Screw Air Compressor High Temperature Failures: Causes, Diagnosis, and Solutions

In industrial production, screw air compressors are essential due to their efficiency, reliability, and adaptability. However, high temperature failures are common during operation, posing risks such as equipment damage, production delays, and even safety incidents. Timely identification and resolution of these issues are critical to ensuring stable operation and workplace safety. This guide outlines the causes, diagnosis methods, and solutions for high temperature failures in screw air compressors.

1. Risks of High Temperature Failures

Excessive heat buildup in screw air compressors can lead to:

• Equipment Damage: High temperatures degrade lubricating oil, age seals, increase bearing wear, and may cause rotor jamming.
• Production Delays: Overheating can trigger emergency shutdowns, impacting production schedules and causing financial losses.
• Safety Hazards: Overheating increases the risk of fires or explosions, endangering personnel and equipment.

2. Common Causes of High Temperature Failures

High temperature failures often result from multiple factors. Key causes include:

2.1 Cooling System Issues

• Cooler Blockage: Dust, oil residues, or corrosion reduce heat dissipation efficiency.
• Cooling Fan Malfunction: Damaged fan motors, broken blades, or loose belts limit airflow.
• Water Cooling System Failures (for water-cooled units): Poor water flow, high water temperature, or blockages reduce cooling performance.

2.2 Lubricating Oil Problems

• Oil Degradation: Oxidation and contamination impair lubrication and cooling efficiency.
• Insufficient Oil Levels: Low oil volumes increase friction and heat buildup.
• Incorrect Oil Type: Using incompatible oil reduces performance.

2.3 Equipment Overload

• Restricted Air Intake: Clogged air filters or pipe leaks limit airflow, increasing system strain.
• High Exhaust Pressure: Blocked exhaust pipes or valve malfunctions can overload the system.
• Continuous Operation: Prolonged running without breaks prevents effective heat dissipation.

2.4 Control System Failures

• Faulty Temperature Sensors: Damaged sensors provide inaccurate readings, delaying alarms and shutdowns.
• Temperature Control Valve Malfunctions: Stuck or faulty valves prevent proper oil circulation.
• PLC Control System Errors: Programming faults or module damage impair control functions.

2.5 Environmental and External Factors

• Extreme Ambient Temperatures: Hot environments impede heat dissipation.
• Poor Ventilation: Inadequate airflow around the compressor traps heat.
• Equipment Aging: Worn components lose efficiency and increase overheating risks.

3. Diagnosing High Temperature Failures

Effective diagnosis is essential for resolving overheating issues. Follow these steps:

3.1 Observe Operating Conditions

• Temperature Indicators: Monitor sensor readings to detect abnormal temperatures.
• Pressure Gauges: Verify that exhaust pressure remains within safe limits.
• Oil Levels: Inspect for oil depletion or leaks.
• Cooling System Check: Confirm fans are operational, cooler surfaces are clean, and water systems function properly.

3.2 Inspect the Cooling System

• Clean the Cooler: Remove dust, oil residues, and debris.
• Fan Maintenance: Ensure motors, blades, and belts are intact and functioning.
• Water System Maintenance: Confirm flow rates, water temperature, and clear pipes of blockages.

3.3 Check the Lubrication System

• Oil Level Check: Maintain proper oil levels.
• Oil Quality Inspection: Assess oil color, viscosity, and impurity content for signs of deterioration.
• Oil Filter Maintenance: Regularly clean or replace filters.

3.4 Assess Equipment Load

• Air Intake Inspection: Verify that air filters are clean and intake pipes are secure.
• Exhaust Pressure Check: Clear blockages in exhaust systems and ensure valves are functional.
• User Air Demand: Ensure user demand aligns with compressor capacity.

3.5 Inspect Control Systems

• Sensor Calibration: Test and replace faulty sensors as needed.
• Temperature Valve Check: Ensure the valve is functioning properly and free of obstructions.
• PLC System Evaluation: Check for programming errors or hardware malfunctions.

4. Solutions for High Temperature Failures of Screw Air Compressor

4.1 Routine Maintenance

• Cooler Cleaning: Regularly clean cooler surfaces to optimize heat dissipation.
• Oil Replacement: Follow manufacturer guidelines for oil change intervals to maintain performance.
• Cooling System Maintenance: Periodically inspect fans, water systems, and related components.
• Lubrication System Checks: Regularly assess oil levels, quality, and filter conditions.

4.2 Fault Repairs

• Cooling System Repairs: Promptly address blockages, fan issues, or water system faults.
• Component Replacement: Replace damaged sensors, valves, or PLC modules immediately.
• Overload Management: Resolve intake restrictions, pressure issues, or excessive air demand.

4.3 Environmental Improvements

• Enhanced Ventilation: Improve airflow around the compressor to support cooling.
• Temperature Control: In extreme conditions, consider air conditioning or additional ventilation.

4.4 Operational Optimization

• Load Balancing: Adjust operating parameters to prevent excessive strain on equipment.
• Alarm Settings: Set accurate temperature limits for timely alerts and automatic shutdowns.

Conclusion

Addressing high temperature failures in screw air compressors requires a proactive approach, including regular maintenance, quick repairs, improved environmental conditions, and optimized operating parameters. By implementing these strategies, businesses can ensure safe, stable, and efficient compressor performance. This guide aims to provide valuable insights for operators and maintenance personnel, helping improve equipment reliability and minimize downtime.

Precautions before starting the air compressor