Air compressor troubleshooting

In a compressed air system, as in any plant system, problems occur during routine operation. Most of these problems are minor and can be corrected by simple adjustments, cleaning or replacing a part, or eliminating an adverse condition. Any major problem that may develop is generally related to improper cooling or lubrication, poor maintenance and operating practices, or misapplying the system.

The troubleshooting table below is not comprehensive, but indicates some common problems that can develop in a compressed air system using positive displacement compressors.

Troubleshooting compressed air systems
Problem	Probable cause	Remedial action
Low pressure at point of use	Leaks in distribution piping	Check lines, connections, and valves for leaks
	Clogged filter elements	Clean or replace filter elements
	Fouled dryer heat exchanger	Clean heat exchanger
	Low pressure at compressor discharge	See below
Low pressure at compressor discharge	For systems with modulating load controls, improper adjustments f air capacity control	Follow manufacturer's recommendation for adjustment of control
	Worn or broken valves	Check valves and repair or replace as required
	Improper air pressure switch setting	Follow manufacturer's recommendation for setting air pressure switch
Water in lines	Faulty air/oil separation	Check air/oil separation system; change separator element
Water in lines	Failed or undersized compressed air dryer	Follow manufacturer's recommendation for proper oil level
Dirt, rust, or scale in air lines	In the absence of liquid water, normal aging of the air lines	Install filters at the point of use
Excessive service to load/hour ratio	System idling too much	For multiple compressor systems, consider sequencing controls to minimize compressor idle time; adjust idle time according to manufacturer's recommendation
Excessive service to load/hour ratio	Improper pressure switch setting	Readjust according to manufacturer's recommendation
Elevated compressor temperature	Restricted air flow	Clean cooler exterior and check inlet filter mats
	Restricted water flow	Check water flow, pressure, and quality; clean heat exchanger as needed
	Restricted fluid flow	Check compressor fluid level, add fluid as required
	Low fluid level	Remove restriction, replace parts as required
	Excessive ambient temperature	Improper ventilation of compressor; check with manufacturer to determine maximum operating temperature