Industrial Automation Goods Repairs And Maintenance Services
Our repair and maintenance services are offered by a skilled and experienced team of professionals & engineers.
We have experience and expertise in rendering services like servo drive repair services, electronic equipment repair services, Industrial automation system repair services, Oil & Gas, Petrochemicals, Power plant, aviation equipment repair services, sugar mill automation parts repair, paper mill automation machinery repair, etc.
In addition, we have all amenities to provide AC drives repair services, PCB board repair services, and servo motor repair services at industry-leading rates.
Certified & Experienced Company
100+ Satisfied Customers in North India
Extensive Testing Post Repairing Services
Excellence After Sales & Services Support
We can do all type of Repairing Service of Compressor PLC like COMTECH,ELEKTRONIKON I & II, ES99,ES3000,ELGI.
Also we are doing PLC repair services, PCB Repairing and electronic card repairing service.
Industrial Automation Goods Repairs And Maintenance Services
Our repair and maintenance services are offered by a skilled and experienced team of professionals & engineers.
We have experience and expertise in rendering services like servo drive repair services, electronic equipment repair services, Industrial automation system repair services, Oil & Gas, Petrochemicals, Power plant, aviation equipment repair services, sugar mill automation parts repair, paper mill automation machinery repair, etc.
In addition, we have all amenities to provide AC drives repair services, PCB board repair services, and servo motor repair services at industry-leading rates.
Certified & Experienced Company
100+ Satisfied Customers in North India
Extensive Testing Post Repairing Services
Excellence After Sales & Services Support
We can do all type of Repairing Service of Compressor PLC like COMTECH,ELEKTRONIKON I & II, ES99,ES3000,ELGI.
Also we are doing PLC repair services, PCB Repairing and electronic card repairing service.
5 things to consider when designing your compressor room
Although the majority of today’s air compressors and all relevant accessories can be purchased as fully-integrated, plug and play packages, it is important to remember that the installation method and siting may still have a significant influence on a compressor system’s performance and reliability.
1. Go for a dedicated and centralized compressor plant close to the point of use
Regardless of the application industry, try to position the compressed air system in one designated, centralized location. As a consequence you benefit from improved operating economy, a better-designed compressed air installation and service provision, greater user-friendliness, better opportunities for controlled ventilation and noise levels and, last but not least, protection against unauthorized access. Wherever the compressed air equipment is situated best practice demands that a ring main is used in order to avoid pressure drops in the system. Direct installation in a workshop or warehouse close to the point of use saves space and enables energy savings due to minimum pressure drop as a result of shorter pipework runs. It can also provide a viable opportunity for energy recovery via the cooling air or oil, for example. If space restrictions indoors demand that the compressor is sited under a roof structure outdoors, stringent measures must be taken to ensure all-weather protection, provision of adequate firm foundations and minimum risk of ingress of dust, flammable or aggressive substances, as well as secure access. Normally only a flat floor of sufficient weight-bearing capacity is required to set up the compressor plant. In most cases, vibration damping is integrated into the equipment. However, it is usual to cast a concrete plinth for the compressor package to allow for floor cleaning and provide a base for new installations.
Are you designing a new compressor room? Our PROFESSIONAL TEAM assists you with the calculations that you need to install your compressed air systems.
2. Ensure enough space and proximity to auxiliary equipment
For trouble-free, efficient operation, compressor intake air must be clean and free of solid and gaseous contamination. Particles of dust and dirt can cause wear, and corrosive gases are particularly damaging. The compressor air inlet is usually located at an opening in the sound-reducing enclosure, but can also be placed remotely in a place in which the air is as clean as possible. Gases from vehicle exhaust fumes can be lethal should they contaminate a breathing air supply. A pre-filter, either a cyclone, panel or rotary band filter, should be used on installations where the surrounding air has a high dust concentration. In such cases, the pressure drop caused by the pre-filter must be accounted for during the design phase of an installation. It is also beneficial for the intake air to be cool. So select an inlet position that is generally in the shade if possible when drawing air from outside.
4. Ensure proper room ventilation
Because compressors generate heat, adequate compressor room ventilation is vital. Ventilation air should be drawn in from the exterior of the building at a maximum velocity of 4 m/s, preferably without extensive ducting and, where possible, the inlet should be positioned on a north-facing wall to provide shade in the hotter months of the year. Grille and air stream damper units prevent foreign objects from entering and they eliminate cold draughts. The intake needs to be positioned as low as possible on one wall while thermostatically-controlled ventilation fans should be sited at the highest point on the opposite wall. Always consult an expert when choosing ventilation methods; many good installations have been spoilt by incorrect cooling methods.
5. Adhere to health and safety regulations
Consider disturbance due to noise or the compressor’s ventilation requirements, the provision of drainage, hazardous surroundings, e.g. exposure to dust or flammable substances and aggressive materials in the air. If the compressor is sited in an area of a building that is used for other purposes or near to staff who are carrying out other duties, then their health and safety needs to be taken into consideration, as well as accessibility for service. In order to ensure the optimum performance and reliability of compressor equipment, as a vital part of the production process, it is important to take all of these considerations into account when designing a compressor room installation. Equally important is to work with a reliable partner for your air compressor installation. Experienced engineers from Atlas Copco and its distributors will go the extra mile to ensure that installation of the compressed air package takes into account the specifics of your site.
In this report we will understand the screw air compressors and importance of lubricants used in Screw Air Compressors. Selection of screw air compressor lubricant and factors involve in oxidation (contamination) of lubricant that turns lubricant into sludge.
