Equipment Condition Assessment for Screw Compressors

We assess screw compressors through a structured protocol covering performance, oil system, cooling, and mechanical condition. Performance assessment includes power measurement at full load, delivered capacity measurement (or calculation from system demand analysis), specific energy calculation and comparison to OEM baseline, and discharge temperature at full load compared to design. Oil system assessment includes oil analysis review (wear metals, viscosity, TAN, moisture, particle count), separator element differential pressure, oil level and condition visual check, and oil cooler effectiveness. Cooling assessment includes aftercooler approach temperature, compressor discharge temperature trending, and cooling fan or water system condition. Mechanical assessment includes vibration measurement at bearing locations, inlet valve and capacity control mechanism operation, drive belt condition and tension (where applicable), and motor amperage at rated load. Each compressor receives a condition grade (1-5 scale) with estimated remaining air-end life based on specific energy trend, oil system health rating, cooling system effectiveness rating, and prioritized recommendations with cost estimates for service actions from routine maintenance items to air-end rebuild.