Jan. 13, 2025
Air compressors are essential pieces of machinery used in a wide variety of industrial and commercial applications. Understanding the different types of air compressors and their average lifespan is important for businesses to ensure they get the most out of their investments.
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When it comes to industrial air compressors, the lifespan can vary greatly depending on the type and use of the compressor. Generally speaking, the average air compressor can last anywhere from five to twenty years with proper maintenance. Factors such as compressed air temperature, humidity, and usage affect how long an industrial air compressor lasts. With good care and regular maintenance, an air compressor system can provide reliable service for many years to come.
The life expectancy of an air compressor can vary depending on several factors. Some of the most critical factors are manufacturing quality, regular maintenance, and frequency of use.
Industrial air compressors made with high-quality materials and excellent manufacturing processes can last many years, even decades. On the other hand, poorly constructed compressors may have a shorter lifespan and require frequent repairs or replacements.
The frequency and intensity of use also play a significant role in determining the life expectancy of an air compressor. Reciprocating air compressors, for example, typically last around 50,000 hours or six years when running 24/7, while rotary screw air compressors usually last over ten years.
Additionally, the type of compressor and its intended use can impact its lifespan. For example, truck-mounted air compressors can last over 15 years if users focus on using a rotary screw air compressor. Therefore, it&#;s essential to consider the compressor&#;s intended use and choose a model that can handle the required workload to ensure a longer lifespan.
Maintenance and upkeep are also crucial factors that affect the life expectancy of an air compressor. Regular maintenance &#; such as air compressor testing, changing the oil, cleaning the air filters, and checking the belts and hoses &#; can help extend the equipment&#;s life. Neglecting maintenance can lead to premature wear and tear and ultimately shorten the compressor&#;s lifespan.
To increase the life expectancy of an industrial air compressor, it is important to perform regular air compressor audits and servicing. Here are some tips to increase the life expectancy of an air compressor system:
By following these tips, the life expectancy of an industrial air compressor can be significantly increased, saving money on air compressor repairs and replacements in the long run.
NiGen is the go-to source for all your air compressor needs. Our team of experts is experienced and knowledgeable in the field, and we can help you with any questions you may have about air compressors. From selection to installation to maintenance, we are here to provide you with the best advice and solutions for your project.
Air compressor life expectancy can vary greatly depending on how well the compressor is taken care of. As with most things, &#;an ounce of prevention&#; will go a long way toward avoiding expensive repairs, unexpected downtime, and early compressor failure. Handling day-to-day preventive maintenance, paying attention to compressor performance, and addressing developing issues promptly will go a long way towards extending the life span of your compressor.
The lifespan of an industrial air compressor can vary depending on several factors, such as the type of compressor, its usage, maintenance, and environmental conditions. Here are some estimates for air compressor life expectancy for different types of industrial air compressors.
If life expectancy is your primary consideration in air compressor selection, it&#;s hard to beat an oil-flooded rotary screw air compressor or rotary vane air compressor. These industrial air compressors are designed for long life and continuous use while also providing exceptional work efficiency. That&#;s why they are usually recommended for industrial applications where longevity and performance are critical.
It&#;s important to note that these are general estimates and air compressor life expectancy can vary depending on many factors, including the quality of the compressor, its usage, maintenance, and environmental conditions. Regular maintenance, including frequent inspections and proactive attention, can help extend the life of your compressor and maximize your investment.
You&#;ve made a sizable investment when you decided to buy an air compressor, so you&#;ll want to get the most life from it that is possible. Here are some simple air compressor tips and tricks that will help you achieve years of trouble-free operation.
It may seem obvious, but reading the manual for your air compressor is a small time investment with a big payoff. You&#;ll learn the maintenance schedule as well as operating guidelines for your compressor. With this information, you can extend the life of your equipment and minimize downtime.
For compressors that use oil, check the oil before every use. Operating with insufficient oil is a quick way to seriously damage your compressor. If oil levels are low, add more oil to top it off. (However, do not overfill &#; this may result in the air compressor &#;spitting&#; oil.)
Also, monitor the oil quality. If it is dirty or seems degraded, plan an oil change at the earliest opportunity. Oil should be changed for a rotary screw compressor at least annually or every 8,000 hours (every 3 months or 2,000 hours for food-grade compressor oil).
Read more: Air Compressor Oil Basics &#; What You Need to Know.
Keep your air intake clean, especially if your environment is dirty or dusty. Particulate from industrial processes, pollen and pollutants from the outdoors, and other indoor air contaminants (such as particulate from diesel engines) can build up on intake vents and filters. This will force your compressor to work harder and rob it of pressure. Cleaning out the intake vent and changing intake filters will reduce wear and tear on the compressor motor and extend its lifespan.
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This separator element needs to be replaced every 2,000-8,000 hours of use (depending upon the make and model of the compressor) and prevents excessive oil usage. Analysis has shown that compressor energy costs rise by 1% for each 2 PSI of separator pressure drop.
Vibration from compressor operation can loosen screws, nuts and bolts. Check them periodically and tighten anything that has wiggled loose. Also, listen to your compressor; excess noise or rattling may indicate that something is loose and needs to be tightened.
