Air-End Overhaul

A 2-days intensive, practical based Twin Screw Air Compressor's Air-End Overhaul Course.





Typical 4-point bearing use in assembling of Air End.

(Model:= QJ )

These bearing will have a shorter interval between bearing change ( Overhaul)

Typical installation position of  tapered roller bearings of some compressors

These bearings used, generally will have a longer life between Air End Overhaul?????

Air End overhaul manual for M-Range 

Special Offer

Included in A Certificate Course on Small Piston and Screw Air Compressors












Air End Overhaul  Manual will be provided.

The above are some consumable Parts !!!!!

"Blow Hole"

One of the design limitations in a Rotary Twin Screw Air Compressors.

One of the Solution:===

Flooded the twin helical screws with coolant ( OIL ).

To seal any leakages

Air End overhaul; Bearing Installation equipment: Electrical Induction bearing heater.

Local Manufactured Bearing Induction Heater.

The latest and simplified Air End Design. 

100 % Energy Efficient in transmission

Direct Drive : Without Coupling

How Filters can cost you Big !

How Filters can cost you Big ?????

You have probably heard that the old story; 

Compressed Air Filter Differential Pressure can cost you extra Energy ?

About 1% more power is consume for every 2 psi higher compressor  discharge pressure.

Ingersoll Rand EP100 air compressor [with 86 kw main motor] overhaul;

Main Motor and Air End;
Penang, Malaysia, on the 15th April 2010


The Air End to be overhaul; awaiting dismantle
Note: 

the check valve [ Non return valve ] with the arrow of flow.









The male rotor DE bearing's outer race.






Both the bearings of the rotors at the front end, where the gear box is.





Male rotor shaft on the left,

Note:
The worn out male rotor drive bearing





The rotors waiting to be push out from their cocoon [Compressor case / Housing ].









The Air End rotors' after the NU type of bearings being remove.









The Air End rotors' after the NU type of bearings being remove.
Both male and female rotors.







The pressure end side, note the tapered bearings.








The Air End cover, the high pressure side.
There is overheating at this end.







Shaft seal to prevent compressor oil [ Coolant ] from leak into the motor windings





The shaft seal is install here. [ inside ]







The dismantling of the Air Compressor main motor.


Non drive end [ NDE ] side of the main motor.
with it's cover on the cement floor.




Showing the stator and rotor shaft with motor shaft bearing.










NDE motor cover






Drive end [ DE ] side of the main motor








The DE bearing cover,








The DE bearing cover, front is the gear box side.










The motor after dismantle, prepare to clean by air jet.
Lot of white powder from the rubber glove manufacturing facilities.






Prepare the motor coil for varnishing.

















After re-varnishing the Stator Coil.








Air End Failure due to lack of Lubrication.

It is A Quincy 30 hp screw air compressor of the male rotor end bearings.

How to save costs Air Compressors for your Operation?

What should you do to reduce energy cost?

Answer !!!!!

Purchase parts & accessories direct from Manufacturer?

Use parts & Accessories from branded suppliers?

Use of parts from NON branded suppliers?

The lowest or cheapest price available?

The lowest or cheapest branded parts?

The lowest or cheapest branded parts from branded suppliers?

Prefer to deal via agents or dealers ( approved or self-claimed ), instead of manufacturers?

If you are seeking or exploring alternative solutions; please do not hesitate to contact us for discussion.

Variable Speed Drives

Variable Speed Drives:

*****

Energy Saving in Air Compressors Operation;

*****

Transmission Losses

Losses due to belt drive = 4 to 6 % due to slip

Losses using Gear Drive = 1 to 2 % due to gaps between tooth.

Losses on Induction motor = Motor efficiency

Example:

friction, heat, eddy current, etc., also known as Power Factor.

*****

Direct Drive Motor has the highest transmission efficiency

close to 100%

NO load speed (RPM) of electric motor

= (Hz X 60 X 2) / no. of poles

Example:

for a two pole Induction motor.

using formulae:

(Hz X 60 X 2) / 2 = (50 X60 X2)/2 = 3000 rpm.

Example: 

4 pole motor.

( Hz X 60 X 2 ) / 4 = (50 X 60 X2 ) / 4 = 1500 rpm.

Unload power cost:

The most inefficiency operation in a screw air compressors is at unload.

The energy cost you pay without getting any compressed air for usage. It cost you from 30% to 60% FLA when off-load.

Why?

1.

It need oil to circulate the system and some air for pneumatic control system. ( usually 15 psig ). ( oil to lubricate ).

2.

Need to cool the oil and air system.

Based on 2 pole standard motor;

Motor Speed at various frequency : 

20 Hz;

( 20 X 120 X 60 ) / 2 = 1200

25 Hz:

(25 X 120 X 60 ) / 2 = 1500

30 Hz:

( 30 X 120 X 60 ) / 2 = 1800

35 Hz:

( 35 X 120 X 60 ) / 2 = 2100

40 Hz;

( 40 X 120 X 60 ) / 2 = 2400

45 Hz;

( 45 X 120 X 60 ) /2 = 2700

50 Hz;

( 54 X 120 X 60 ) /2 = 3000

HRDF Claimable Training on Air Compressors

Testimonial from Institute Latihan Perindustrian, Jitra, Kedah for conducting a one day workshop on Basic Air Compressor course to teachers and students of the Institute.

From Almig Compressor of Germany. The number Air Compressor Company in Germany, 

The hot bed of compressor manufacturer and air end manufacturing.

You will learn in one year, what others take at least three to five years to learn this much.