Air End Overhaul and Bearing Replacement in Rotary Screw Compressors
The Heart of the Compressor: Why Does the Airend Wear Out?
One of the most sensitive and expensive mechanical components of a rotary screw air compressor is the airend (screw compressor element). Even if the compressor motor, electrical panel, and filtration system are in perfect condition, deterioration of the micron-level mechanical tolerances within the airend can significantly affect compressor performance.
Wear occurring over time can lead to reduced pressure generation, overheating, mechanical failures, and even complete compressor seizure, resulting in production downtime. Timely professional airend overhaul helps restore equipment performance while providing significant cost advantages compared to purchasing a new airend.
How Do You Know When an Airend Needs Overhauling?
Depending on operating conditions, maintenance history, and manufacturer recommendations, screw airends may require a comprehensive overhaul after approximately 20,000 to 40,000 operating hours.
- Mechanical humming and abnormal vibration
- Reduced air efficiency and delivery capacity
- Frequent compressor overheating faults
- Higher than normal motor current consumption
- Mechanical noises originating from bearings and rotors
- Increasing frequency of unexpected shutdowns
Advantages of Professional Airend Overhaul
A professional airend overhaul supports reliable compressor operation by replacing worn mechanical components and readjusting precision tolerances.
- Cost-effective alternative to purchasing a new airend
- Renewal of bearing and rotor systems
- Reduction of mechanical vibration and friction
- Improved compressed air production performance
- Helps prevent unexpected mechanical failures
- Extended compressor service life
Main Symptoms of Airend Failure
Mechanical Humming and Vibration: When deformation begins to develop in bearing housings and bearing components, the compressor may produce high-pitched noises and excessive vibration. These symptoms can be early warning signs of progressive mechanical wear.
Reduced Air Delivery Performance: An increase in the time required to fill the compressor air receiver may be associated with increased clearances between the rotors due to wear or other efficiency losses within the system.
Frequent Overheating Faults: Increased friction between the rotors and housing, deterioration of lubrication performance, and higher mechanical resistance can cause operating temperatures to exceed normal levels.
Excessive Current Draw: Increased mechanical resistance within the airend may cause the main electric motor to draw more current than normal, triggering protection systems and shutting down the compressor.
If one or more of these symptoms occur, the airend and other compressor components should be inspected using professional diagnostic equipment.
Explore Our Airend Overhaul Services
Stages of a Professional Airend Overhaul
- Disassembly and Micron-Level Inspection: The airend is carefully disassembled using hydraulic presses and specialized removal tools. Mechanical tolerances on rotor shafts, helical profiles, and the cast housing are inspected using precision measuring instruments and dial indicators.
- Bearing Replacement to Original Standards: High-speed precision compressor bearings designed to withstand axial and radial forces are inspected. Worn bearings are replaced with SKF or FAG quality bearings that comply with the manufacturer's technical requirements.
- Rotor Clearance Adjustment: Micron-level clearances between the male and female rotors, as well as between the rotor end faces and housing cover, are adjusted using precision shims. Excessively tight clearances increase the risk of overheating and seizure, while excessive clearances increase internal air leakage.
- Shaft Sealing and Seal Replacement: PTFE shaft seals, sealing components, and wear sleeves that prevent oil leakage are inspected. Necessary components are replaced to maintain the sealing performance of the airend.
- Test Bench and Performance Inspection: After assembly, the mechanical operation, vibration levels, lubrication condition, and operating temperatures of the airend are inspected. Following the necessary rotor balancing and performance tests, the system is prepared for commissioning.
The Assurance of the Ercom Overhaul Workshop
At Ercom Compressor, we perform professional airend overhauls for rotary screw compressors of various brands and models.
Through precision mechanical measurements, bearing replacements, rotor clearance adjustments, and sealing procedures, we aim to restore reliable and efficient airend operation.
We provide long-lasting service solutions through high-quality spare parts, expert workmanship, and controlled testing procedures during the overhaul process.
Overhaul Support to Minimize Production Downtime
Preventing production losses during an airend overhaul is extremely important for industrial businesses. Ercom Compressor helps maintain production continuity by providing the technical support required throughout the overhaul process.
During overhaul operations, we aim to meet your facility's compressed air requirements by offering temporary replacement compressor support, subject to suitability and availability.
Contact our technical team for detailed information about compressor airend overhauls and bearing replacement services.