Inspect all of your air compressor&#;s hoses regularly because any cracks can lead to leaks, which in turn imposes strain on the compressor&#;s other components. Replace any hoses that are cracked or damaged.
Moisture inside the compressor can lead to corrosion, blockages in control lines, filter loading, and other problems within the compressed air system. Moisture is a natural result of compressing air; as air is squeezed into a smaller volume, excess moisture (i.e., humidity) is wrung out of the air like a sponge. As air cools in the aftercoolers, air receiver tank, and distribution system, more water will fall out as condensation. It is important to drain water from the air compressor and other system components, including receiver tanks and air dryers, to prevent problems with your system and keep moisture out of the final air supply.
An industrial air compressor may require several different types of filtration, including the oil filter, an intake filter to keep airborne contaminants out of the compressor, and inline filters to remove oil carryover, particulate, and moisture from compressed air.
Your manufacturer will specify acceptable operating ranges for your air compressor. Excessive heat will cause extraordinary wear and shorten oil life and your compressor&#;s longevity. To help with this, your compressor may have a built-in safety shutdown system if it gets too hot, so test this feature to make sure it&#;s functioning. To prevent air compressor overheating, you need to make sure you have ample space and ventilation around the compressor, keep the compressor and aftercoolers clean and free of grime and debris, and maintain filters. If your compressor is outdoors or in a room without air conditioning, make sure you take proper steps to prepare your air compressor for summer weather.
We can&#;t say it enough: unless you have an oil-free air compressor, lubrication is absolutely essential to the proper functioning and overall longevity of your compressor. Low oil, or degraded/contaminated oil, is the fastest way to kill an industrial air compressor.
Compressed air leaks can originate from lines, gaskets, fittings, valves, clamps, and connections. They can divert an estimated 25-30 percent of your compressed air, so check the entire system regularly. Ultrasonic leak detectors can be helpful. Most compressed air leaks occur in the &#;dirty 30&#;: the last 30 feet of hoses and couplings in between the compressor and the end use. The good news? Thanks to programs from your energy company, you may be able to get compressed air leaks fixed for free.
Keep your ears tuned for strange noises and watch for things like excessive vibration or belts that slip. Know what your compressor&#;s gauges should read when it&#;s operating normally. If you are monitoring your machine closely, you can prevent major damage.
It&#;s easier to avoid a problem than to fix it after the fact. Follow all recommendations for preventive maintenance, troubleshooting, and diagnostics in your user&#;s manual to reduce the likelihood of emergency repairs and downtime. Here is a handy air compressor maintenance checklist that will help you increase air compressor longevity and reduce potential problems.
If you do have a problem, or just notice that your compressor is behaving a little differently, don&#;t delay in scheduling an air compressor repair service. Air compressor problems almost never just go away on their own &#; if you are noticing an issue today, chances are it will only get worse with time. Without prompt compressor maintenance and repair, a small issue such as a faulty oil pump can quickly escalate into a catastrophic compressor failure. Emergency air compressor repair is expensive, as is unexpected downtime. In the worst case, delaying simple repairs may lead to an unplanned replacement of the entire compressor or an expensive air end rebuild.
For basic maintenance and repairs, it&#;s helpful to have a stock of common air compressor parts at hand, so you can make the replacement immediately. For an industrial air compressor, that may include hoses, filters, high-voltage fuses, ball valves, regulators, switches, and lubricators. Make sure you are using high-quality compressor replacement parts that are compatible with your make and model of air compressor.
Industrial air compressors are complex machines that require proper maintenance to ensure they work correctly and efficiently. Many standard daily and weekly preventive maintenance or minor repair tasks can be done safely in-house. However, if you are experiencing a more complex issue that requires expert troubleshooting and major repair, it is usually best to call the professionals.
An experienced compressor technician can diagnose and repair the problem quickly and correctly, extending the life of your air compressor and ensuring optimal performance. Call a professional if:
If you are facing extensive repairs and a hefty repair bill, you may be wondering if it&#;s worth it to extend your compressor life or if it&#;s better to bite the bullet and buy new ones. If your air compressor has failed, you&#;ll need to look at the total cost of repair and evaluate how much more life the repair will give your compressor.
Read more: Should I Repair or Replace My Air Compressor?
The experienced compressor service and repair technicians at Fluid-Aire Dynamics are here to help you with preventive maintenance, troubleshooting, diagnostics, and repair for your industrial rotary screw, rotary vane, or reciprocating air compressor. We service industrial air compressors of all makes and models. We&#;ll help you extend the life of your air compressor and ensure optimal compressor performance.
We also offer the best air compressor extended warranty in the business. Our Extend-Aire Warranty Protection Program extends your compressor warranty to 20 years or 80,000 hours &#; even if we didn&#;t sell it to you originally! The Extend-Aire program is available for any make or model of oil-flooded rotary screw or rotary vane industrial air compressor. Contact us to see if you are eligible.
If you have additional questions, contact us online or call us to talk to an expert.
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