Monday, August 24, 2009

Typical Bearings Failures

Prevent over 60% of Premature Bearing Failures

Poor Fitting [16%]
About 16% of all premature bearing failures are caused by
1. Poor fitting (usually brute force ...)
2. Being unaware of the availability of the correct and proper fitting tools
3. Laziness

Individual installations may require mechanical, hydraulic or heat application methods for proper, correct and efficient dismounting or mounting.

The use of specialised tools, equipments and techniques will make the above job easier, faster and more cost effective.

These is one positive step towards long bearing life, thurs achieving maximum compressor uptime.


Poor Lubrication [36%]
About 36% of premature bearing failures are caused by incorrect specification and inadequate application of the lubrication.

Any bearings deprived of proper lubrication will long before its normal service lifespan. Bearings are usually the least accessible components of the compressors, therefore, neglected lubrication compounds the problem.

Effective lubrication, using recommended lubrication [grease, oil, coolant], Special tools, equipments, and techniques, really helps to greatly reduce downtime.


Contamination [14%]


Bearings are precision components that will not operate efficiently, unless both the bearings and its lubricants are isolated from contamination. At least 14% of all premature bearing failures are attributed to contamination.






Fatigue [34%]
Whenever compressors are overloaded, incorrectly serviced or neglected, bearings will suffer, resulting in 34% of all premature bearing failures.

Sudden or unexpected failure can be avoided, because neglected or overstressed bearings emit "early warning" signals, which can be detected and interpreted using Condition Monitoring Equipment.








Condition Monitoring Equipment
CME includes hand-held instruments, hard-wired systems and data management software for periodic or continuous monitoring of key parameters.


edited from
http://www.skf.com

A failed QJ bearing, behind is the Controller for Screw Air Compressors.

Sunday, August 23, 2009

High Oil Consumption

Increased Oil [Coolant] Consumption


1. Blocked drainage [scavenging] line

2. Type of Oil [Coolant]
[ oil vapour content]

3. Over filled sump

4. Air Release
[Oil foam build-up]




Rotary Compressor Coolant
One of the best for Rotary Screw & Vane Air Compressors
Mineral based, Long change intervals

Packing := 5 us gal.

Economic Service Life Of Oil Separators

Economic Service Life

1. Oil Care
2. Selection of Oil / Coolant
3. Operating Conditions

1. Oil Care
Oil Change Interval!
Oil Filter Change Interval!
Air Filter Change Interval!
Oil Compatibility
Oil Contamination!

2. Selection of Oil / [Coolant]
Aging Resistance
Insensitivity with Water
Compressor Suitability
Air Separation Efficiency

3. Operating Conditions
Ambient Temperature
System Cooling Oil Temperature
Foreign Harmful Bodies in Air