SCREW AIR COMPRESSORS
Screw air compressors also called rotary screw compressor. This type of air compressors uses two rotating screws (also known as rotors) to yield usable compressed air. Rotary screw air compressors are compact in design, quiet and more efficient than other compressor types. These machines are more trustworthy and dependable in when used continuously. Reliability of the screw air compressors is more efficient when they are looked after as per user manual and consumable parts are replaced on-time. Top of the list in consumable parts is lubricant which must be selected very carefully as low quality lubrication may cause reduced efficiency and machine break down in extreme cases. Other than lubricant Oil Filter, Air filter and Air/Oil Separator are consumables.
LUBRICANTS
Most of users of Screw Air Compressors use mineral oil for lubrication. Mineral oils are used widely in the world since more than 100 years. They are very efficient and low cost lubricants. Mineral oils are byproduct of crude oil. They directly come of ground after high level of processing and purification. Due to cheaper cost they are affordable when frequency of the oil change is high. Mineral oils use additives that may change their behavior and viscosity due to environmental variables. However mineral oil is time tested to use in screw air compressor. It is an inert and stable compound.
MINERAL OIL CHARACTERISTICS AND BEHAVIOR
Unlike most other lubricated components, rotary screw air compressors face a unique triple threat to their life span: A constant influx of excessive heat, oxygen and water Any one of these three forces can degrade a lubricant and lead to equipment problems. In a rotary screw air compressor, all three are continuously present — increasing the challenge of proper lubrication and protection
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Oxidation in a lubricant can be caused by Heat, Water and Oxygen which leads to increase the possibility of poor lubrication leads to equipment failure.
ROOT CAUSES OF OXIDATION AND TAN FACTOR
It is an established fact that Heat, Water and Oxygen are common elements in a lubricant oxidation. In Screw Air Compressor working mechanism, Oxygen comes in through Air Inlet with Lubricant. Compressions of Air cause Heat and Moisture (Humidity from Atmosphere). Thanks to the modern research and development we have more advanced lubricant formulations which are proficient of resisting extreme temperature and deal with heat and water. But truth is no lubricant last forever and eventually oxidation will degrade the fluid and cause damage to equipment. TAN (Total Acid Number) is an oxidation tracking factor. It is the key factor to find the oxidation of lubricant. The rise of TAN is cause by the rise of oxidation [https://iselinc.com/].
When the increase in TAN level reaches above the acceptable range the following consequences are likely to happen [https://iselinc.com/].
Rust and Corrosion accelerate
Sludge and varnish formation
Consumable parts blockings
Above issues can result in compressor failure. This may lead to massive downtime and more costly repairs.
THERMAL EFFECT ON COMPRESSOR OIL
According to https://iselinc.com/ every 20 F° (11C°) increase in operational temperature beyond the lubricant recommended temperature cut the lubricant life to half.
For an example, a lubricant is rated 2000 operational hours and recommended operational temperature is 85 C°. This lubricant will last only 1000 hours in today’s common temperature of 96 C°. A further increase of every 1C° will cut down the life of lubricant significantly.
OVERCOMING THE PROBLEM
It is not possible to eliminate the problem 100%. You can take multiple actions to reduce the chances of root cause, which ultimately leads to lubricant oxidation.
In Screw Air Compressor triple threat (Heat, Water and Oxygen) can reduced by following
Checking oil condition on regular basis
Oil change-outs timely and regularly
Physical procedure in place to control of contamination
In standard oil drain it is anticipated that up to 20% of old lubricants remain in the equipment. This will cause direct contamination. As a result new oil will oxidize more quickly and will considerably shorter service life. To resolve this issue, equipment must be down for longer period of time to make sure maximum of the old lubricant is drained. All system components that contact lubricant must be cleaned thoroughly to drain the old lubricant as maximum as possible. Must keep all the equipments very clean, like pumps and pipes used to drain old lubricant before using them to add new oil. If possible separate equipment should be used to drain and add lubricant. Unused lubricant must kept in sealed containers to avoid physical contamination [https://iselinc.com/].
In high humidity environments, oxidation of the oil can be overcome by increasing the frequency of oil change.
Working with air compressors and the handheld tools that come along with it may get the job done quicker, but there are some potential risks in using them without taking proper safety measures. Air compressors powering pneumatic tools are powerful enough to cause serious damage when not used carefully, so don’t take safety reminders for granted.
When handling any type of industrial equipment, it is important to keep in mind some general safety reminders. Wearing the proper equipment, checking your surroundings, and not leaving your tools unattended are those things that can easily be overlooked if you’re not being careful. Still, they can make all the difference in preventing any sort of possible harm to you or your surroundings.
There are definitely a couple more safety steps to take to keep everything under control. Read more about work safety tips for air compressors and then scroll down to take advantage of this infographic that lists down all the important work safety tips that you have to be mindful of at all times when air compressors are used in the workplace.
General Safety Reminders
When using any form of industrial equipment, including air compressors and pneumatic tools, it is important to remember these safety guidelines.
Wear appropriate PPE, which might include safety goggles, industrial gloves and hearing protection.
Keep your environment cool to prevent machines from overheating.
Use a self-retracting cord to avoid tripping accidents.
Keep spaces near exits clear of obstruction.
Learn how to use the equipment properly before operating such machinery.
Work Safety Tips When Using Air Compressors
Take It Outside Unless electrically powered, air compressors have to be used outside. Diesel air tools emit carbon monoxide, which is highly toxic. If the air compressor model is made for indoor use keep it away from moist or wet environments.
