Summer Air Compressor Cooler Maintenance

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As temperatures rise, air compressors cooling systems often face additional strain. Intercoolers, aftercoolers, and oil coolers that performed well during cooler months may struggle to maintain operating temperatures when exposed to higher ambient temperatures and humidity.

A seasonal cooler inspection can help identify fouling, restricted airflow, and other issues before they affect compressor performance. Taking time to inspect and clean coolers before peak summer temperatures arrive may help reduce downtime and maintain consistent airflow throughout the season.

How Dirty Air Coolers Affect Compressor Performance

Dirty intercoolers and aftercoolers can increase the temperature inside the compressor due to higher humidity levels and rising temperatures. If you do not schedule time for intercooler maintenance, your coolers may schedule it for you, causing a loss of plant air.

Dirty or aged intercoolers can increase air temperature and reduce air density in the compression stage, resulting in a reduction in the efficiency range or turndown. Ultimately, this will decrease the airflow produced. In the summer months, heat and humidity can exacerbate this situation, further compromising an air compressor’s capacity.

These factors create the perfect environment for a surge, which occurs when inlet flow is reduced to the degree that is insufficient to overcome the discharge pressure of the compressor. Compressors that experience surge are operating in a state of aerodynamic instability. Surge is a state of the air compressor that, if experienced long enough it could cause harm to the components of the compressor.

Maintaining Proper Oil Temperature

Another important cooler to keep clean is the oil cooler. Oil coolers help maintain the air compressor’s oil at a steady temperature level of 115-125F. Higher temperatures above 140F can affect the quality of the oil and lead to varnish. Anything below 115F will carry water, which decreases oil lubricity, leading to early bearing failures and failures of other parts that are lubricated by the oil. Keeping the oil cooler clean will help maintain the oil temperature at the ideal 115-125F/C levels.

Why Summer Conditions Matter

Higher ambient temperatures reduce a cooling system's ability to remove heat from the compression process. Increased humidity can further affect cooler performance, particularly when heat exchangers are already partially restricted by dirt, debris, or scale buildup.

As cooling efficiency decreases, compressor temperatures rise. This can affect air density, operating range, and overall compressor performance. Facilities operating near peak demand during summer months may notice these effects sooner than during cooler parts of the year.

Recommended Cooler Inspection and Cleaning Intervals

With this in mind, FS-Elliott’s scheduled maintenance guidelines call for annual inspection of all heat exchangers, including intercoolers, aftercoolers, and oil coolers.

Intercooler(s) & Aftercooler - Replace tubesheet gaskets every 8,000 hours or annually
Oil Cooler - Replace tubesheet gaskets every 8,000 hours or annually
Drains - Test condensate drain valves or auto drain traps every 2,000 hours or quarterly
Check the cold temperature differential (CTD) - Check every 2,000 hours or quarterly

Preparing for Warmer Weather

Summer operating conditions can place additional demands on compressor cooling systems, making routine inspections even more important. Clean intercoolers, aftercoolers, and oil coolers help support stable operating temperatures, maintain compressor capacity, and reduce the likelihood of temperature-related issues.

Your authorized FS-Elliott channel partner or sales representative can provide the know-how to inspect, maintain, and help keep your compressors operating at peak efficiency.

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