected shutdowns are often due to overheating. Assess your temperature sensors. Check your thermostatic valve for issues and evaluate your compressor cooler device for functionality problems or a build-up of dust and dirt.
- Problem: Your compressor is producing unusual noises.
- Solution: Look for loose bolts, belts, pulleys and/or damaged flexible coupling elements. If the sound is coming from the machine itself, assess the oil level and the condition of the oil. If the sound is changed in response to changing oil levels, confirm that inlet and outlet valves are working properly.
- Problem: There’s oil in your compressed air.
- Solution: Check to ensure that oil return/scavenger lines are functioning. Always monitor oil levels. Check that you are using the correct oil and check the viscosity of your oil. If your oil is of relatively low viscosity, high heat levels can exacerbate the problem.
- Problem: Your compressor’s temperature is higher than recommended.
- Solution: Check oil level and refill if needed. Check the system’s air and water flow for potential restrictions. If the machine is air-cooled, check that the ambient temperature is within the recommended range and that there is proper ventilation.
- Problem: Excessive amounts of water in your compressed airline.
- Solution: Examine your automatic drain trap mechanisms for blockages. Drain your air receiver by hand. Install a moisture separator in your airline to reduce potential issues.
- Problem: Your air pressure drops when using pneumatic tools.
- Solution: Survey filter elements for damage or clogging. Examine piping, valves and lines for potential leaks. Ensure the diameters of your hose and the quick-disconnect bore are suitable for your airflow needs.
To avoid problems with your rotary vane compressor, invest in a quality compressor unit designed with high-performance output and durability in mind and hire a competent company to provide qualified service technicians for inspection and service of your compressor units.
Troubleshooting rotary screw compressors:
Keep in mind that isolating the cause of a complex system failure in a rotary screw compressor may require professional assessment and assistance. However, the following guide may help with common operational problems.
- Problem: The compressor won’t start.
- Solution: Check the power supply for adequate voltage. Check fuses. Make sure power wires are tight. Check the temperature switch and system pressure.
- Problem: Compressor starts then stalls.
- Solution: Check for adequate breaker and wire size. Inspect check valve for proper operation. Tighten belts. Check oil level.
- Problem: Low discharge pressure.
- Solution: Tighten compressor belts to the manufacturer’s recommended specifications. Check voltage supply.
- Problem: The compressor does not build up pressure.
- Solution: Find and fix air leaks. Check the inlet valve for proper function. Check pressure switch setting. Check solenoid for proper function.
- Problem: Compressor will not load to compress air.
- Solution: Check the pressure switch for the proper setting. Check the inlet valve and solenoid for proper function.
- Problem: Excessive oil consumption.
- Solution: Check the sump for proper oil level. Check lines for cracks. Replace separator. Add a timer.
- Problem: High-temperature shutdown
- Solution: Lower ambient temperature. Check for proper oil level. Replace the oil filter and clean the oil cooler. Check thermal bypass and temperature switch for proper operation.
To avoid problems with your rotary screw compressor, invest in a quality compressor unit designed with high-performance output and durability in mind and hire a competent company to provide qualified service technicians for inspection and service of your compressor units.
Troubleshooting reciprocating compressors:
Keep in mind that isolating the cause of a complex system failure in a reciprocating compressor may require professional assessment and assistance. However, the following guide may help with common operational problems.
- Problem: The breaker trips.
- Solution: Check incoming power wire size. Check that you’re using a dedicated circuit. Adjust belt tension. Check wire connections. Inspect transfer tubes and check valves.
- Problem: Compressor stalls.
- Solution: Check compressor power supply for adequate breaker and wire size. Inspect check valve for proper operation and tighten belts. Check compressor for proper oil level.
- Problem: Low discharge pressure
- Solution: Tighten and/or replace leaky fittings and/or joints. Clean and/or replace the air filter.
- Problem: Compressor Pump Knocking
- Solution: Tighten pulley/flywheel. Keep oil at the recommended level. Use recommended oil.
- Problem: Excessive oil discharge in the air.
- Solution: Clean or replace air filters. Reduce oil level and reduce compressor duty cycle. Repair leaks or add another unit to handle the demand.
- Problem: Compressor overheating.
- Solution: Relocate the compressor to an area with better ventilation. Clean all cooking surfaces. Reduce compressor duty cycle (repair leaks or add another unit to handle the excess demand).
- Problem: Excessive belt wear.
- Solution: Realign the pulley with the flywheel and readjust the belt.
- Problem: The compressor won’t start in cold weather.
- Solution: Use compressor oil intended for cold weather conditions. Move the compressor to a warmer location. Use a heat lamp near the compressor.
- Problem: Compressor motor hums – won’t start.
- Solution: Reset the breaker or replace the fuse. Inspect the check valve. Check power wires leading to solid connections. Replace the starter and pressure switch.
- Problem: The unit has power but won’t run.
- Solution: Reset starter or replace starter and pressure switch. Check for proper oil levels. Replace the motor or pump.
To avoid problems with your reciprocating compressor, invest in a quality compressor unit designed with high-performance output and durability in mind and hire a competent company to provide qualified service technicians for inspection and service of your compressor units.
How to avoid compressor problems:
A few simple steps can reduce compressor system issues and increase the longevity of your compressor. Prevent system failure by taking the following steps:
- Follow specifications: The most common issues trace back to incompatible or improperly installed parts. It’s essential to double-check specifications to ensure purchased parts can work together seamlessly.
- Consult with professionals: When purchasing new equipment, consult with industry peers and professionals. They can provide concrete examples of how well the equipment works for your industry.
- Perform maintenance: Review your daily, monthly and annual maintenance procedures to ensure you are covering every aspect of your system according to best maintenance practices. Hire a competent company to provide qualified service technicians for inspection and service of your compressor units.
Gaspro Compression Corp has qualified service technicians to inspect and service all compressor units. We rebuild many types of compressors, not limited to the oil and gas industry. Our fully stocked service trucks handle all our clients’ needs. We take pride in our work. We strive to provide dependable products and prompt service to all clients. We’re continually improving and innovating our products to meet changing industry demands. Gaspro is a leading provider of compressor packages in Canada. Contact us to request a proposal.