Inspect Your Machine Always inspect your air compressor before turning it on for any dirt or rust that may have accumulated. Low-pressure air compressors discharge up to 151 psi, medium-pressure compressors discharge 151 to 1,000 psi and high-pressure compressors discharge over 1,000 psi.
Check the Hose Make sure that the air hose won’t kink or bend. Also, check if they are properly connected. This will affect the performance of the machine. And don’t leave them on the floor, else they become a tripping hazard.
Make Maintenance a Priority Make it a habit to check for any leaks, whether air or oil, before turning it on. Small leaks can still lead your machines to blow. Ensure a qualified technician repairs the machine before it is used again.
Turn It Off When:
installing, removing, fine-tuning, or doing any kind of maintenance on connected powered tools
a tool malfunctions
the tool is not in use
Keep It Clean Always have your air compressor checked every now and then. Maintenance helps keep the machine from being prone to combustion.
Industrial Automation Goods Repairs And Maintenance Services
Our repair and maintenance services are offered by a skilled and experienced team of professionals & engineers.
We have experience and expertise in rendering services like servo drive repair services, electronic equipment repair services, Industrial automation system repair services, Oil & Gas, Petrochemicals, Power plant, aviation equipment repair services, sugar mill automation parts repair, paper mill automation machinery repair, etc.
Our team often fields questions about when to service rotary screw air compressors, so we are sharing some general maintenance tips to help inform teams on best practices.
As a reminder, these are only general service tips and situational errors or concerns may prompt additional work.
Initial Maintenance
Initial maintenance is typically recommended after the first 600 hours of operation. That includes a “break-in” change of the oil and oil filter.
After that, we recommend following routine maintenance practices as listed below.
Routine Maintenance
We have broken down general maintenance by specific part for easier reading. Remember to follow the manufacturers’ guidelines when servicing various air compressor brands. Quicy, Kaeser, and Ingersoll-Rand all have different service intervals that should be followed exactly to keep your factory warranty.
Oil filter – The oil filter should be changed every 1,000 hours of use, depending on the environment. The dirtier the setting, the more frequently it should be changed.
Air filter – The air filter should be changed approximately every 2,000 hours of use, again depending on the environment it’s being used in.
Separator – This should be changed annually or every 4,000 running hours, whichever comes first. It should be completed along with an oil change.
Belts – These should be checked regularly for correct tensioning and are usually changed between every year to 18 months.
Parts needed for routine maintenance can be purchased from Compressor World, though we recommend ordering a complete maintenance kit when buying parts. If any questions pop up along the way, contact our team of air compressor experts by calling +92 300 8844 184 or sending an email to contact@airpowerservices.com.pk
Screw Air Compressors are commonly used in all types of industries. A screw compressor works with an electric motor and a male and female rotor that rotate in the opposite direction. This efficient compression process results in continuous and consistent airflow delivery, which is critical for various industries where uninterrupted compressed air is a necessity. Efficiency of the Electric motor defines the energy consumption. Energy efficient compressors are always a key factor in sales.
Fix Speed Rotary Motors
As its name clearly indicates, a fixed-speed air compressor operates by supplying a consistent or fixed voltage and frequency to its motor, which in turn drives its rotary screws at a consistent speed to draw in and pressurize air. If your plant operates on a 24/7 basis without significant fluctuations in production cycles, then your energy consumption may be fairly consistent and a fixed-speed air compressor might be a good choice.
If, however, your facility goes through daily, weekly, or even seasonal changes to its production outputs—and subsequently has varying levels of air demands—then a fixed-speed air compressor will end up using more energy and be somewhat wasteful over the course of its life cycle [https://kaishanusa.com/].
Variable Speed Rotary Motors
In contrast, a Variable Speed Drive (VSD) air compressor can operate anywhere in the range between its minimum and maximum speed, and it automatically adjusts the speed so production of compressed air matches demand in real time. When demand increases, the motor speeds up. When demand decreases, the motor slows down. This capability saves energy because the compressor doesn’t have to run flat out whenever it’s on. You can think of VSD like the accelerator in a car, which allows you to vary the car’s speed according to road conditions, level of traffic and whether you’re in a hurry! [https://www.atlascopco.com/]
Advantages and Disadvantages
No.
Fixed Speed
Variable Speed
1
Flat Run
Fixed speed runs on the specified speed and keeps consuming power at contact rate. [https://www.atlascopco.com]
Energy Efficient
Variable speed machines have special design. They reduce/increase speed depending on the consumption. [https://www.atlascopco.com]
2
Initial Cost
Fixed speed machines are conventional, where initial cost is less. [https://www.atlascopco.com]
Initial Cost
Variable speed involve inverter to control speed which leads to higher initial cost, however they recover initial cost over the period of time due to less power consumption. [https://www.atlascopco.com]
3
Pressure Band
Fixed speed compressor does not have capability to work in tighter pressure band. [https://www.atlascopco.com]
Pressure Band
Variable speed compressors are designed to work efficiently in much tighter pressure band, due to speed variable faculty. [https://www.atlascopco.com]
4
Minimum Working Pressure
Fixed speed compressor does not maintain the minimum working pressure. [https://www.atlascopco.com]
Minimum Working Pressure
A VSD compressor can operate at lower delivery pressures and still maintain the air system’s required minimum working pressure.
