Compressor Servicing FAQs

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 burner
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 questions we’ve found are the most frequently asked

Servicing & Replacement:

Usually, maintenance and service intervals will depend on the operating time and hours of your compressor. However, even if your air compressor doesn’t reach its operating hours within a 6 to 12 month period, or until the next recurring maintenance, it will need a service. This is down to wearing filters, oil and parts, which are subject to a sustained ageing process. To ensure operational safety and trouble-free operation, it’s recommended to observe the specified maintenance intervals depending on the type of facility. The absolute minimum interval is once a year.

This completely depends on the type and function of the filter element and the environment and ambient conditions of the installation. Generally speaking, though, all filter elements should be changed at least every 12 months.

Regular replacement of any filter element, regardless of its type or function, is critical to reducing pressure drops and energy costs and ensuring the continuous delivery of high-quality air to the correct standard required.

An oil change goes hand in hand with recurring maintenance. However, this answer is entirely dependent on what type of compressor oil you use. Typically, mineral oil should be changed every 4,000 operating hours, whereas synthetic oils can last twice as long. Here, you also need to consider suction conditions and installation as these factors may influence oil change intervals. If you are unsure, it's recommended to have a laboratory oil analysis, which checks the oil condition.

In principle, the compressor oil approved by the plant manufacturer is the ideal choice. In oil-lubricated systems, compressor oil is of great importance and must cool, compress, and lubricate. It also needs to be separable again afterwards. Depending on your application, mineral, synthetic, or food grade oils can be used.

On an oil-lubricated compressor, the compressor airend is often subject to bearing wear due to its design. The bearing manufacturers specify a running performance of around 35,000 hours. Once they have reached this number of operating hours, we’d recommend a preventative exchange of bearings.

Operating hours is the significant factor that contributes to the service life of a compressor, rather than its year of manufacture. Therefore, it’s hard to quantify a service life. Due to technical progress and subsidy programmes, it should instead be quantified whether an economic or ecological value can be created by replacing older compressed air equipment. This value may be otherwise achieved by modifying existing compressors, for example, by replacing energy-efficient electric motors, or by retrofitting heat recovery systems.

Air Compressor Testing:

The Ordinance on Industrial Safety and Health (BetrSichV) regulates recurrent pressure vessel inspections. This specifies that a visual inspection should be performed every 5 years and a pressure test every 10. This could vary in different regions and countries – please check local requirements.

If the pressure volume product is less than 1000L (maximum permissible pressure of the tank x tank volume < 1000L), this test can be performed by a competent person.

If the volume is over > 1000L, the test must be carried out by an expert from an approved inspection body (ZÜS), such as TÜV or DEKRA.

Servicing Agreements & Monitoring:

Every individual compressed air system has its own bespoke features and requirements. It is possible to obtain a service agreement for all of these features and requirements, and determine the scope of the servicing agreement yourself. In this way, together, we can ensure that operational costs and reliability are guaranteed.

For all of our compressors, we offer the Helix™ Connected Platform as a standard feature on new models and a potentially retrofitted addition to older systems. Helix™ monitors the operating conditions of your compressors, thus enabling 24/7 monitoring of your compressed air system.

General Questions:

Compressor tanks heat up because compression generates heat. When air is compressed, both the air and the oil inside the compressor increase in temperature, which in turn heats the tank. This is a natural by-product of the compression process.

The airflow through a pipe depends on several factors: pipe diameter, material, operating pressure, length of the pipe, and the temperature and humidity of the air. For precise specifications, consult the pipe manufacturer or compressor guidelines.

Yes, compressed air can be dangerous. Even high-quality compressors can fail if improperly maintained or used. Since the air is under high pressure, defects may cause sudden decompression or rupture. Always follow safety guidelines.

Welding an air compressor tank must only be done by an ASME-certified welder. All pressure vessels from certified manufacturers require specialized procedures to ensure safety. Unauthorized welding can compromise the tank’s integrity.

Electric compressors do not produce carbon monoxide. Gas-powered compressors can produce carbon monoxide. Even electric compressors can compress ambient air containing carbon monoxide, so ensure proper ventilation and safety compliance.

Yes. A tank filled with compressed air weighs slightly more than an empty one due to the mass of the compressed air. Never work on or move a compressor connected to power or under pressure.

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