The compressed air system plays a key role in every production line. However, over time, technical faults frequently appear, not only causing energy waste but also reducing efficiency and even damaging end-use equipment. In this article, Quoc Thinh Industrial will analyze in detail the 4 most common issues and provide definitive troubleshooting solutions.

1. Compressed Air Leakage (Air Leakage)

Leakage is the number one energy waste issue in any compressed air system. It is estimated that leaks can account for 20% to 30% of the total compressed air produced. This is the "silent thief" that increases electricity costs and forces the air compressor to run more than necessary.

Causes:

• Worn or loose fittings, quick couplings.
• Gaskets, seals at control valves, and cylinders are hardened or damaged.
• Improper piping installation, unsealed welds or threads.

Definitive Solutions:

1. Perform regular leak checks: Use a specialized Ultrasonic Leak Detector to pinpoint the exact leak location, even in noisy areas.
2. Replace weak points: Prioritize replacing old quick-connect fittings with high-quality types that offer better sealing.
3. Comprehensive maintenance: Schedule periodic replacement of gaskets/seals, and check/tighten bolts at flanges.

2. Unstable System Pressure Error

Unstable pressure (too high or pressure drop) directly affects product quality and equipment lifespan. Pressure drop can slow down production, while excessively high pressure wastes electricity and increases the compressor load.

Causes:

• Pressure loss: Piping is too small, air filter is dirty, or the pipe run is too long with many sharp bends.
• Control valve malfunction: Minimum pressure valve or Load/Unload Valve operating inaccurately.
• Fluctuating demand: The system is not equipped with a Variable Speed Drive (VSD) air compressor, leading to an inability to promptly meet sudden changes in air demand.

Definitive Solutions:

Consider installing a VSD (Variable Speed Drive) air compressor so the machine can flexibly adjust the motor speed, maintaining stable pressure within the narrowest possible range, thereby optimizing electricity consumption.

3. High Air Compressor Temperature Error (High Temperature)

Operating temperature exceeding the safety limit (usually above 105°C to 110°C for oil-flooded screw compressors) can cause an emergency trip, damage lubricating oil, and shorten the lifespan of internal components.

Causes:

• Poor cooling: The cooler (radiator) is dirty, clogged, or the cooling fan is weak/broken.
• Installation environment: Compressor room is too hot, poorly ventilated, or the machine is placed too close to walls/other machinery.
• Oil level/Quality: Low lubricating oil level or use of poor quality oil that has degraded due to heat.
• Clogged oil filter: Reduces oil flow through the oil cooler.

Definitive Solutions:

1. Periodic cleaning: Regularly clean the exterior (blow away dust, oil) and interior (solution washing) of the oil and air coolers.
2. Improve ventilation: Install industrial ventilation ducts and exhaust fans to ensure cool air circulates continuously.
3. Use genuine oil: Ensure the air compressor oil is replaced with the correct type and according to the recommended timeframe.

4. Substandard Compressed Air Quality Error

Compressed air containing moisture, oil, and particulates is the main cause of damage to end-use equipment such as cylinders, valves, paint spray guns, and reduces product quality (especially in the food and pharmaceutical industries).

Causes:

• Air dryer failure: Dryer is operating inefficiently or capacity is insufficient to remove moisture.
• Oil/Fine Filters: Filters have not been replaced in time, allowing oil and particulates to enter the system.
• Drainage point: Automatic drain trap is clogged or broken, causing condensed water to accumulate in the receiver tank.

Definitive Solutions:

1. Check and replace the dryer: Ensure the air dryer's Dew Point meets the required standard for your application.
2. Adhere to replacement schedule: Replace the filter elements (coarse filter, fine filter, super-fine filter) and oil filter elements strictly according to the machine's running hours.
3. Automatic draining: Inspect and maintain/replace the Auto Drain Valves to ensure condensate is effectively discharged, preventing accumulation in the receiver tank and piping.

Conclusion

Managing and maintaining a compressed air system requires attention to every small detail. By focusing on resolving the 4 common errors above – Leakage, Pressure, Temperature, and Air Quality – businesses can not only save a huge amount on electricity costs but also ensure production runs continuously, stably, and achieves high quality.

If you encounter any complex issues, do not hesitate to contact the technical team at Quoc Thinh Industrial for professional consultation and support.