VSD also delivers more consistent discharge pressure for all the compressed air applications throughout your facility. [https://www.atlascopco.com]
5
Unloading Pressure
Fixed speed compressor must have an unloading pressure set, where the compressor will start again to maintain working pressure, This process cause a torque load on power that effect cost factor. [https://www.atlascopco.com]
Unloading Pressure
Unlike fixed speed compressor VSD compressor have no set unloading working pressure. They can reduce pressure as low as the demand can go. [https://www.atlascopco.com]
6
Energy Saving on Pressure
Fixed speed does not work below unloading pressure set, So minimum energy consumption is much higher. [https://www.atlascopco.com]
Energy Saving on Pressure
Since there is no minimum pressure is set for VSD compressors. Each 1 Bar down save 7% of the energy consumption. [https://www.atlascopco.com]
7
Conventional Three Phase Motor
Fixed machine mostly use conventional three phase induction motor, where they have less benefits.
1. Increased maintenance on increased start/stop per hour
2. Single cooling system.
3. Much higher noise
4. Geared/Belt Connection
5. Lesser control over PLCs
Permanent Magnet Motor
Latest VSD machines mostly come with PM motors which have standalone benefits, For Example.
1. Unlimited Motor Start/Stop per hour
2. Dual cooling system
3. Low Noise
4. Direct Connection (No Gearing)
5. Easy to maintain
6. Easy to maintain full-function controller. [https://www.industrialair.co.nz/]
8
Starting Current
Fixed machines have much higher current consumption on start, sometimes more than a double of the capacity of the motor. High Starting current may cause power line issues.
Starting Current
In-comparison to fixed speed VSDs does not have any starting current surge. They work smoothly and increase current as per demand. As a result VSDs have fower power line issues. [https://www.ceccato.com]
9
Components Life Cycle
Fixed Speed and load/unload function can cause a shorter life cycle of the attached components. [https://www.ceccato.com]
Components Life Cycle
Variable speed and soft start feature result in longer life cycle of attached components. [https://www.ceccato.com]
We at Air Power Services offer both VSD and fixed speed compressors from the wide variety world’s top manufacturers. Each type offer advantages in specific circumstances. For example, a fixed speed compressor is a smart choice when the demand for air is essentially constant. A factory running 24/7 with automated equipment that consumes compressed air at a predictable and uniform rate is a good application for a fixed-speed compressor. A VSD compressor is a smart choice when demand for air varies by process, time of day, shift or time of the year, when demand fluctuates. [https://www.atlascopco.com]
Conclusion
Since the dawn of the 21st century, a new awareness has taken hold of the industrial sector. The old school age when manufacturers were happy just to maximize profits with the lowest possible overhead — today, all companies that thrive make eco-friendliness a central tenet of brand identity. As part of that goal, innovations in compressed-air technology have made the variable speed-driven air compressor into an industry standard among companies around the world. With one innovation after another.[https://www.quincycompressor.com]
For a wide range of applications, the finest compressed-air systems are those that run on variable speed drives. Not only do VSD-driven units offer some of the greatest longevity and energy efficiency, but they also adjust to the variable speed and torque requirements of each application. [https://www.quincycompressor.com]
The air end of a rotary screw or rotary vane compressor is the part of the machine that actually makes air. In other words, it is the mechanical element that compresses air from atmospheric pressure to the required pressure (PSI) for your application. It consists of the compression device (in the case of a rotary screw compressor, the screws or rotors) and the chamber in which they are contained. In a rotary screw air compressor, the air end is particularly critical because the precision and alignment of the twin rotors significantly affect the compressor’s performance.
How Does the Air End Work?
In a rotary screw air compressor, the air end consists of two interlocking rotors (or screws) within a casing. As the rotors turn, air is trapped in chambers created by the precisely machined interlocking screws. As the rotors continue to turn, these pockets of air are moved along the rotor, getting progressively smaller. This reduction in volume results in the air being compressed.
In a rotary vane compressor, the air end consists of a cylindrical rotor placed within a larger cylindrical housing. The rotor has multiple slots in which movable vanes are placed. As the rotor spins, centrifugal force pushes the vanes out from the slots, creating compression cells between the vanes and the outer casing.
What Are the Components of the Air End?
The air end of a rotary screw air compressor is composed of several key components that enable it to effectively and efficiently compress air. For a screw compressor, these include:
Rotors: These are the central components of the air end. The rotors, often referred to as screws, consist of a male rotor with lobes and a female rotor with valleys or grooves.
Casing or Housing: The rotors are enclosed in a sturdy casing. This casing not only protects the rotors but also forms the compression chamber.
Bearings: The rotors are supported by bearings that enable them to rotate smoothly with minimal friction. These bearings must be able to withstand the high-speed rotation and the forces generated during compression.
Lubrication System: In oil-injected rotary screw compressors, oil is introduced into the air end for cooling, lubrication, and sealing purposes. This oil is injected into the compression chamber, mixes with the air being compressed, and then separated from the air after compression.
Seals: Seals are used to prevent compressed air and oil (in oil-injected compressors) from leaking out of the system. There are typically seals around the shafts of the rotors where they pass through the casing.
Inlet and Outlet Valves: The air end casing has an inlet valve (or intake port) that allows outside air into the compression chamber and an outlet valve (or discharge port) where the compressed air is released.
Do All Air Compressors Have an Air End?
All air compressors have an element that compresses air, but the term “air end” is usually associated with rotary screw air compressors. Air ends can also be found in other types of rotary compressors, such as scroll compressors or vane compressors. Other types of compressors, such as reciprocating compressors or centrifugal compressors, have similar mechanisms to the air end, but these might not be specifically referred to as an ‘air end’. Instead, they may have ‘cylinders’ (in the case of reciprocating compressors) or ‘impellers’ (in the case of centrifugal compressors).
