Running a rotary screw air compressor in the UAE isn’t without its challenges-especially when summer temperatures often soar past 45°C (113°F). With such intense heat and variable humidity levels, compressors are at high risk of overheating, which can lead to breakdowns, safety issues, and costly downtime.
To keep your system operating smoothly, especially in these demanding conditions, here’s a straightforward guide to preventing compressor overheating-based on industry best practices and real-world data.
1. IMPROVE VENTILATION INSIDE THE COMPRESSOR ROOM
Why it matters: Most rotary screw compressors are designed to operate in ambient temperatures between 5°C and 45°C. When temperatures climb beyond this range, especially in closed indoor areas, performance drops and overheating risks rise.
How to fix it:
· Install intake and exhaust louvers or use mechanical ventilation systems to remove hot air and bring in cooler air.
· Maintain at least 1 metre of clearance around the compressor to ensure unrestricted airflow.
· Avoid placing compressors in sealed or cramped utility rooms without air movement.
2. USE HIGH-TEMPERATURE GRADE COMPRESSOR OIL
Compressor oil plays a critical role in cooling the system, providing lubrication, and ensuring an effective seal during operation. In high-heat environments like the UAE, using the wrong oil viscosity can lead to increased wear and overheating.
Recommended oil for UAE climate:
Switch to ISO VG 68 synthetic compressor oil or higher. These oils are engineered for high ambient temperatures, offering better thermal stability, slower oxidation, and longer service intervals.
3. KEEP COOLERS CLEAN-ALWAYS
Over 60% of compressor overheating issues in the Middle East are due to blocked oil coolers and aftercoolers. Dust, sand, and oil buildup reduce the cooling efficiency, especially in outdoor or partially open facilities.
Best practices:
· Clean the coolers at least every 2–4 weeks during summer.
· Use compressed air or low-pressure water to clear debris from the fins.
· Avoid using high-pressure washers, as they may bend the fins or cause damage, leading to decreased performance.
4. INSPECT COOLING FANS AND THERMOSTATIC VALVES REGULARLY
The cooling fan and thermostatic valve work together to regulate internal temperature. If either one fails, the oil may not cool efficiently, leading to system shutdown.
Maintenance checklist:
Check fan blades and motor every 500 operating hours.
Ensure the thermostatic valve opens fully around 71°C to 85°C. If a valve gets stuck, it can prevent hot oil from circulating properly, causing it to become trapped within the compressor system.
5. USE A PRE-COOLER OR EXTERNAL HEAT EXCHANGER (IF NEEDED)
In facilities where the ambient temperature exceeds 50°C, even high-capacity OEM coolers may struggle. This is common in poorly ventilated rooms or extreme desert environments.
Solution:
Add a pre-cooler or auxiliary heat exchanger to reduce oil or air temperature before it enters the compressor’s main cooling system. This is particularly helpful for continuous-duty air compressors.
6. LOG AND MONITOR COMPRESSOR TEMPERATURE
If you're only reacting after alarms go off, you're already late. Real-time monitoring helps detect early signs of trouble.
Tools to use:
Most rotary screw compressors include PT100 or NTC thermistors to measure internal oil and air-end temperature.
Set warning levels if temperature exceeds 100°C, which is typically the shutdown threshold.
Set warning levels if temperature exceeds 100°C, which is typically the shutdown threshold.
7. STICK TO A TIMELY FILTER REPLACEMENT SCHEDULE
Clogged air, oil, or separator filters make your compressor work harder, which means more internal heat and pressure buildup.
Suggested intervals:
Replace air filters every 1000 – 1500 hours, especially in dusty areas.
Change the oil filters and separators every 2,000 to 4,000 operating hours, depending on the type of oil used and the compressor’s workload.
Change the oil filters and separators every 2,000 to 4,000 operating hours, depending on the type of oil used and the compressor’s workload.
8. USE THE RIGHT-SIZED COMPRESSOR
A poorly sized compressor-either too large or too small-can run inefficiently and generate more heat than necessary.
What you can do:
· Perform a load profile assessment to see how your compressor is being used.
· If your load varies widely, consider switching to a Variable Speed Drive (VSD) model that adjusts output to match demand.
FINAL THOUGHTS
In a region like the UAE, air compressor overheating is a real risk-but also entirely preventable. Whether you're operating in Dubai’s urban core or a dusty industrial zone in Abu Dhabi, following these best practices will help you run more efficiently and avoid downtime.
At Master Power, we recognize the specific challenges rotary screw compressors encounter in Middle Eastern environments. From choosing the right oil to assessing your cooling setup, our technical team is here to help with climate-specific solutions.