Air Compressor Overhaul
Air Compressor Overhaul
When it’s time for an air compressor overhaul, you hope the process will be as smooth as possible. There are different ways to rebuilding air compressor, and each has its own implications for cost, parts, service and performance. This means that there is no single ideal way of rebuilding an air compressor .
Screw Compressor Overhaul will vary from a reciprocating compressor overhauls or a Centrifugal Compressor overhaul.
An experienced mechanic will know exactly how to handle the project, and can prescribe a suitable compressor maintenance & overhauling method. This ensures you get good performance from your machine after it has been repaired in-house–again saving you money for parts over time.
When is the best time to overhaul an air compressor?
If you're paying attention, you'll be able to tell when it's time for an overhaul on your unit. By keeping an eye on fluid levels, oil samples, and bearing vibration, you can catch any signs that your unit needs attention before it's too late. Increase in airend temperature can also be a warning sign that something is wrong, so it's important to stay on top of things.
Options for Overhaul Air compressor: Remanufacture or Rebuild
The rebuild approach to overhauling an air compressor typically takes place on-site, where the compressor is already installed. Product testing after the rebuild occurs on-site and may include checking discharge pressure, vibration levels and testing for oil leaks.
A remanufactured air compressor is brought back to life in the Service providers factory. To bring the unit back to its original specifications, the factory will have all of the design drawings and specifications.
The service provider may also build the replacement airend with in-house parts, replacing bearings, seals, gaskets, pumps and more with new parts. Prior to leaving the factory, the unit will also undergo a complete mechanical and performance test.
Weigh all the pros and cons.
- The bidding process for an overhaul often starts with a low price that seems reasonable. However, as the disassembly and inspection process begins, it's not uncommon to find additional items that are worn or broken.
- With each new discovery, the price and scope of the overhaul can change. Unless there’s a fixed-price guarantee in place, additional parts and labor can quickly add up.
- A successful overhaul can be evaluated by ensuring the unit delivers the rated capacity at the specified discharge pressure, with “as new” efficiency. Additionally, the surge pressure should meet new equipment standards.
After being tested for leaks and ensuring that stage and bull gear vibration levels meet new equipment specifications, the air cooler performance should be evaluated to match new equipment requirements. There are many other things that can be looked at to ensure a high standard of quality and reliability, but these are a good places to start.
Don't Compare the quotes based on price only !
When comparing two quotes, it’s important to remember that the lower quote may not always be the most cost-effective in the long run. In some cases, the provider may quote a low price up front, but the costs can increase as additional issues are discovered during the teardown and inspection process.
This can lead to more repairs, parts and service labor that were not part of the original quote.
A compressor overhaul with a fixed price and scope means there are no surprises and no additional costs to worry about. This includes the typical cost overruns, customer downtime, and onsite productivity loss.
Before you begin your overhaul, be sure to take some precautions!
Before overhauling your air compressor, make sure you have the necessary spare parts on hand. This includes joints, gaskets, pistons, rings, bearings, and other major components as per air compressor needs.
Make sure you have copies of past survey reports, running hours, maintenance reports, and clearance records on hand before beginning the survey.
How to Overhaul your Air Compressor
The compressor should be carefully isolated both electrically and mechanically. Safety notices are prominently displayed for all workers.
The oil and cooling water are drained from the compressor, and it is carefully stripped down. All oil feed lines, seal air lines, interconnecting piping, coolers, control valves, and instrumentation are removed.
The coupling bearing and compression element are carefully removed from the piston using the proper tools.
After the parts & accessories have been cleaned for inspection, they are gauged and the readings are recorded. Safety devices are then checked, and if necessary, the hydraulic tester can be used to test the opening pressure of relief valves. Worn out parts can then be identified and prepared for replacement. Mating surfaces should be made ready after cleaning.
Air Compressor Assembly
To ensure optimal performance, it is important to inspect and renew major parts such as seals, valves, bearings, and more on a regular basis. Gaskets and rubber seals should be replaced with new parts to prevent leakage, and control valves should be stroke tested to ensure they are functioning properly.
All nuts should be torque tightened to the correct settings, and new locking devices such as split pins should be used to keep them in place. Finally, suction and discharge valves must be either renewed or overhauled for best results.
After a major overhaul, be sure to check the clearance between the compressor and the housing & between the housing and gears to ensure it is still within specifications. Use a squeezable plastic or lead wire ball to measure the bumping clearance. If you are not sure how to measure bumping clearance in air compressor contact Turbo Airtech.
Before you start the compressor, make sure to clean or renew the oil suction filter and refill with new oil. Renew the lube oil filters and air filter, and open the cooling water valves to check for any leaks. Prime the lube oil pump and conduct an initial running of the compressor in an unloaded condition.
Check the motor amperage, noise levels, and other factors before loading the compressor. Once you’re satisfied, test run the compressor and measure the time it takes to fill the air receiver from empty to full.
Keep a detailed record of all clearances, spare parts consumed, and other maintenance work performed.
Raise requisitions for necessary spares immediately and update the work done and running hours in the planned maintenance system.
Having a contingency plan will help you avoid emergencies.
A comprehensive contingency plan can help you stay prepared for any unexpected event.
A contingency plan should be comprehensive, addressing potential interruptions and their impact on your business. By undertaking a financial risk analysis, you can get a better understanding of the areas of your facility that are most reliant on compressed air equipment. If your main air compressor breakdown, your service provider can help minimize the financial consequences. Having a contingency plan in place can help you weather any storm.
1. Reduce the chances of financial losses by completing paperwork ahead of time.
2. Avoid production downtime and losses by making employees aware of their roles.
3. Reduce delivery time by anticipating maintenance needs and installing new equipment.
4. Minimize weaknesses in the compressed air system to ensure efficient operation.
Not all parts are created equal.
Rebuilding an air compressor can be a tricky business. Non-OEM rebuilders often rely on third-party parts, which can lead to reliability and performance issues. This can be a problem if an inferior part fails, or if the compressor exhibits inefficient performance that slows productivity.
Turbo Airtech employs only OEM quality parts to ensure that the overhauled compressor perform as good as new, ever better in most of the cases .
Air compressor overhauls can be a costly investment. By asking the right questions, you can ensure that you get the most out of your unit. Some key questions to ask include:
-What quality of work and parts will be used?
-How long will the overhaul take?
-What are the expected results?
-What are the risks and potential problems associated with the overhaul?
-How often should the overhaul be repeated for optimal performance?
To overhaul the compressor with a fixed price and scope means there are no surprises and no additional costs to worry about. This includes the typical cost overruns, customer downtime, and onsite productivity loss.
