What is monitored
Common indicators:
- Discharge and oil temperature
- Pressure and differential pressure across filters and separators
- Motor current and power
- Vibration and noise
- Oil condition and running hours
Baseline and trends
A single reading means little. A baseline taken when the machine is healthy lets later readings be compared under similar conditions, and trends show gradual change.
From data to action
Set alert levels, decide who reviews the data and what action follows. Condition-based maintenance can reduce unplanned stops and avoid unnecessary changes, but only when it is acted on.
Limits
Condition indicators suggest where to look. They do not replace inspection, and the limits for a machine should come from its documentation and history.
What to prepare
Information that helps us advise:
- Number, make, model and size of the compressors
- Current controllers and how they are connected
- Pressure settings and the lowest pressure the process needs
- Demand pattern across shifts and any known problems
Frequently asked questions
What is the difference between monitoring and condition monitoring?
Monitoring shows status and alarms. Condition monitoring analyses trends to find developing problems.
Can I extend service intervals using it?
Possibly, but only with evidence from the machine's history and the manufacturer's guidance. Do not change intervals on assumption.
Which measurements matter most?
Temperatures, differential pressures and power are the usual starting points, depending on the machine.
Field guide
Condition monitoring: spotting failures before they happen
Most compressor failures announce themselves weeks in advance. Condition monitoring is simply measuring the right things regularly and noticing when they change.
| Indicator | What a change can mean |
|---|---|
| Discharge temperature rising | Cooler fouling, low oil, thermostatic valve fault, hot room |
| Separator differential pressure rising | Separator loading; oil carryover risk |
| Vibration rising | Bearing wear, misalignment, looseness |
| Motor current higher for the same pressure | Airend wear, mechanical drag, electrical issue |
| Pump-up time longer | Lower delivery: valve wear, inlet restriction, airend wear |
| Oil analysis changes | Contamination, oxidation, wear metals |
Setting up a programme
- Record a baseline on a healthy machine.
- Choose a few indicators that suit the machine and its criticality.
- Measure at fixed intervals, under similar load and ambient conditions.
- Set alert levels relative to the baseline, not only the trip limits.
- Act on trends: plan the repair while the machine is still running.
What to send for a quotation
- Make, model and serial number of every compressor and dryer in the station.
- Running hours and a typical week of operation (shifts, weekends).
- Current pressure settings and controller type on each machine.
- Any alarm or fault history you have.
Send it through find my part or the spare parts enquiry, or call +91 99590 60718 or +91 92468 88812.