Taking The Guesswork Out Of Compressor Servicing

• We understand that running your facility takes precedence—compressor servicing can slip to the back burner.
• That’s why Ingersoll Rand provides the information and support you need to take the guesswork out of servicing.
• For complete peace of mind, here are answers to the questions we’re asked most often.

Servicing & Replacement:

How often should you service your air compressors?
Service intervals depend on operating time and hours. Even if your compressor doesn’t reach its operating hours within 6–12 months, it still needs a service due to ageing filters, oil, and wear parts. Observe the specified maintenance intervals for your plant type—at minimum, once per year.

How often should you change your compressed air filters (oil, separator, air, downstream)?
It depends on element type, function, and ambient conditions, but as a rule of thumb replace all filter elements at least every 12 months.

Why is it important to replace filter elements regularly?
Regular changes reduce pressure drop and energy use, while ensuring continuous delivery of air to the required quality standard.

How often should compressor oil be changed?
Oil changes typically align with recurring maintenance. Mineral oil is usually changed every 4,000 hours; synthetic oils can last roughly twice as long. Installation and suction conditions may vary intervals—when in doubt, run a lab oil analysis.

What type of compressor oil should you use?
Use plant-manufacturer-approved oil. In oil-lubricated screws, oil must cool, seal/compress, and lubricate—then separate cleanly. Depending on application, mineral, synthetic, or food-grade oils may be appropriate.

When does the compressor airend need replacing?
Airends in oil-lubricated screws are subject to bearing wear. Bearing makers typically rate around 35,000 hours; plan a preventive bearing exchange around this point.

What is the lifetime of a compressor—and how can you extend it?
Service life is driven more by operating hours than calendar age. Consider the economic/environmental value of upgrading older systems versus retrofits (e.g., heat recovery, high-efficiency motors) to extend useful life and improve efficiency.

Air Compressor Testing:

When do you need a pressure vessel test?
Under the Ordinance on Industrial Safety and Health (BetrSichV), perform a visual inspection every 5 years and a pressure test every 10 years. Requirements may vary by region—always confirm locally.
If the pressure-volume product is < 1000 L (max permissible pressure × tank volume), a competent person may test it. > 1000 L requires an approved inspection body (ZÜS) such as TÜV or DEKRA.

Servicing Agreements & Monitoring:

Can you get a bespoke service agreement?
Yes—every system is unique. We’ll tailor scope and coverage to your needs so reliability and operating costs are controlled.

Is there a monitoring system for compressors?
Helix™ Connected Platform is standard on new models and can be retrofitted to older systems. It enables 24/7 monitoring of operating conditions across your compressed-air network.

Energy Saving:

Can you retrofit heat recovery to older compressors?
Yes. Heat recovery recycles compression heat to cut energy use. A proper engineered design ensures safety and efficiency.

Should you switch off refrigerated dryers after production?
Only if they can be restarted early enough to pre-cool. Refrigerated dryers need a pre-run; as a precaution, start them about 30 minutes before the compressor. If that isn’t feasible, keep them running—removing condensed moisture later usually costs more than the energy saved by shutting down.

General Questions:

Why does the compressor tank heat up?
Compression generates heat; that heat raises oil and air temperatures, which in turn warms the tank.

How much compressed air can flow through a pipe?
It depends on material, condition, and diameter. Refer to the pipe manufacturer’s specifications for sizing guidance.

Can air compressors explode?
Compressed air is stored energy. Improper use or maintenance can lead to sudden decompression. Always follow safety procedures.

Can a compressor pressure vessel be welded?
Yes, but only by an ASME-certified welder. All pressure vessels must maintain certification.

Do compressors produce carbon monoxide?
Electric compressors don’t generate CO, but they can ingest it from ambient air. Follow local safety regulations where CO is a concern.

Does a tank weigh more when pressurised?
Yes. A vessel with compressed air weighs more than when empty. Never move or work on equipment under pressure or while powered.

Any other questions? Contact us—our experts are happy to help.