Root Cause Analysis for Screw Compressors

Specialized Root Cause Analysis programs for Rotary Screw Compressor Reliability & Maintenance.

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47% Reduction in unplanned downtime

85% Faults detected before failure

3-6mo Average fault lead time

5:1 Typical program ROI

Why it matters

Key Benefits

Repeat Failure Elimination

Structured root cause analysis of screw compressors failures identifies the physical, human, and systemic causes behind failures of the male and female rotors, bearings, slide valve, and oil separation system. Addressing root causes eliminates repeat failures rather than simply replacing broken parts.

Corrective Action Effectiveness

RCA for screw compressors produces specific, measurable corrective actions with assigned owners and completion dates. Tracking corrective action implementation ensures that investigation findings translate into actual reliability improvements.

Organizational Learning

Documenting RCA findings for screw compressors failures creates a knowledge base that prevents similar failures across the fleet. Sharing lessons learned across sites and equipment types multiplies the value of each investigation.

Context

Challenge & Approach

The Reliability Challenge

Rotor contact damage is often attributed to bearing failure without determining whether the bearing failed from oil starvation, contamination, thermal overload, or improper installation during a prior rebuild. Oil separator element fires are blamed on the separator element when oil degradation, excessive carryover, or hot spot ignition may be the root cause. Capacity control valve failures are attributed to component wear when the root cause may be control system misconfiguration or excessive cycling from demand fluctuations. Air-end rebuilds performed by unqualified shops introduce clearance and alignment errors that cause repeat failures.

Our Approach

We preserve the air-end assembly for detailed disassembly examination. Rotor surfaces are inspected for contact patterns that indicate bearing displacement direction and magnitude. Bearing surfaces are examined for evidence of oil film breakdown, contamination, or fatigue spalling. Timing gear tooth surfaces are inspected for wear patterns per AGMA 1010. Oil analysis history is reviewed for trends in viscosity, total acid number, water content, and particle count preceding the failure. Operating data—discharge temperature, sump pressure, motor current, and specific energy—is analyzed for anomalies. Maintenance records are reviewed for prior air-end work, oil changes, and filter service. The RCA report documents findings and corrective actions including vendor qualification requirements where applicable.

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Root Cause Analysis for Screw Compressors

Key Benefits

Repeat Failure Elimination

Corrective Action Effectiveness

Organizational Learning

Challenge & Approach

The Reliability Challenge

Our Approach

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