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Low Hour Compressors Still Need Regular Servicing
A Perth business contacted Nessco Pressure Systems after its rotary screw compressor broke down.
NPS had not previously serviced the compressor and, despite its relatively low operating hours, the unit had not received regular scheduled maintenance.
When our technician inspected the compressor, we found moisture inside the unit had contributed to damage to the rotors and bearings.
The compressor hadn’t accumulated high operating hours. But in this case, low usage was part of the problem rather than a reason to delay servicing.
What caused the problem?
The business only operated the compressor when compressed air was required and switched it off between periods of use.
During short or infrequent operating cycles, a rotary screw compressor may not reach and maintain its normal operating temperature for long enough to manage moisture effectively.
Atmospheric air naturally contains water vapour. Your compressor draws that moisture into the system along with the surrounding air.
When operating conditions allow moisture to condense inside the compressor, water can accumulate in the oil and around internal parts.
If the compressor then sits unused for extended periods, that moisture can remain in contact with internal surfaces and contribute to corrosion and deterioration.
Low hours don’t always mean low maintenance
It’s easy to assume a compressor with low operating hours doesn’t need servicing yet.
However, compressor maintenance isn’t always based on operating hours alone.
Manufacturers may specify maintenance requirements based on operating hours or time intervals, whichever comes first. Oil, filters and other service items can still deteriorate over time, even when the compressor runs relatively infrequently.
Operating conditions also make a difference. Short run times, moisture, heat, dust and the compressor’s working environment can all influence maintenance requirements.
This is why the service schedule should reflect the manufacturer’s recommendations and how the compressor actually operates.
What about the dryer and drains?
Compressed air systems use equipment such as dryers, filters, air receivers and drains to manage moisture after the air leaves the compressor.
A refrigerated dryer, for example, cools compressed air so water vapour condenses and can be separated and drained from the system.
But downstream air treatment doesn’t prevent every moisture-related issue inside the compressor itself.
If operating conditions allow condensation to form internally, regular servicing gives technicians an opportunity to identify signs of moisture or oil deterioration before they contribute to more serious damage.
What happened to this compressor?
By the time NPS attended the breakdown, moisture had already contributed to damage within the compressor.
The unit required multiple replacement parts to return it to operation. The resulting repair cost was considerably higher than the cost of routine servicing would have been.
The important lesson wasn’t simply that the compressor needed to run more often. It was that low operating hours shouldn’t be used as the only measure of when a compressor needs attention.
When was your compressor last serviced?
Regular compressor servicing gives our technicians an opportunity to check the condition of the oil, filters and other service items and identify signs of wear, moisture or deterioration.
If your compressor only operates occasionally, check the manufacturer’s maintenance schedule rather than assuming low hours mean servicing can wait.
Not sure when your compressor is due? Call the Nessco Pressure Systems service team on 1300 290 638 or email us to discuss your compressor and servicing requirements.
