Taking The Guesswork Out Of Compressor Servicing

• We understand that the running of your facility and operations will take precedence, often resulting in air compressor servicing taking a back seat.
• This is why Ingersoll Rand aims to provide you with all the information and support you need to take the guesswork out of compressor servicing.
• To offer you complete peace of mind, below are some of the most frequently asked questions.

Servicing & Replacement:

How often should you service your air compressors?

Maintenance and service intervals depend on the operating time and hours of your compressor. However, even if your compressor doesn’t reach its operating hours within a   6–12 month period, it still requires servicing due to the natural ageing of filters, oil, and parts. To ensure operational safety and reliability, follow the specified maintenance intervals — at least once a year.

How often should you change your compressed air filters?

This depends on the type, function, and installation environment. Generally, all filter elements should be changed at least every 12 months.

Why is it important to regularly replace your filter elements?

Regular filter replacement reduces pressure drops, lowers energy costs, and ensures consistent air quality as per required standards.

How often should your compressor oil be changed?

Oil change intervals depend on oil type. Mineral oils should be changed every 4,000 operating hours, while synthetic oils can last twice as long. Conditions and installation factors may influence this — consider a lab oil analysis for precise monitoring.

What type of compressor oil should you use?

Always use the oil approved by your compressor’s manufacturer. Depending on the application, mineral, synthetic, or food-grade oils may be used.

When does the compressor airend need replacing?

On oil-lubricated compressors, airends often require bearing replacement after around 35,000 hours of operation. Preventative replacement at this point helps avoid costly downtime.

What is the lifetime of a compressor and how can you extend it?

Compressor life depends on operating hours, not age. Upgrading components such as motors or adding heat recovery systems can extend efficiency and lifespan while reducing operational costs.

Air Compressor Testing:

When do you need to carry out a pressure vessel test?

According to the Ordinance on Industrial Safety and Health (BetrSichV), visual inspections must be performed every 5 years and pressure tests every 10 years. Requirements may vary by region, so check local regulations.

For tanks with a pressure-volume product under 1000L, a competent person can perform the test. For those over 1000L, an approved inspection body (e.g., TÜV or DEKRA) must carry it out.

Servicing Agreements & Monitoring:

Can you conclude a special service agreement for your air compressor?

Yes. Each compressed air system has unique needs, and custom service agreements can be designed to ensure consistent performance, cost control, and reliability.

Is there a monitoring system available for compressors?

Yes. The Helix™ Connected Platform is standard on new Ingersoll Rand models and can be retrofitted to older systems. It provides 24/7 remote monitoring of operating conditions.

Energy Saving:

Can you retrofit a heat recovery system to old compressors?

Yes. Heat recovery enables repurposing of heat from compression for energy savings. However, the retrofit design must be approved for safety and efficiency.

Does it make sense to switch off your refrigerated dryer after production?

While turning off idle equipment saves energy, refrigerated dryers require a pre-cooling phase before resuming operation. Turn them on about 30 minutes before compressors start, or leave them on if pre-start isn’t possible, as restarting costs may exceed savings.

General Questions:

Why does your compressor tank heat up?

Heat generation is a natural by-product of the compression process. The oil, air, and tank absorb heat during operation.

How much compressed air can flow through a pipe?

This depends on factors like pressure, pipe diameter, and materials. Refer to Ingersoll Rand or manufacturer specifications for accurate data.

Can air compressors explode?

Compressed air can be hazardous if misused or poorly maintained. Always follow safety procedures, as defects or misuse can cause sudden decompression.

Can the container of an air compressor be welded?

Only ASME-certified welders should perform any welding on compressor vessels to maintain certification and safety standards.

Does air compressor operation produce carbon monoxide?

Electric compressors do not generate CO, but they can intake CO from the surrounding environment. Always ensure proper ventilation and adherence to safety standards.

Does an air compressor filled with compressed air weigh more?

Yes, compressed air adds weight. Never attempt to move or work on a pressurised or connected system.

Any other questions? Please contact us, and one of our experts will be happy to help.