4 Reasons for Insufficient Gas Production in Air Compressors
Air compressors play a crucial role in many industries, but when they fail to meet the necessary gas production, it can disrupt operations. Understanding the potential causes behind insufficient gas output is key to maintaining efficient performance. Here are four common reasons why an air compressor may not produce enough gas, along with solutions to address them.
Table of Contents
1.Air Compressors: Incorrect Model Selection
One of the most frequent issues arises when users do not accurately assess their gas consumption needs and choose an air compressor model that cannot handle the required load. In this case, the exhaust pressure remains lower than the rated pressure, unable to meet the factory’s normal gas demands.
Solution:
To identify the issue, check for potential leaks in the pipeline by closing the valve behind the gas storage tank. If the unit’s pressure rises quickly after the valve is closed but drops rapidly when reopened, it indicates that the compressor is too small for the gas demand. Adding a new unit with a larger exhaust volume—10-20% greater than the actual gas consumption—can resolve the issue.
Air Compressors
2. Increased Gas Demand
If additional equipment that requires compressed air has been added to your production process, the gas consumption may exceed the production capacity of your screw compressor. This causes the compressor to work harder but still fall short of the required gas output.
Solution:
In this scenario, it’s important to evaluate whether your gas consumption has increased beyond the compressor’s capacity. If so, upgrading the air compressor or adding a supplementary unit can balance the gas production with the new demand.
Air Compressors
3. Machine Wear
Over time, wear and tear can reduce the efficiency of an air compressor, particularly the rotors. When the yin and yang rotors (male and female rotors) of the compressor or the stator cavity wear out, internal air leakage increases, making the compressor less effective under load. Additionally, using incorrect or low-quality lubricating oil can lead to inefficiencies, as emulsified oil cannot properly seal the unit.
Solution:
Listen for changes in the noise of the compressor, particularly at the suction end, where a noticeable difference between no-load and load conditions can indicate internal leakage. If you suspect wear or improper lubrication, consult a professional air compressor maintenance technician to inspect the unit and replace any damaged components.
4. Air Compressors :Air Leakage
Air leaks in the system are another common cause of insufficient gas production. Leaks in external pipelines, joints, safety valves, pressure switches, or other components can drastically reduce the pressure in the air tank, causing the compressor to produce less gas.
Solution:
To check for leaks, start and stop the oil-free compressor when the pressure in the air tank is slightly higher than atmospheric pressure. Then, listen carefully around the external pipeline for any hissing sounds indicating air escaping from the system. If you identify leaks, repair or replace faulty valves, switches, or other affected parts.