Technology is nothing. What’s s important is that you have a faith in people, that they’re basically good and smart, and if you give them tools, they’ll do wonderful things with them
Air End Problems: Signs That the Air End Is Failing
The air end of an air compressor is a robust component designed for durability and performance. However, like all mechanical parts, it can eventually wear down and show signs of failure. There are several common signs that the air end may be failing, including decreased CFM, increased energy consumption, excessive noise or vibration, increased operating temperatures, increased oil consumption, and loss of pressure. Remember, though, that these symptoms can also be caused by issues elsewhere in the compressor, so thorough diagnostics are necessary to confirm the source of the problem. If the air end is suspected to be failing, it’s important to consult with a compressor service professional who can assess the condition of the air end and recommend appropriate actions, such as repair, rebuild, or replacement.
Decreased Performance
Decreased performance may be one of the first signs of a failing air end. If the volume of compressed air (measured in cubic feet per minute, or CFM) generated by the compressor starts to drop, it’s likely that the efficiency of the air end is deteriorating. This could be due to worn rotors, damaged bearings, or problems with the seals, all of which can reduce the effective compression of air.
Increased Energy Consumption
The air end is designed to convert mechanical energy into pneumatic energy efficiently. If the compressor is drawing more electrical power (amperage) than usual for the same air output, it’s a sign of decreased efficiency, possibly due to wear and tear inside the air end. More energy is needed to overcome the increased internal resistance due to this wear.
Excessive Noise or Vibration
Unusual noises or vibrations could be the result of several issues within the air end. Misalignment or damage to the rotors, worn or failing bearings, or problems with seals can create abnormal operational conditions that generate noise and vibration. These symptoms should never be ignored, as they can quickly lead to more serious damage.
Increased Operating Temperature
The compression of air generates heat, but a properly functioning air end — especially in an oil-injected compressor — should manage this heat effectively. If the compressor is running hotter than normal, it might indicate inadequate lubrication, cooling issues, or increased friction from worn components — all potential signs of air end failure.
Increased Oil Consumption or Leakage
If the compressor is using or losing oil more rapidly than usual, it’s a sign that something is wrong. In oil-injected compressors, the oil serves as a coolant, lubricant, and sealant in the air end. Damaged seals or increased wear within the air end can lead to excessive oil consumption. If oil is leaking externally, it could be a sign of a seal failure or a crack in the air end housing.
Presence of Metal Particles in the Oil
The presence of metal particles in the oil can indicate severe wear or damage inside the air end. When components like the rotors or bearings wear out, they can shed metal particles into the oil. These particles are a clear sign of a serious issue and warrant immediate inspection of the air end.
Loss of Pressure
A significant drop in the pressure output of the compressor can be a sign of air end problems. If the rotors are worn or damaged, or if the seals between the rotors and the casing are failing, the compressor won’t be able to build up the same pressure as before. However, pressure loss can also be caused by issues elsewhere in the system, so a thorough diagnostic is needed.
Causes of Air End Failure
Wear and tear on the air end is a natural result of the operation of the air compressor. Over time, the rotors will lose tolerance. Normally, the rotors in a screw compressor do not directly touch each other or the sides of the compression chamber (instead, the oil forms the seal between parts). But when they lose tolerance, the rotors will start to rub against each other or against the chamber walls, resulting in additional wear and tear. Bearings, seals, and valves also deteriorate over time. The more you run your compressor, the faster this will occur. Proper maintenance will extend the life of your air end.
There are several factors that may lead to premature failure of the air end in an oil-flooded rotary screw or rotary vane air compressor. These are some of the most common causes.
Inadequate Lubrication
Lubrication is crucial in a rotary screw compressor. The oil serves not only as a lubricant but also as a coolant and sealant. If the oil level is too low, if the oil is not of the correct type or quality, or if the oil change intervals are not adhered to, it can result in excessive wear and heat, leading to premature failure of the air end.
Contamination
Dust, dirt, or other contaminants entering the compressor can cause significant wear on the rotors and bearings. These contaminants can enter the compressor through the air intake or with the oil, emphasizing the importance of good air and oil filtration.
Overheating
High operating temperatures can lead to a breakdown of the lubricating oil, causing varnish and sludge buildup. Overheating can also cause damage to seals and other components, potentially leading to air end failure. Overheating can be caused by inadequate cooling (for example, a blocked or malfunctioning oil cooler), high ambient temperatures, or excessive load on the compressor.
Poor Maintenance
Regular maintenance is critical for the longevity of the air end. This includes not only regular oil changes and air filter replacements but also periodic checks of the bearings, seals, and rotors for signs of wear or damage. Neglecting maintenance can lead to a variety of problems, including air end failure.
Operating Beyond Specifications
Running the compressor beyond its designed operating parameters — such as pressure, temperature, or duty cycle — can put excessive strain on the air end and lead to premature failure.
Misalignment or Imbalance
The rotors in a rotary screw air compressor need to be precisely aligned and balanced to operate smoothly. Misalignment or imbalance can result from improper installation, bearing wear, or damage to the rotors or casing. This can cause abnormal vibration and wear, potentially leading to air end failure.
How Long Does an Air End Last?
The longevity of the air end will depend on several factors, including the make and model of the compressor, operating conditions (including run speeds), and how well it is maintained. In general, an air end for an oil-lubricated rotary screw compressor can be expected to last about 80,000 hours (or ten years with continuous operation) before requiring a replacement or rebuild. However, a new air end can last as long as 100,000 hours or require a rebuild in as little as 50,000 hours or less, depending on operation and maintenance. An oil-flooded screw compressor that is not used continuously may last up to twenty years before requiring an air end replacement or rebuild.
