Methods and steps for the maintenance of twin-screw air compressors

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During the long-term use of twin-screw air compressors, proper maintenance methods are crucial in order to ensure their reliability and extend their operational life; this is highly necessary from the perspective of the actual interests of businesses. The maintenance of twin-screw air compressors involves taking care of the main components of the compressor, including the air filter, oil filter, oil-gas separator of the compressor, compressor screw oil, intake valve, radiator, and compressor belt. Below are the methods and steps for maintaining twin-screw air compressors, one by one. 1. Maintenance of the air compressor’s air filter: The air filter in an air compressor removes dust and prevents the oil from becoming dirty, as well as stopping clogging of the filters in the oil filter and oil mist separator. If the air filter of the air compressor is not maintained regularly, the air production volume decreases and the exhaust pressure drops, which accelerates the degradation of the oil. This leads to clogging of the oil mist separator and causes the air compressor to stop operating abnormally. Failing to perform maintenance on the air compressor’s air filter at the same time can cause the oil filter to become clogged, increasing the amount of impurities in the oil and leading to premature wear and damage of the bearings in the compressor itself. Methods for maintaining the air filter of an air compressor: Stop the air compressor, remove the air filter, clean it with air, and then reinstall it. 2. Maintenance of the air compressor screw oil filter: The air compressor screw oil filter removes impurities from the screw oil, keeping it clean. Failing to maintain this filter can lead to its clogging; as a result, more impurities end up in the oil, causing premature wear and damage to the compressor’s bearings and screws ； A decrease in the amount of oil in the screw compressor leads to an increase in the exhaust temperature of the compressor, causing abnormal shutdowns. It also causes dirt to accumulate within the compressor’s oil circuit system, posing a risk to the safe operation of the compressor. Methods for maintaining the air compressor oil filter: Replace it with a new one (a failure of this component can have a significant impact on the compressor; it is essential to use genuine parts, and replacement should be carried out after 3,000 hours of operation). 3. Maintenance of the air compressor oil-gas separator: The air compressor oil-gas separator is capable of separating lubricating oil from the air after compression, returning the lubricating oil to its proper place, and delivering the compressed air. Failing to maintain the air compressor’s oil-gas separator can lead to an increase in the compressor’s exhaust temperature (resulting in abnormal shutdowns), higher power consumption by the engine. The rising temperature also accelerates the deterioration of the oil, and the high oil content in the discharged air has a severe negative impact on subsequent processing steps. Methods for maintaining air compressor oil mist separators: The best way to maintain an air compressor’s oil-gas separator is to have it replaced by the manufacturer or by a service facility authorized by the manufacturer to carry out such tasks (do not attempt to replace it yourself). 4. Maintenance of air compressor screw oil: Air compressor screw oil serves to lubricate, cool, and seal the moving and working components (such as screws and bearings), thereby enabling the air compressor to operate at its optimal performance. Failing to maintain the compressor screw oil can lead to its deterioration, resulting in a significant decline in the performance of the compressor. In severe cases, this can cause damage to the compressor itself (such as burns, damage to the surface coating, metal fatigue wear, etc.). It can also block the oil circulation system, or an increase in exhaust temperature due to dirty screw oil may cause the compressor to stop operating abnormally. Methods for maintaining air compressor lubricating oil: Shut down the air compressor, ensure that there is no pressure, and drain all the old screw oil from the oil receiver, oil cooler, compressor unit, pipelines, etc. Fill it with new screw oil (the oil level should be between the highest and lowest marks on the gauge while the compressor is running). 5. Maintenance of the air compressor inlet valve: The air compressor inlet valve uses the amount of air drawn in (or expelled) by the valve body to maintain the required pressure. Failing to maintain this valve can result in low exhaust pressure in the air compressor and increased power consumption. Methods for maintaining the air compressor intake valve: For the replacement of internal wear parts, it is necessary to entrust the manufacturer or a service facility designated by the manufacturer that possesses the necessary technical expertise to carry out the replacement (replacement is required after 12,000 hours of operation). 6. Maintenance of the air compressor radiator: The air compressor radiator is used primarily to cool the lubricating oil, thereby extending its service life and reducing the temperature of the moving parts of the compressor. It also helps to lower the temperature of the air being discharged. Failing to maintain the air compressor radiator can lead to an increase in exhaust temperature (causing abnormal shutdowns), as well as an increase in oil temperature, which accelerates the degradation of the oil. Methods for maintaining air compressor radiators: cleaning with a brush, blowing with clean air ； In very dirty conditions, it can be rinsed with high-pressure water. 7. Maintenance of the air compressor belt: The air compressor belt transmits the driving force from the diesel engine to components such as the cooling fan and generator. Failing to maintain the air compressor belt can lead to various faults in the compressor, preventing it from functioning properly. Belt slippage, belt breakage, and premature belt wear are the most common belt failures. Methods for maintaining the air compressor belt: Regularly inspect the belt, adjust its tension to an appropriate level, and replace it with a new one at regular intervals (the replacement interval is 1200 hours).