Compressed air is a critical component in the manufacturing process in the industrial sector. Rotary screw air compressors power many applications throughout the assembly line in auto-assembly facilities and newspaper pressing machines alike. As a result, air compressors are heavily used and must be maintained on a regular basis. Even a well-maintained air compressor might experience problems with its numerous components, any of which could be a sign of a greater issue.
Unfortunately, many compressor operators ignore these warning indications, owing to a lack of familiarity with the symptoms. As a result, having an air compressor troubleshooting guide on hand is essential in order to know how to handle specific symptoms, as well as a list of measures to do with each problem.
Most common factors for air compressor failure:
A rotary screw air compressor might fail much before its full life expectancy due to a number of issues. Air leaks, filter blockages, and insufficient lubrication can all be indicators of a deteriorating system.
While you should always perform compressor maintenance on a regular basis, problems linked with system failure might still take root if certain difficulties and their symptoms go unnoticed. The following are the primary concerns to look for as you go with your air compressor troubleshooting efforts.
Air Leakages
Leaks in a system are frequently the source of air compressor failure. These leaks can occur as components deteriorate with age. As fractures grow along with one of the pipes or hoses, air loss can be a slow but progressive process. The fracture will gradually reduce the efficiency of your system.
When a leak develops significantly enough, it may become an audible problem that isn’t too difficult to track down if you follow the sounds. In many circumstances, however, ultrasonic equipment is required to isolate the cause of the problem. In any event, air leaks may be an expensive problem owing to the lost productivity that arises from lower compressed air volumes in a given set of processes.
Excessive Pressure
Excessive pressure is also a common cause of compressor failure. When system operators use compressors at pressure levels over the permissible limits, the additional pressure imposes an excessive strain on system components. Air compressors have restrictions for a purpose.
When a single air compressor performs too many processes at once, pressure constraints might be exceeded. If you use a tiny machine to undertake a variety of high-powered activities, you risk shortening the life of the air compressor. While it may appear that you are saving money by overworking one air compressor, you may really save money in the long term by investing in a second compressor and balancing the workloads.
The expenditures associated with excessive pressure levels may be financially draining in numerous ways, as excess pressure leads to inefficient energy use, longer service intervals, higher incidences of downtime, and premature compressor failure.
Air Filters that are choked up
Air filters are one of the most critical components of a compressed-air system. Without the air filters, the compressed air generated by your system would get contaminated with dust and debris as it travelled to each terminal application. Air filters, on the other hand, become unclean and must be cleaned on a regular basis.
Impurities travel through the system and decrease the quality of compressed air when dirt and dust gather on the air filters.
Furthermore, unclean air filters hamper system performance and compel the system to expend more energy merely to complete fundamental duties. If the problem persists, filthy air filters can result in excessive energy usage, costly maintenance, and downtime. Clogged air filters can also cause rotary screw air compressor overheating.
Not conducting maintenance regularly
Inadequate maintenance is another error that can contribute to premature compressor failure. If you have not created a maintenance programme for your air compressor and its many attachments, problems may arise that are likely to spread before you notice them. In other circumstances, the difficulties may begin with small concerns that may be quickly resolved in minutes during a normal examination.
Daily checks of the filters and valves, for example, may prevent dirt accumulation and the progressive deterioration of system resources. When no one is using the system, turn off the compressor and seal the valves. Furthermore, you should check system sounds on a regular basis to ensure that no odd patterns occur. It is recommended practice to designate a day of the week or month for each area of system maintenance.
Not doing appropriate lubrication
Air compressors, like automobiles, require adequate oiling and maintenance to perform properly. Inadequate oil changes and maintenance intervals are two of the most prevalent reasons for air compressor failure. Friction between metal surfaces arises when the internal components of an air compressor are not adequately lubricated.
Lubricant loses viscosity when it ages as a result of repeated heating and cooling cycles.
When the working environment gets very humid, grease might liquefy and lose its capacity to adequately lubricate the moving components. Similarly, if the workplace is exposed to excessively cold temperatures, the lubricant might become frozen and useless. Alternatively, if a lubricant is allowed to age past its usefulness, its characteristics might become acidic and have a varnishing, corrosive impact on the inner parts.
Uncleaned air separator
Oil from the system must be filtered away before the compressed air leaves the machine and travels through the hoses in order for it to be clean and pure when it reaches the endpoint. Oily compressed air can affect the quality of pneumatic activities such as sanding, spray painting, and air drying significantly.
The air/oil separator, which separates oil from the air before it exits the compressor, keeps compressed air from getting saturated with oil mist. However, the air/oil separator can only store so much greasy accumulation before it spreads to neighbouring elements and degrades the system as a whole. As a result, the air/oil separator must be replaced on a regular basis, preferably every 800 hours of usage.
Inadequate Lubrication
The screw component of a rotary compressor, often known as the pump or airend, is the system’s primary functioning component. The pump, on the other hand, might wear out and require maintenance long before it reaches the end of its useful life. As a result, screw compressor troubleshooting is frequently required in this field.
Overheating and excessive system pressure are two issues that might contribute to pump failure.
If condensation builds up within the machine, the moisture’s effects might be damaging to the airend. Vibrations and the impacts of greasy residue can also wear down the screw component. When the air compressor lags, stalls, or looks to be faulty, this is frequently the source of the problem. Leaks from the oil seal and odd bearing sounds are signs of a more serious problem.
Drive train problems
Belts and sheaves on belt-driven versions should be examined after 500 hours of usage. When the motor and airend are not correctly aligned, direct-coupled rotary screw versions require alignment. If the alignments are incorrect, the motor and airend bearings will wear out and cause the compressor to fail. It is normally recommended to consult an air compressor servicing specialist to guarantee proper alignment.
Motor bearings inappropriately greased
The compressor motor’s bearings power the system. A sufficient amount of grease applied on a regular basis aids in the smooth movement of the bearings. If the grease level is insufficient, the bearings are prone to causing friction between one another, lowering the overall performance of the motor.
To keep the motor bearings in good working order, use a lubricant of the right grade and viscosity. Failure to do so may result in system overheating, excessive energy use, and premature system failure. Do not combine motor grease grades or alternatively apply them to bearings, as the qualities of each lubricant may conflict and have a corrosive impact