Oil-free rotary screw air ends generally will not last as long as their oil-lubricated cousins. The typical lifespan for the air end of an oil-free screw compressor is closer to 50,000 hours. Rotary vane compressors, on the other hand, tend to be highly durable; the air end can easily last 100,000 hours or more with proper maintenance.
How Much Will an Air End Rebuild Extend the Life of the Compressor?
A rebuilt air end will not last as long as a brand new compressor air end, but it can help you get a lot more life out of your compressor — typically, another 40,000 to 60,000 hours, or several years of use. The lifespan of a rebuilt rotary screw air end can vary widely and depends on several factors, including the quality of the rebuild, the operating conditions, and the maintenance practices. To get the most out of your rebuilt air end, be sure to complete regular preventative maintenance, including timely oil and filter changes and periodic inspections.
Remember also that compressor life depends on other elements, such as the motor, drive system, cooling system, oil sump, and compressor controls. Replacing the air end will not prevent a failure in these other components. When deciding between rebuilding an air end or replacing the whole compressor, be sure to consider the service life left on the motor and other critical components.
Extending the Life of the Air End
To maximize the longevity of your air end, proper care and maintenance are essential. By performing regular maintenance, using proper lubrication, and operating the compressor within its specifications, it is possible to extend the life of the air end and improve the overall efficiency of the air compressor. Strategies for extending air end life include the following.
Regular Maintenance
Stick to a regular maintenance schedule as recommended by the compressor manufacturer. This includes timely oil changes, filter replacements, and regular checks of all key components.
Use the Right Lubricant
Always use the air compressor lubricant recommended by the manufacturer and keep it at the correct level. The right lubricant will reduce friction, absorb heat, and carry away contaminants, all of which will extend the life of the air end.
Keep It Clean
Cleanliness is key to the longevity of an air end. Regularly clean or replace the air filters to prevent dust and dirt from entering the system. Keep the area around the compressor clean and free of dust and debris.
Manage Heat
Overheating can accelerate wear and tear in the air end. Ensure that the cooling system (whether it’s air-cooled or water-cooled) is functioning properly. Regularly clean the oil cooler to ensure efficient heat exchange.
Operate Within Specifications
Always operate the compressor within the manufacturer’s specified parameters. This includes pressure, temperature, and duty cycle. Operating beyond these specifications can cause excessive wear and strain on the air end.
Regular Inspections
Regularly inspect the air end for any signs of wear or damage. Look for unusual noises, vibrations, or changes in performance, which could indicate a problem.
Proper Installation and Startup
Make sure the compressor is installed correctly, including proper alignment and balancing of the air end. Also, ensure that the startup process is carried out correctly, following the manufacturer’s instructions.
Environment Control
Wherever possible, try to control the environment in which the compressor operates. Keep the compressor room well ventilated, minimize dust and contaminants, and, if possible, maintain a steady, moderate temperature.
Operator Training
Ensure that all operators are well-trained in the correct operation and maintenance of the compressor. Mistakes or neglect in operation can lead to premature wear and failure of the air end.
When Is It Time to Rebuild the Air End?
The right time to rebuild an air end generally comes when you start to notice decreased performance, increased noise or vibrations, excessive oil consumption, or increased operating temperatures. In addition, if the air end has reached its recommended operating hours (usually around 80,000 hours for an oil-lubricated screw compressor), it may be time to consider a rebuild. Always consult with a compressed air professional when these signs appear to determine the most appropriate course of action.
Rebuild or Replace? How to Make the Decision?
Deciding when to rebuild the air end or replace the entire compressor can depend on several factors, including the age and condition of the compressor, the extent of the damage or wear to the air end, and the cost comparison between a rebuild and a new unit. Here are some considerations when deciding between compressor repair or replacement.
Symptoms of Failure: If your compressor is experiencing decreased performance, increased energy consumption, excessive noise or vibration, increased operating temperature, or other symptoms of air end failure, it may be time to consider rebuilding or replacing the air end.
Maintenance and Operating History: If your compressor has been well-maintained and operated within manufacturer specifications, it’s more likely that a rebuild can effectively extend the compressor’s life. However, if the compressor has been poorly maintained or operated under harsh conditions, there may be additional hidden damage or wear that could make a complete replacement more cost-effective.
Cost Comparison: Compare the cost of a rebuild, including any associated downtime, with the cost of a new compressor. Don’t forget to consider the potential energy savings and warranty benefits that might come with a new unit.
Age of the Compressor: If the compressor is nearing the end of its expected life span, or if other key components (such as the motor) are also showing signs of wear or failure, it may be more cost-effective to replace the entire unit rather than rebuild the air end.
Availability of Parts and Service: Check whether the necessary parts and skilled service technicians are readily available for a rebuild. For older models, parts may be discontinued, and technicians may not be familiar with the rebuild process.
Future Requirements: Consider your future compressed air requirements. If your needs are expected to increase, or if you anticipate a need for better energy efficiency, it may be worth investing in a new, larger, or more efficient model.
Advantages of a Proactive Air End Rebuild
If your air end is close to the limit of its natural life span or is showing signs of potential failure, it makes sense to schedule an air end rebuild before experiencing a failure of the air end. Timely air end refurbishment can prevent costly unscheduled shutdowns and emergency repairs. A scheduled air end rebuild can be completed during a holiday shutdown to avoid unplanned closures. Alternatively, you may consider renting an air compressor or moving production to a backup air compressor during the rebuild so operations can continue.
Practicing scheduled or preventative replacement of the air end in a rotary screw compressor has several advantages.
Improved Reliability: Proactively replacing the air end can help to prevent unexpected compressor failures and the associated downtime. This is particularly beneficial in industries where uninterrupted compressed air supply is critical.
