A compressed air system is a significant asset in many industries, and like any critical machine, its performance and longevity depend heavily on how it is treated every single day. Implementing a brief, non-negotiable set of daily operating rituals is the easiest way to detect minor issues before they become expensive failures, guaranteeing consistent uptime.
These simple checks will only take a few minutes each day, but provide priceless peace of mind.
One of the most common operational errors is misusing the machine's shutdown procedure, particularly using the Emergency Stop (E-Stop) button for routine power-down.
The Emergency Stop Button: The E-Stop button is a critical safety device designed to immediately cut all power and shut down the machine in a genuine emergency (e.g., fire, severe mechanical failure, safety hazard). Using it for a standard stop forces the compressor to power off abruptly, preventing it from completing its crucial internal shutdown sequence. This can cause the rotors to decelerate without proper lubrication or cooling, potentially damaging bearings, motors, and other vital components.
The Proper Shutdown: Modern rotary screw compressors feature intelligent controllers (like the KAESER Sigma Control 2) that initiate a specific shutdown sequence. When you press the standard STOP button, the compressor often runs for a brief period—usually unloaded—to cool down the air end, release pressure, and ensure all components are returned to a ready-state before power-off. This controlled cool-down is essential for preventing thermal stress and maximising component life.
Looking and listening to your compressor - this simple step can save you time and money. Before starting the machine and during operation, perform a simple walk-around:
Listen for Irregular Noise: Compressors have a distinct operating sound. Be alert for any changes: rattling, grinding, pulsing, or a sudden increase in noise. These often indicate a failing bearing, a loose coupling, or excessive vibration.
Look for Leaks: Visually inspect all hoses, pipes, and fittings for signs of oil or water leaks. Even a small oil leak can indicate a potential problem with a seal or gasket.
Check the Control Panel: Before startup, ensure the controller displays a normal status. During operation, routinely check the operating pressure and temperature readouts. Sudden spikes in temperature (high discharge temperature) are the number one warning sign of restricted cooling or poor ventilation.
For oil-injected compressors, the correct oil level is essential for cooling, sealing, and lubricating the air end.
Routine Check: Check the oil sight glass or dipstick daily. The check should be done when the compressor is stopped and depressurised. Consult your manual for the exact procedure specific to your machine.
Maintaining Level: If the level is low, top up immediately using only the manufacturer-specified lubricant (e.g., genuine KAESER fluid). Using incorrect oil types or mixing brands can lead to chemical breakdown, foaming, and costly air end damage.
Compressors take in ambient air. If the ambient air is dirty or excessively hot, the compressor’s performance and lifespan suffer.
Sight the surrounds: Ensure the compressor room ventilation is running effectively.
Check ducts and vents: make sure no objects or buildup are obstructing the air intake or exhaust vents. Poor ventilation forces the unit to run hotter, demanding more energy and accelerating component wear.
By integrating these five simple steps into your daily operating routine, you move from reactive maintenance to proactive management. This vigilance ensures maximum operational efficiency and increases the uptime of your operations.