Screw Compressor Overhauling Service in Bangladesh

Screw Compressor Overhauling Service in Bangladesh: A Complete Step-by-Step Guide for Industrial Maintenance

In any modern industrial setup, a screw compressor is considered one of the primary sources of energy. From a textile factory to a pharmaceutical plant, a food processing unit to a manufacturing factory, compressed air is required for the efficient operation of any machine. This is where the importance of Screw Compressor Overhauling Service comes into play. If overhauling is not done in time, it directly affects the efficiency of the compressor. In this article, we shall discuss what overhauling is, why it is required, and what the process involves when a professional service is hired for the purpose.

Step 1: What Is Screw Compressor Overhauling?

Screw compressor overhauling is a complete process of inspection, maintenance, and restoration of all the internal as well as external components of a compressor. In this process, all the worn-out parts of the compressor are replaced, the internal systems are cleaned, and any damaged component is repaired as well as replaced.

In a rotary screw compressor, there are a number of components involved. These include:

• Airend/Rotor Unit

• Bearings

• Oil Separator

• Oil Filter

• Air Filter

• Cooling System

• Electric Motor

• Control Panel

During the process of overhauling, all the above-mentioned parts are thoroughly inspected.

Step 2: Why is Screw Compressor Overhauling Necessary?

It is not possible to achieve the desired performance by simply performing maintenance work on the compressor. There are various reasons why the compressor requires overhauling, such as:

• If the compressor makes unusual sounds.

• If the compressor is vibrating excessively.

• If the amount of oil being consumed increases.

• If the air pressure is unstable.

• If the electricity bills increase unexpectedly.

• If the compressor is shut down too frequently.

• If the compressor is not performing as desired.

By performing the overhauling of the compressor, the following benefits can be achieved:

• Improved efficiency of the compressor

• Reduced energy consumption

• Increased life of the compressor

• Reduced costs of maintenance

• Reduced downtime during the production process

Step 3: Complete Inspection and Diagnosis

The process of overhauling the compressor is initiated by performing the inspection of the compressor, as follows:

During the inspection, the operating pressure is checked.

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• The temperature is also checked.

• The quality of the oil is analyzed.

• The vibration is also checked.

• The electrical systems of the compressor are also inspected.

The inspection is performed by the prominent compressor manufacturing companies, such as Atlas Copco, Ingersoll Rand, and Kaeser Kompressoren, using sophisticated machines for the diagnosis of the problem with the compressor.

Step 4: Airend Disassembly and Bearing Replacement

The airend is the core part of the screw compressor. When the bearings in the airend deteriorate, this can lead to:

• More noise

• Less efficiency

• Rotor misalignment

• Severe internal damage

When the compressor is being overhauled:

• The airend is disassembled

• Worn-out bearings are replaced

• New bearings are fitted

• Rotor clearance and alignment are determined

This is the most critical part of the whole process.

Step 5: Oil System Cleaning and Replacement

In the case of the oil-injected screw compressor, the lubrication system plays an important role in the smooth running and efficient cooling of the compressor.

When the compressor is being overhauled:

• The old compressor oil is removed

• New oil filters are fitted

• The oil separator is replaced

• The internal oil pipes are cleaned

• New compressor oil is added

This ensures the smooth running and efficient cooling of the compressor.

Step 6: Cooling System Overhaul

Overheating is the leading cause of compressor failure. Therefore, the cooling system should always be in good working condition.

When the compressor is being overhauled:

• The air or oil cooler is cleaned

• The radiator is flushed

• The fan and motor are checked

• The thermostatic valve is inspected

This ensures efficient and smooth running of the compressor.

Step 7: Electrical and Control Panel Testing

In new screw compressor designs, PLC and smart control systems are used for automatic control of the compressor. Electrical testing is an important part of screw compressor overhaul.

In screw compressor overhaul, the following are carried out:

• Control panel wiring test

• Sensor calibration

• Pressure switch test

• Motor insulation test

• Overload relay test

If electrical testing is not carried out properly, it will not be possible to obtain satisfactory results from screw compressor overhaul and repair work alone.

Step 8: Reassembly and Performance Testing

Once all repairs and replacement of damaged parts are complete, reassembly of the screw compressor begins.

• No-load test

• Full-load test

• Stability test

• Pressure test

• Air leakage test

All these tests are carried out to ensure that the screw compressor performs optimally and within the required standards.

Step 9: Benefits of Professional Screw Compressor Overhauling Service

If professional screw compressor overhaul services are availed of, several benefits are obtained in the long term:

Maximum Efficiency

The compressor will regain its original efficiency.

   Energy Saving

Energy consumption can be reduced by 10% to 20%.

   Long Service Life

The compressor’s working life will increase by several years.

Less Chances of Breakdown

Unexpected breakdowns will be significantly reduced.

Cost-Effective Solution

Overhauling will be more economical than purchasing a new compressor.

Step 10: When Should You Perform Overhauling?

Overhauling is suggested in the following scenarios:

• After 20,000 to 30,000 running hours

• When excessive vibration or noise is detected

• When signs of wear on the airend are evident

• When excessive trips or pressure instability occur

In the case of heavy industrial applications, it may be suggested that the overhauling be carried out even earlier.

Why Choose Professional Overhauling Service in Bangladesh?

Bangladesh has a rapidly expanding industrial sector, especially in textiles, garments, pharmaceuticals, and manufacturing industries. Compressed air systems play a vital role in the smooth operation of such industries.

What does a professional service provider offer?

Authentic spares used in the process

Expert and experienced engineers at work

On-site support available at all times

Warranty guarantee offered

Emergency services available in case of a breakdown

Working with experienced professionals will ensure that your compressor is running efficiently, safely, and reliably.

Final Thoughts

Screw Compressor Overhauling Service should be viewed as an investment and not as a cost.