Screw compressors, specifically rotary screw compressors, are integral to various industrial operations due to their efficiency and reliability in delivering compressed air. A common query among users is whether these compressors can be serviced. The unequivocal answer is yes—screw compressors not only can be serviced but require regular maintenance to ensure optimal performance and longevity.
Proper servicing of these compressors is crucial to prevent unexpected breakdowns, enhance efficiency, and extend their operational lifespan.
Understanding Industrial Screw Compressors
Industrial screw compressors operate using two interlocking helical rotors that compress air as they rotate. This design provides a continuous flow of compressed air, making them ideal for applications that require a steady air supply. Their robust construction and ability to perform efficiently under demanding conditions make them a preferred choice in various industries.
However, like any machinery, screw compressors require regular servicing to maintain efficiency, prevent breakdowns, and optimise energy consumption.
Why Air Compressor Service is Crucial for Industrial Screw Compressors
Regular air compressor service ensures efficiency, reliability, and longevity. Here’s why industrial screw compressors must be serviced consistently:
1. Prevents Unexpected Breakdowns & Costly Repairs
Even the most durable compressors experience wear and tear over time. Regular servicing helps detect small issues before they escalate, reducing downtime and expensive repairs.
2. Improves Energy Efficiency
A poorly maintained compressor can waste up to 30% of energy due to air leaks, clogged filters, or improper lubrication. Servicing ensures optimal efficiency, lowering power consumption and costs.
3. Ensures Reliable Air Supply
Industries rely on steady compressed air. Poor maintenance can lead to pressure fluctuations, airflow inconsistencies, and system failures that disrupt operations.
4. Extends the Compressor’s Lifespan
With proper maintenance, a rotary screw compressor can last 10–15 years or more. Lack of service shortens its lifespan, leading to frequent breakdowns and higher replacement costs.
5. Enhances Workplace Safety
Leaks, overheating, and faulty pressure controls can cause serious safety risks. Routine inspections ensure the system operates safely without endangering workers.
Key Maintenance Practices for Screw Compressors
Servicing an industrial screw compressor involves regular checks, cleaning, and part replacements to maintain its efficiency and longevity. A structured maintenance routine ensures that the system operates optimally and prevents costly breakdowns.
To keep screw compressors in optimal condition, consider the following maintenance practices:
Routine Inspection of Components
Before performing any maintenance, a thorough visual inspection of the compressor is essential. Inspect the compressor for:
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Leaks in hoses and connections – Even minor leaks reduce efficiency.
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Unusual noises or vibrations – These can indicate misalignment or internal wear.
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Oil stains around seals and gaskets – Potential signs of leaks affecting lubrication.
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Dust and debris buildup – Can clog air filters and reduce performance
Draining Moisture from the Air Tank
Since compressed air naturally contains moisture, the accumulation of water inside the air tank can lead to corrosion and internal damage over time. To prevent this, the moisture should be drained daily using the designated drain valve or automatic moisture trap. If your facility is in a humid environment, installing an air dryer can help minimise moisture buildup and protect the integrity of the system.
Cleaning and Replacing Air Filters
Air filters play a crucial role in maintaining clean airflow within the compressor. Over time, these filters accumulate dust and debris, causing restricted airflow and increased energy consumption. Filters should be checked weekly and cleaned if they are reusable. If they are clogged or excessively dirty, replacing them every three to six months is recommended. A dirty air filter can be identified by a drop in pressure, overheating of the compressor, or a noticeable increase in energy consumption.
Checking and Changing Compressor Oil (For Oil-Lubricated Models)
Lubrication is essential for preventing friction, overheating, and excessive wear on internal components. The oil level should be checked weekly, ensuring that it is within the recommended range on the dipstick or sight glass. Oil should be changed every 2,000 to 4,000 hours of operation, or as specified by the manufacturer. Using the correct type of oil is crucial, as mixing different oil types can cause lubrication failure and internal damage to the compressor.
Inspecting and Replacing Oil Filters and Separators
The oil filter is responsible for removing contaminants from the lubrication system, while the oil separator ensures that oil does not mix with compressed air. Both components must be replaced at regular intervals to maintain efficiency. Oil filters should typically be replaced every 1,000 to 2,000 hours of operation, while oil separators should be changed every 4,000 to 8,000 hours. Signs of a failing oil separator include the presence of oil mist in the compressed air or a noticeable increase in pressure drop across the separator.
Checking Hoses and Fittings for Air Leaks
Even minor air leaks can significantly reduce the efficiency of a screw compressor and lead to increased energy costs. A simple way to detect leaks is by applying soapy water to the hoses and fittings and watching for bubbles, which indicate air escaping. If leaks are found, tightening the fittings or replacing damaged hoses should be done immediately to restore system efficiency.
Testing Safety Valves and Pressure Gauges
Safety valves play a crucial role in preventing over-pressurisation, while pressure gauges ensure that the system operates within the correct parameters. The safety valve should be tested monthly by pulling its relief ring to confirm proper function. If the valve does not release air as expected, it should be replaced immediately. Similarly, if pressure readings fluctuate unexpectedly or seem inaccurate, the pressure gauge should be checked and replaced if necessary.
Cleaning the Cooling System
A well-maintained cooling system is essential for preventing overheating, which can lead to performance issues or damage internal components. Dust and debris should be removed from cooling fans and heat exchangers regularly to ensure proper airflow. Additionally, the compressor should be placed in a well-ventilated area to allow adequate heat dissipation.
How Often Should an Industrial Screw Compressor Be Serviced?
Implementing a structured maintenance schedule is crucial for the reliable operation of screw compressors:
Note: Always refer to the user manual for manufacturer-specific maintenance guidelines.
At All Air Compressors, we understand that businesses need reliable, efficient, and well-maintained air compressors to keep operations running smoothly. That’s why we offer comprehensive air compressor service, including preventative maintenance, repairs, and emergency servicing for all types of industrial screw compressors.
Conclusion
Regular maintenance is the key to ensuring that industrial screw compressors operate efficiently, safely, and cost-effectively. A well-serviced compressor reduces downtime, improves energy efficiency, and extends its lifespan, ultimately lowering operational costs and maximising productivity.
At All Air Compressors, we specialise in professional air compressor servicing, offering preventative maintenance, emergency repairs, and complete system overhauls. Our team of highly trained technicians ensures that your screw compressor remains in peak condition, minimising disruptions to your business.
If your business relies on air compressors, don’t wait for a breakdown to take action. Ensure consistent performance and efficiency by scheduling regular air compressor service with All Air Compressors.
Get in touch with us today for expert servicing and tailored maintenance solutions. Visit All Air Compressors or call us to schedule your next service