ROTARY SCREW AIR COMPRESSOR KEEPS SHUTTING DOWN. WHY? AIR COMPRESSOR TROUBLESHOOTING. DFW. TEXAS

 

COMPRESSOR TROUBLESHOOTING

Understanding Why Your Atlas Copco Rotary Screw Compressor Overheats and Shuts Down During Production

Introduction

Atlas Copco rotary screw compressors are renowned for their reliability, efficiency, and durability in various industrial applications. However, like any complex machinery, they can experience issues, one of the most common being overheating and subsequent shutdown during production. This problem can cause significant disruptions and impact productivity. Understanding the causes of overheating is crucial for diagnosing and resolving the issue. This essay explores the potential reasons why an Atlas Copco rotary screw compressor might overheat and shut down during production, providing a comprehensive guide to identifying and addressing these issues.

Basic Operation of a Rotary Screw Compressor

To understand why a rotary screw compressor might overheat, it’s essential to understand its basic operation. A rotary screw compressor works by trapping air between two meshing helical screws (rotors) and compressing it as the screws rotate. The main components involved in this process include:

1. Air Filter: Cleans the incoming air.
2. Compressor Element: The rotors that compress the air.
3. Oil Filter and Separator: Filters and separates the oil used for lubrication and cooling.
4. Coolers: Reduce the temperature of the compressed air and oil.
5. Control System: Manages the compressor’s operation.

TROUBLESHOOTING

Common Causes of Overheating

1. Inadequate Ventilation

Proper ventilation is critical for maintaining optimal operating temperatures. Inadequate ventilation can lead to heat build-up within the compressor, causing it to overheat.

Solution: Ensure that the compressor is installed in a well-ventilated area. Check for obstructions around the air intake and exhaust vents. If necessary, install additional fans or ventilation systems to improve airflow.

2. Dirty or Clogged Filters

Air filters, oil filters, and separators play a crucial role in maintaining the compressor's efficiency and temperature. Dirty or clogged filters can restrict airflow and reduce cooling efficiency, leading to overheating.

Solution: Regularly inspect and clean or replace air filters, oil filters, and separators according to the manufacturer’s recommendations. Keeping these components clean ensures proper airflow and cooling.

3. Insufficient Oil Levels

Oil in a rotary screw compressor serves multiple purposes, including lubrication, sealing, and cooling. Low oil levels can impair the cooling process, causing the compressor to overheat.

Solution: Check the oil level regularly and top up as needed. Ensure that you use the correct type and grade of oil specified by Atlas Copco. Implement a regular oil change schedule to maintain optimal oil quality.

4. Faulty Oil Cooler

The oil cooler is responsible for dissipating the heat generated during compression. A faulty or dirty oil cooler can reduce cooling efficiency, leading to overheating.

Solution: Inspect the oil cooler for signs of damage or blockages. Clean the cooler fins to ensure proper heat dissipation. If the cooler is damaged, replace it to restore cooling efficiency.

COMPRESSOR TROUBLESHOOTING

5. Ambient Temperature

High ambient temperatures can increase the operating temperature of the compressor, making it more susceptible to overheating, especially if the compressor is located in a hot environment or near heat sources.

Solution: Ensure the compressor is installed in a location with a stable, moderate ambient temperature. If high temperatures are unavoidable, consider installing air conditioning or additional cooling systems to reduce the ambient temperature around the compressor.

6. Overloading

Running the compressor at or beyond its maximum capacity can cause it to overheat. Overloading can result from demanding production schedules or using the compressor for tasks beyond its rated capabilities.

Solution: Monitor the compressor’s load and ensure it is operating within its specified capacity. If production demands exceed the compressor's capabilities, consider upgrading to a larger compressor or adding an additional unit to share the load.

7. Faulty Thermostatic Valve

The thermostatic valve controls the oil temperature by regulating the flow of oil through the cooler. A faulty thermostatic valve can result in inadequate cooling, leading to overheating.

Solution: Inspect the thermostatic valve for proper operation. If it is not functioning correctly, replace it to ensure proper regulation of oil temperature.