Extended Equipment Life: By replacing the air end before it fails, you can prevent collateral damage to other components of the compressor, potentially extending the overall life of the equipment.
Cost Predictability: Scheduled replacement allows for more predictable maintenance costs, as opposed to the potential for sudden, costly repairs if the air end fails unexpectedly.
Energy Efficiency: Over time, wear and tear on the air end can reduce the efficiency of the compressor, leading to higher energy consumption. Refurbishing the air end can help maintain the compressor’s energy efficiency.
Performance Consistency: An air end rebuild ensures that the compressor’s performance remains consistent, providing the required pressure and flow rates for your operations.
Reduction in Maintenance: A new or refurbished air end will typically require less maintenance than an older, worn one, reducing maintenance time and costs.
If the Air End Has Failed, Can It Still Be Rebuilt?
Whether a failed air end can be rebuilt largely depends on the extent and type of the failure. In some cases, if the failure is limited to specific components like bearings or seals, it may be possible to rebuild the air end by replacing these components. However, if there’s extensive damage to critical components such as the rotors, or if the failure resulted in a significant amount of metal debris circulating through the system, a rebuild may not be feasible or cost-effective.
In any case, it’s crucial to work with an experienced air compressor technician or service provider to accurately diagnose the failure and assess whether a rebuild is possible and worthwhile. It’s also important to address the underlying cause of the failure to prevent a similar issue from occurring after the rebuild.
How Much Does It Cost to Rebuild the Air End?
The cost of rebuilding an air end compared to buying a new compressor can vary significantly depending on the make and model of the compressor, the size (HP) of the compressor, the extent of the repairs needed, labor costs in your area, and other factors. In general, a rough estimate might be that rebuilding an air end could cost about 20-25% of the cost of a new compressor. However, this can vary widely, and in some cases could be closer to 50% of a new compressor cost. For example, if you have a larger, more expensive compressor, the cost to rebuild the air end might be relatively lower compared to the cost of replacing the entire compressor, while for a smaller, less expensive compressor, the cost to rebuild might be closer to the cost of a new compressor.
However, it’s important to consider more than just the upfront cost. You should also factor in the potential for increased energy efficiency with a new compressor, the warranty that comes with a new unit versus the guarantee on the rebuild, the expected lifespan of a new versus rebuilt compressor, and the potential downtime associated with each option.
Is It Worth It to Rebuild the Air End?
Whether it’s worth it to rebuild the air end depends on several factors, including the condition and age of the compressor, the cost of the rebuild versus a new compressor, warranty coverage, and your operational needs. If the compressor is in generally good condition and the cost of the rebuild is significantly less than a new unit, a rebuild could be a cost-effective option. However, if the compressor is old or has other issues, it might be more cost-effective in the long run to invest in a new compressor with higher efficiency and a new warranty.
Will My Warranty Cover the Cost of an Air Compressor Air End Rebuild?
Warranty coverage for the air end of the compressor varies widely between manufacturers, ranging from one to three years on the low end to five or even ten years on the high end. Warranty coverage may be given in years or operating hours (e.g., up to five years or 40,000 hours). If the air end fails within the warranty period, this typically indicates a manufacturing defect. The manufacturer will either cover the cost of the rebuild or provide a new replacement air end.
Important: Failure to properly maintain and operate the compressor is likely to void the warranty. If the air end fails because it has not been maintained (e.g., inadequate lubrication) or has been run outside its normal operating conditions, the warranty will not apply.
Fluid-Aire Dynamics offers an Extended Warranty that covers the air end, oil cooler, and oil sump tank of the air compressor for up to 20 years or 80,000 hours — even if we did not sell you the compressor originally. The warranty applies to any make or model of rotary screw air compressor that is less than 20 years/80,000 hours old, in good running condition, and installed according to the manufacturer’s specifications. All you have to do is complete the preventative maintenance at recommended intervals using materials supplied in your Extend-Aire kit and send in an oil sample every six months or 2,000 operating hours.
What Happens in an Air Compressor Air End Rebuild?
An air end rebuild involves the disassembly, inspection, repair, or replacement of worn or damaged components, and reassembly of the air end. The exact process may vary depending on the make and model of the compressor and the extent of wear or damage, but here’s a general idea of what typically happens.
Disassembly: The air end is carefully disassembled to access the internal components. This often involves separating the rotors from the casing and removing the bearings and seals.
Cleaning: All disassembled parts are thoroughly cleaned to remove any oil, dirt, or other contaminants. This may require the use of specialized cleaning equipment and chemicals.
Inspection: The individual components are closely inspected for signs of wear or damage. This includes checking the rotors for wear or damage to the screw profiles, inspecting the bearings for signs of wear or damage, and checking the seals and casing for any defects.
Measurement: Critical dimensions such as rotor clearances, bearing fits, and seal areas are measured and compared to manufacturer specifications to assess the level of wear.
Replacement or Repair: Any components that are worn or damaged beyond acceptable limits are either repaired or replaced. This typically includes bearings and seals but may also include the rotors or other components if necessary.
Reassembly: The air end is carefully reassembled, ensuring all components are properly aligned and fitted. New gaskets and seals are typically installed during reassembly.
Testing: Once reassembled, the air end is typically bench tested to verify proper operation. This includes checking for any leaks, unusual noises, or other signs of problems.
Documentation: Detailed records are usually kept of all inspection findings, measurements, and work performed. This serves as a record of the rebuild and can be useful for future maintenance or troubleshooting.
