Best practices for process compressor maintenance and reliability

Process compressors are essential in a wide range of industrial operations. When they fail or even operate below optimum levels, the impact on production and profits can be significant.

That’s why keeping your compressor running reliably, efficiently, and safely should be a top priority. The good news? With the right approach, it’s actually pretty straightforward. In fact, the time and cost of regular maintenance are minimal compared to the expense and disruption of a mechanical failure.

In this post, we’ll walk through some best practices for maintaining your process compressor and keeping it operating at its best.

Process compressor issues to look out for

Different types of process compressors may have specific signs indicating something is wrong, but here are some common examples indicating potential issues:

• Unusual instrument readings or alarms – always pay attention to temperatures, pressures, vibration, and discharge gas composition readings. These often catch problems early.
• Overheating – may be caused by fouling, dirty or ineffective filters, or issues with the cooling system.
• Reduced output pressure or flow – could indicate valve or rotor issues.
• Excessive vibration – a red flag for fouling, valve malfunctions, seal problems, or incorrect settings.
• Unusual vibration – often linked to imbalance, misalignment, worn parts, or fouling.
• Strange noises – knocking, rattling, or high-pitched sounds may indicate bearing wear or internal damage.
• Oil leaks – a sign seals are worn or failing.
• Excessive power consumption – tells you the system is working harder than it should, and efficiency is dropping.

Preventative maintenance

Spotting warning signs is helpful, but the real key to reliability is preventative maintenance. Simple, effective and cost-saving measures are key to getting the most out of your equipment. Implementing a daily, weekly, monthly, and annual schedule with logs and accountability will keep small problems from turning into big ones.

Here’s an example of what you might include:

Daily

• Check oil levels
• Inspect for leaks
• Monitor vibration and noise
• Check pressure and temperature readings

Weekly

• Perform on-line process compressor washing (in some cases, daily washing may be necessary to manage rapid buildup) to prevent foulants from accumulating and impacting production/causing irreversible damage.

Monthly

• Clean or replace filters
• Test safety devices including pressure relief valves and alarms

Every six months

• Analze oil samples for contaminants
• Calibrate sensors
• Inspect valves and seals

Yearly

• Conduct a full vibration analysis
• Consider thermal imaging to check for hot spots
• Inspect internal components
• When your process compressor is shut down for maintenance, consider off-line washing

How regular washing optimizes process compressor performance in industrial settings

Process compressors become fouled through normal use. Contaminants enter through process gases, lubricants/grease, polymeric compounds, production chemicals, and more. Under high pressure and temperature, these contaminants build up faster leading to friction, reduced output, and potential equipment damage.

The best defense is regular online cleaning, which can be done while the compressor is in operation, minimizing disruption. For deeper cleans, off-line soak washing is also effective during scheduled downtime.

Find out more

We hope these best practices help you get the most out of your equipment. If you’d like to dive deeper, we’ve published more insights on fouling and process compressor washing in this blog.

With over 40 years of experience, Rochem’s specialized cleaning equipment and FYREWASH® chemicals are trusted by sites worldwide to keep compressors operating efficiently and reliably.

Interested in extending the life of your process compressor while reducing costs? Contact our team today, we’d be glad to help.