The Most Common Air Compressor Failures (and How to Prevent Them)
Air compressors are the heartbeat of industrial operations across the Mid-South—from automotive suppliers in Jackson, to food processors in Little Rock, to medical packaging plants in Memphis. When a compressor fails, it’s more than an inconvenience—it can bring production to a grinding halt.
At Process & Power, we respond to emergency compressor service calls across Tennessee, Arkansas, and Mississippi every day. While every failure feels urgent, many are preventable with the right maintenance and system design.
Here are the top compressor failures we see—and how to stop them before they stop your business.
1. Overheating
🔧 Symptoms:
High-temperature shutdowns
Burnt oil smell
Discolored or warped components
🔍 Common Causes:
Clogged or dirty coolers
Ambient temperatures too high
Restricted airflow around the unit
Wrong or low-quality lubricant
Dirty or inadequate ventilation
✅ Prevention:
Keep coolers and filters clean
Use OEM-approved lubricants
Maintain adequate space around the compressor
Schedule regular maintenance during peak summer heat in Memphis, Tupelo, and other high-humidity zones
2. Excessive Oil Carryover
🔧 Symptoms:
Oil in downstream filters or tools
Slick residue in piping or tanks
More frequent filter replacements
🔍 Common Causes:
Failed separator element
Overfilled oil reservoir
Wrong oil type or viscosity
Operating below minimum pressure
✅ Prevention:
Replace separator elements as scheduled
Maintain oil at correct fill level
Monitor pressure and system load
Perform oil analysis if problems persist
3. Electrical Failures
🔧 Symptoms:
Blown fuses or tripped breakers
Motor won’t start
Fault codes on the controller
🔍 Common Causes:
Bad starter or contactor
Ground faults or short circuits
Loose connections from vibration
Undersized wiring or poor grounding
✅ Prevention:
Inspect electrical panels during every PM visit
Ensure wiring meets spec, especially for older systems
Invest in surge protection—especially during storm season in the Mid-South
Keep terminals tight and clean
4. Moisture in the Air Lines
🔧 Symptoms:
Water coming out of hoses or valves
Rust in piping or tools
Reduced product quality (paint, packaging, etc.)
🔍 Common Causes:
Undersized or failed dryer
Faulty drain valves
Overloaded system or improper piping slope
High ambient humidity (especially in Arkansas and Mississippi summers)
✅ Prevention:
Check dryer capacity against real-world load
Test drains weekly—automated isn’t always reliable
Repipe with proper slope and moisture traps
Upgrade to desiccant dryer if needed for critical air applications
5. Air Leaks
🔧 Symptoms:
Compressor runs constantly
High energy bills
Loss of pressure at end-use points
🔍 Common Causes:
Worn fittings, cracked hoses, or bad valves
Leaky condensate drains
Poor installation or old piping
✅ Prevention:
Schedule regular leak detection (we offer ultrasonic testing)
Use high-quality aluminum piping for new installs
Log compressor run times—if they creep up, you may have a leak
6. Controller or Sensor Failures
🔧 Symptoms:
Inconsistent pressure
Fault codes or shutdowns
No response to load changes
🔍 Common Causes:
Failed pressure transducers
Broken temperature sensors
Software bugs or outdated firmware
✅ Prevention:
Keep controller firmware updated
Replace sensors proactively during major PMs
Avoid power spikes—use voltage regulation or UPS on control circuits
7. Improper System Sizing or Operation
🔧 Symptoms:
Short cycling
Low pressure during peak demand
Excessive energy consumption
🔍 Common Causes:
Compressor too small or too large for load
Poor staging of multiple units
Using pressure to compensate for poor piping layout
✅ Prevention:
Schedule a system assessment to review sizing, controls, and piping
Use VSD (variable speed drive) compressors when load varies
Install a looped piping layout for balanced airflow
How to Prevent These Failures with Process & Power
We offer comprehensive service and support for compressed air systems across the Mid-South, including:
Preventative maintenance plans
Emergency 24/7 repair
System design and efficiency audits
Leak detection and dryer testing
Equipment replacement and upgrades
Our technicians are trained across all major brands and work daily in environments just like yours.
Serving the Mid-South with Fast, Reliable Compressor Service
We support industrial and commercial operations in:
Memphis & Jackson, TN
Springdale & Little Rock, AR
Tupelo, MS
And surrounding towns, industrial parks, and rural plants
No matter where you are or what you produce, we’re here to keep your air system running strong.
Don’t Let a Small Issue Turn into a Shutdown
Most compressor failures show warning signs—if you know what to look for. And with regular maintenance from Process & Power, you don’t have to look at all.
Call (901) 362-5500 or visit www.processnpower.com to schedule service, start a PM plan, or request a system evaluation.
Process & Power
📍 1721 Corporate Avenue, Memphis, TN 38132
📞 (901) 362-5500
🌐 www.processnpower.com
Serving Memphis & Jackson, TN | Springdale & Little Rock, AR | Tupelo, MS
