Kaishan USA | May 3, 2023 | Uncategorized
In harsh environments like metallurgy, you’ll need to take special care with your air compressor maintenance.
Following a regular schedule of rotary screw compressor maintenance will keep downtime to a minimum and maximize the lifetime of your equipment.
You’ll realize significant energy savings and improve the working environment for your employees, lessening the heat, vibration, pollution and noise impact on your people.
Maintaining your rotary screw air compressor, however, is not a simple job. But it pays for itself many times over.
The most common problems we see in rotary screw compressor maintenance include the following:
One of the critical elements of maintenance is adjusting service intervals to allow for a more challenging environment. In a cement plant, for example, the dust and dirt quickly build up in air and oil filters, so you will want to change them more often. And, while a manufacturer might say that the compressor oil needs to be changed every 8,000 hours, you may want to cut that time in half in a setting like metallurgy, since the harsh, high-temperature environment will cause oil to degrade more rapidly.
Maintaining your compressor requires a regular program of daily inspection, weekly maintenance and more long-term service.
A daily inspection of the main elements of your system will keep your air compressor running at optimal levels. We recommend that you review the following:
It’s always a good idea to check electrical and mechanical connections.
Once a week, you should clean all exposed surfaces, especially the heat exchanger fins, to remove dust and dirt that would limit the unit’s ability to release heat into the ambient air.
You’ll also want to tighten up the various connections periodically.
Your extended maintenance schedule should include a walkthrough with your air compressor consultant monthly or at least quarterly. They can spot an issue before it becomes a problem. And a problem before it becomes a catastrophe.
When it comes time to service your compressor, your checklist should include the following:
While compressor oil is typically rated at 8,000 hours, you will want to accelerate the pace of oil changes if your compressor is running at high temperatures. And, if your compressor begins to use more oil than usual, contact your air compressor professional.
To keep your compressor motor operating efficiently, you’ll want to ensure the grease is changed at manufacturer-recommended intervals and swap out motor couplings or belts as they begin to show wear.
To keep your rotary screw air compressor in top shape, you should inspect couplings or belts and replace as needed.
Almost all compressor manufacturers require that you use their original OEM parts to keep their product warranties in force. We recommend using genuine Kaishan parts to ensure that your air compressor system achieves the expected performance level.
Here’s why: As we improve our products, we also enhance our parts to take advantage of the latest technologies and improve system performance. You can be confident that the performance of your new parts will conform to the specifications of your equipment, giving your compressor higher energy efficiency, greater reliability and longer life expectancy, resulting in better air quality and enhanced productivity for your entire air compressor system.
Industry research has proven that a proactive maintenance strategy can help you reduce maintenance costs by as much as 70%.
The goal of preventive maintenance is to anticipate problems before they happen, addressing compressor issues that could worsen and lead to a shutdown. A good preventive maintenance program thus will pay for itself in lower service and replacement costs, reduced energy consumption (not to mention lower utility bills) and fewer costly shutdowns. The result? Fewer instances of lost production time and the associated labor and overtime costs.
Many companies are finding that they no longer have the expertise in-house to deal with advanced equipment like air compression systems. That’s why we encourage all our customers to seek outside help when problems arise.
Kaishan is fortunate to work with a nationwide network of independent distributors, who can provide on-site help and consultation as needed. These factory-trained air compression experts have an investment in their local communities and can service your air compressor system without a problem.
Maintaining your rotary screw air compressor is critical to the operation, not only of your compressed air system but also of all the processes that rely on that system. If you need help setting up a rotary screw compressor maintenance program that works for you, get in touch with the experts at Kaishan. Contact us today.
Following a regular schedule of rotary screw compressor maintenance will keep downtime to a minimum and maximize the lifetime of your equipment.
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