8. Blocked or Damaged Aftercooler

The aftercooler reduces the temperature of the compressed air before it enters the storage tank or distribution system. A blocked or damaged aftercooler can impair the cooling process, causing the compressor to overheat.

Solution: Inspect the aftercooler for blockages or damage. Clean the aftercooler fins and ensure that there is no debris obstructing airflow. Replace the aftercooler if it is damaged.

9. Electrical Issues

Electrical problems, such as faulty wiring, overloaded circuits, or malfunctioning components, can cause the compressor to overheat and shut down.

Solution: Inspect the electrical system for any signs of issues. Check wiring connections, circuit breakers, and electrical components. Address any problems by repairing or replacing faulty electrical parts.

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Diagnosing Overheating Issues

Diagnosing the cause of overheating involves a systematic approach to identify and address the root cause. Here’s a step-by-step guide to help you diagnose the issue:

1. Visual Inspection:

   • Start with a visual inspection of the compressor and its components. Look for any obvious signs of damage, wear, or blockages.

2. Check Ventilation:

   • Ensure that the compressor is installed in a well-ventilated area. Remove any obstructions around the air intake and exhaust vents.

3. Inspect Filters:

   • Remove and inspect the air filters, oil filters, and separators for any signs of clogging or damage. Clean or replace the filters as needed.

4. Check Oil Levels:

   • Inspect the oil level and top up if necessary. Ensure you are using the correct type and grade of oil specified by Atlas Copco.

5. Inspect Oil Cooler:

   • Check the oil cooler for signs of damage or blockages. Clean the cooler fins and replace the cooler if necessary.

6. Monitor Ambient Temperature:

   • Check the ambient temperature around the compressor. If it is too high, consider installing additional cooling systems or relocating the compressor to a cooler area.

7. Check Load:

   • Monitor the compressor’s load to ensure it is operating within its specified capacity. Adjust the load or consider upgrading the compressor if necessary.

8. Inspect Thermostatic Valve:

   • Check the thermostatic valve for proper operation. Replace it if it is not functioning correctly.

9. Inspect Aftercooler:

   • Inspect the aftercooler for blockages or damage. Clean the aftercooler fins and replace it if necessary.

10. Check Electrical System:

• Inspect the electrical system for any signs of issues. Check wiring connections, circuit breakers, and electrical components. Address any problems by repairing or replacing faulty electrical parts.

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Preventive Maintenance to Avoid Overheating

Regular preventive maintenance is essential to avoid overheating and ensure the efficient operation of your Atlas Copco rotary screw compressor. Here are some preventive maintenance tips:

1. Regular Inspections:

   • Conduct regular inspections of the compressor and its components to identify and address any potential issues early.

2. Routine Cleaning:

   • Keep the intake filter, oil filter, separators, oil cooler, and aftercooler clean to ensure proper airflow and cooling.

3. Timely Replacements:

   • Replace worn or damaged parts, such as filters, oil coolers, thermostatic valves, and aftercoolers, promptly to prevent further damage and ensure efficient operation.

4. Monitor Operating Conditions:

   • Monitor the operating conditions, including ambient temperature and load, to ensure they are within the recommended range for your compressor.

5. Proper Ventilation:

   • Ensure the compressor is installed in a well-ventilated area with adequate airflow to dissipate heat.

6. Regular Oil Checks:

• Check the oil level and quality regularly, and top up or change the oil as needed to ensure proper lubrication and cooling.

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Conclusion

Overheating and shutdown of an Atlas Copco rotary screw compressor during production can be caused by a variety of factors, including inadequate ventilation, dirty or clogged filters, insufficient oil levels, faulty oil coolers, high ambient temperatures, overloading, faulty thermostatic valves, blocked or damaged aftercoolers, and electrical issues. Diagnosing and resolving these issues requires a systematic approach and regular preventive maintenance to ensure the compressor operates efficiently and reliably. By understanding the common causes of overheating and implementing the solutions and preventive maintenance tips outlined in this essay, users can minimize downtime, extend the lifespan of their compressor, and maintain productivity in their operations.