It’s important to note that an air end rebuild is a complex process that requires specialized knowledge and equipment. It should always be performed by a skilled technician or service provider with experience in compressor repairs. The quality of the rebuild can significantly affect the performance and longevity of the air end, so it’s critical to ensure the job is done right.
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The primary reason is that do-it-yourself methods will never remove all of the debris and crud from an oil cooler. The leftover debris and contaminants, a significant amount of which will have been loosened via the cleaning process, can break off and seriously damage your equipment / machine.
The second reason is that improper cleaning procedures (wrong chemicals, wrong pressure, wrong temperature) can damage an oil cooler. A damaged oil cooler is just a problem waiting to happen to the system it is connected to.
The third reason is the same as the primary reason. I know, we are stating it again! But, it is just that important to understand. If you clean your oil cooler yourself, the leftover contaminants that did not get removed can wreak havoc on the machine connected to the partially cleaned oil cooler. Do not risk the engine or machine you use the oil cooler on; you can easily be in for a total failure of that engine or machine. It’s just not worth the risk.
Because the cost and risks associated with do-it-yourself oil cooler cleaning can be very high; and the results often sub-par, it is better to replace the oil cooler IF you don’t want to get it professionally cleaned.
All professional oil cooler cleaning services are not equal. We invite you to take our challenge, and see just how clean Flushing Services can get your oil cooler. Our customers are often shocked at how clean their oil coolers come back to them! We pride ourselves on being the best in our industry!
Why an Oil Cooler Needs Cleaning
An oil cooler is a piece of equipment that is used to transfer heat away from oil (or another fluid) to another medium; be it air or another fluid. An oil cooler performs this function without the two fluids combining or being in direct contact. This is accomplished by flowing the hot oil through a device that the oil can heat up, and then in turn heat the surrounding air or fluid with that heat. These devices often have small channels which the oil flows through; and, this makes them prone to being clogged with fouling and debris.
When the channels in an oil cooler are clogged, the efficiency of the oil cooler is reduced. The loss of the ability to effectively transfer heat can cause the engines or machinery the oil flows through to have higher operating temperatures. And, of course, this can lead to malfunctions and decreased device life spans.
In addition to the buildup of heat, the debris that builds up inside an oil cooler can break loose and pass, with the oil, into the internal system of the machine it is keeping cool. For automotive oil coolers, this can lead to a transmission failure. In larger industrial oil coolers, this debris can cause severe damage to expensive equipment. The prevention of such scenarios is often paramount for those that understand the importance of oil cooler maintenance and cleaning.
Only a Professional Should Clean an Oil Cooler
Oil coolers must be cleaned by a professional. Using basic cleaning techniques; such as solvents, reverse flow, pulsating flow, wand flush tools, charged particle separators, or mechanical cleaning (scrapping or brushing out the material by hand or with a machine); will not adequately clean an oil cooler. The remaining debris, scaling, and other fouling can cause serious damage to an engine or industrial machine. That is why, if you don’t remove all of the debris and contaminants in your oil cooler, you could end up with a significant problem shortly thereafter.
Again, there is simply no good technique that a mechanic or do-it-yourselfer can employ to clean an oil cooler enough for it to be safe to reuse. You must have your oil cooler professionally cleaned if you want to be ensured that your oil cooler won’t cause a future system problem. You are going to be better off buying a new oil cooler than trying to reuse a dirty unit.
Should I Buy a New Oil Cooler?
Even the cleaning process, if not done correctly, can lead to problems with your cooler. When you introduce incorrect fluid chemicals, fluid flow, temperature, or pressure into an oil cooler, it can have negative ramifications on the oil cooler. The valves, seals, and other components of the device can suffer. The result can be immediate component failure and system damage.
And, as already stated, even if a cleaning process removes half or more of the debris and contaminants in the cooler, what’s left behind can cause problems.
If your oil cooler cleaning company can’t give you 99.9% removal of debris and contaminant, than you may want to consider trying our service. We can, and do, remove 99.9% of the gunk, buildup, and any other contaminants from oil coolers.
The best course of action, if you can’t remove 99.9% of the contaminants and fouling from an oil cooler is simply to replace it with a new unit. Don’t take chances!
Flushing Services provides a more cost effective option that can restore a cooler by getting as clean, or cleaner, than a brand new device. Even oil coolers from the factory have some debris in them; this debris is left over from the manufacturing process. With Flushing Services you don’t have to buy a new oil cooler; we can restor your old cooler to as good or better than a brand new device!
We Totally Clean Oil Coolers & can Save you Money
Flushing Services has been cleaning oil coolers and heat exchangers of all kinds for over 30 years. We even have a cooler flushing machine, utilizing patented technology, called Hot Flush (you may have heard of it)! Suffice it to say, we can guarantee that your oil cooler will have 99.9% of the debris and contaminants removed from it by our proprietary cleaning process.
Many mechanics and factory technicians can warn you about the dangers of using a poorly cleaned oil cooler. Cleaning a transmission oil cooler simply isn’t a job that should be done without professional help. And, the same is true for business with large oil coolers. You need to be sure the device is free from contaminants. That is why we are here: we totally clean oil coolers.
By using our service, you can save yourself the need to buy a new oil cooler. Our clients are often shocked at how pristinely cleaned their oil coolers come back to their facilities. We clean these devices to the extent that they are as clean, or cleaner, than new oil coolers from the factory. That’s right, even factory oil coolers can have residual debris in them left over from the manufacturing process.
We can breathe new life into an old oil cooler; enabling it to serve you well for the foreseeable future. When you trust your oil coolers to Flushing Services, you can be assured that the old unit will perform like new again. And, you can also trust that the cleaned cooler will not cause other problems with your machinery or operation.
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