Industrial compressors are essential – over a large scale – for different manufacturing industries and plants. However, maintaining them can be a tough challenge as they usually require ultra-specific spare parts for replacing damaged components.
Most owners also have a hard time searching for an exhaustive range of equipment, pumps, etc. But this usually depends significantly on the model or brand of the compressor unit. Certified or highly trained professionals must check the unit and make the necessary replacement.
Compressor Parts You Should Know
Specialists can identify all compressor components and their purpose. These manufactured parts are designed to be durable.
However, some of these parts may fail if the unit is used daily to facilitate manufacturing processes. Identifying the part numbers, brand name, year/model of the parts, etc., can confuse non-skilled individuals. This is why this aspect is best left in the hands of professionals.
Nevertheless, the major categories that require spare compressor parts include:
- Compressed air filter
- Dust collector
- Air dryers
- Drain valves
- Heat exchanges
- Receiver tanks, etc.
Some of these parts require replacement from time to time for the smooth operation of the compressor. Those parts usually include:
- Hose reels
- Drain valves
- Flex hoses
- Drain cocks, etc.
These parts are easier for non-skilled personnel to identify because they are generally listed according to size and manufacturer.
Common Types of Compressor Repair
There are different compressor units used in industrial capacities. Each one has issues peculiar to it. This section covers 2 different compressor units and the issues they throw up from time to time and repairs.
Rotary Screw Compressors
This type of air compressor makes use of a rotary-type positive-displacement mechanism. Some of the critical components that require checks, maintenance, or replacement include;
Most problems with rotary screw compressors stem from the sensors and controls. A sticky thermal valve element or defective pressure transducer can shut down your compressor unceremoniously.
This is why it is considered an excellent practice always to have these accessories or components in stock. You should also know a highly reliable service provider or center that usually has such products in stock.
Excessive Oil Carryover
The primary cause of oil carryover is a faulty or blocked scavenge line check valve. You may need to change the scavenge line by replacing it with a newer one.
Oil separators can also cause excessive oil carryover. Change them occasionally as they can easily rupture if used for extensive periods.
Inability to Build Pressure
If the compressor cannot build pressure, you should focus on two things. The first is that you may have an inlet air filter that is dirty. Secondly, the minimum pressure valve or inlet valve may also be defective.
Inspect these components and clean them regularly. Both components generally have seals or packing rings that must be replaced once in a while.
Items that Require Routine Maintenance
Changing the oil filter as well as the air filter from time to time is essential. This helps to prevent several problems with the compressor unit. Changing the filters regularly also helps preserve the life of the oil cooler and compressor lubricant.
That is that for rotary screw compressors. Let’s head over to reciprocating compressors.
This type of compressor reciprocates within a cylinder unit. Its piston continuously moves up and down to pump air right after compression into the air receiver.
Some of the crucial components that require regular checks or maintenance include:
Valves cause problems in compressors due to the buildup of carbon deposits. This causes the compressor to take longer to build up the needed pressure for smooth operation.
Therefore, make sure you clean valves regularly or replace them if discovered to be faulty.
If the pressure switch or check valve is faulty, you may find it somewhat challenging to start the compressor. Even problems with pilot valves can cause compressors not to unload appropriately.
Get a trained specialist to check out and replace faulty pilot valves and check valves.
Piston rings tend to wear out when the compressor is used extensively. The worn-out piston rings may bring about excessive oil consumption if left unchanged.
Therefore, as soon as you notice that the piston rings are worn out, get them replaced with new ones immediately.
At times, belts can be too loose or too tight, which could affect the operation of a compressor. The pulley could also be out of alignment, and this causes the belt to wear excessively.
Check and change the belts. Get a professional to check out the pulley in order to ensure it is still locked in position. If it isn’t, you may have to replace the pulley.
Air Intake Filters
Dirty air filters cause overheating and long pump-up times. Inspect these carefully and then change now and again. These are issues you want to avoid as any problem from this area can halt operations for hours or even days.
Routine Maintenance Components
You should carry out routine maintenance on the compressor. This includes changing the oil and air filter regularly, etc. Check and change Routine maintenance components on occasion.
These changes help prevent lots of mechanical problems. They also help extend the lifespan of rings and valves on the unit.
When compressor parts fail, they cause a breakdown of the unit, bring business to a halt, and cause panic. However, it doesn’t have to be that way. There are more than a few maintenance and repair issues you should focus on when it comes to your air compressor—replaced with identical but authentic spare parts.
But only if you work with authorized compressor distributors and certified professionals who will check and then work on the entire system. This is crucial so that you don’t experience any downtime during your day-to-day operations. You will also bring in more revenue if your compressor is working as it should, as every process runs smoothly.
Contact Samco today if you have any questions concerning your compressor.