FTG Technical Tuesday – Air End Maintenance

FTG Technical Tuesday – Air End Maintenance

High quality rotary screw compressors such as those offered for sale by Rotair are designed, engineered and built to provide many years of reliable service. However, a screw-type air compressor is a complex machine consisting of many moving (and non-moving) parts and components. Regular preventive maintenance is essential for ensuring efficient operation, a long air compressor lifespan and reduced downtime due to the need for unscheduled repairs.

The Air-End, is the heart of any rotary screw compressor: This is where the actual compression takes place. Air-Ends can be damaged by excessive heat, contamination in the air and even dirty rotary screw compressor fluid. Your preventive maintenance procedure should include regular Air-End inspections — excessive noise and vibration can also be a telltale sign of an Air-End issue.

One of the easiest and most cost-effective ways to prevent premature wear is to replace your rotary compressor’s filters on a regular basis, as this will reduce Air-End wear and component contamination. Replacement of air inlet filters and compressor oil filters is recommended every five hundred (500) hours, and you should change the fluid every one thousand five hundred (1500) hours.

Have a technical question on an air compressor or generator? Give us a call at 855-303-7900 or email nick@ftgequipment.com

 

FTG Technical Tuesday – Load Bank Testing

FTG Technical Tuesday – Load Bank Testing

Load testing your generator system should be part of a standard planned maintenance program for all systems. The main reason to test your system under load is to make sure the generator will perform as designed, when it is needed most. This is the only true way to check the performance of the generator. A load test will allow verification that the generator system will produce and maintain full load without overheating and shutting down. It also allows testing of all components of the system, to ensure all work together as designed and intended and can help identify any potential weaknesses in controlled conditions. This allows proactive maintenance, as weaknesses are identified during controlled conditions.

Benefits of Load bank Testing

  • Verifies, the generators capabilities as opposed to just starting it up.
  • Helps to avoid “wet stacking” and cleans out carbon deposits.
  • Verifies the engine cooling system will perform properly under load

Contact (855) 303-7900 or nick@ftgequipment.com for your technical questions.

 

FTG Technical Tuesday – What is Wet Stacking?

With the new Tier 4 emissions requirements, especially in a rental application, it is very important to properly load bank a generator when it is returned. Customer’s requirements sometimes fall short of proper use of a generator. Sizing a generator too large for the job at hand, sizing a generator by fuel tank size instead of load, etc. All these issues can and will contribute to poor performance of the generator overtime. The most common issue is wet stacking. Wet stacking is when a diesel engine operates without sufficient load, it will operate at below its optimum temperature. This will allow unburned fuel to accumulate, foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce the operating performance. Symptoms of wet stacking are oily residue found around the turbo charger, leaking from the exhaust manifold gaskets and in and around the exhaust stack. Next week we will discuss Load Banking procedures. Have a technical question? (855) 303-7900 or nick@ftgequipment.com

FTG Technical Tuesday – What is the purpose of a check valve on an air compressor?

FTG Technical Tuesday – What is the purpose of a check valve on an air compressor? An air compressor check valve has only one function: to let air flow from one side to the other, while blocking air flow in the opposite direction. Once the compressed air passes the check valve, there is no way it can go back again. With the help of a check valve, a compressor can keep certain parts pressurized and other parts de-pressurized. Check valves also prevent that compressed air that has left the compressor (to the piping / air tank) back into the compressor. Have a technical question? Contact us at (855) 303-7900 or nick@ftgequipment.com

FTG Technical Tuesday – Proper grounding should always be used when running portable generators

FTG Technical Tuesday – Proper grounding should always be used when running portable generators: Generator systems must have proper grounding and bonding of all electrical components and transfer switches to minimize the possibility of uncommon current flow resulting in a power outage, damage to equipment and/or injuries to personnel. The importance of grounding and bonding circuits cannot be overstated. It is especially problematic with standby power systems as circuit breakers can trip, generators can drop offline, and important emergency and life safety loads can be lost due to hidden grounding problem(s) that could occur during a utility power outage, when standby power operation is vital.


Most mobile generators have a grounding rod (see diagram) supplied with the system should it be required. A qualified technician should be consulted to advise if the generator has to be grounded as a separately derived system, or can use the ground of the system being supplied through a solid neutral connection. Local codes should also be checked regarding the use of a ground rod, some local authorities having jurisdiction require such an accessory to be utilized by the operator. Call (855) 303-7900 or email nick@ftgequipment.com if you have a technical question.

FTG Technical Tuesday – Warning Symbols & Labels

FTG Technical Tuesday – Warning Symbols & Labels: Be sure to adhere to all warning symbols and labels located on your air compressor or generator and in the operators manuals. Going against manufacturer’s warnings may result in damage to your machine or injury to yourself. Don’t assume that every make/model of air compressor and generator has the same warnings. Have a technical question on your Rotair compressor or TecnoGen generator? Give us a call at (855) 303-7900 or email nick@ftgequipment.com

FTG Technical Tuesday – Radiator Cleanliness

FTG Technical Tuesday – Radiator Cleanliness. The biggest cause of overheating is a clogged or dirty radiator. Silt, sand and other debris can get stuck between the fins of your radiator. This causes the air from the fan to be blocked and not allowing it to pull the heat from the fins. Radiators should be checked and cleaned weekly (more so when used in an extremely dusty environment). Only low to medium pressure compressed air should be used. High air or water pressure may cause the fins to bend and block air flow. Pressure washer should only be used as a last resort on a completely plugged radiator.

Have a technical question? Give us a call at (855) 303-7900 or email nick@ftgequipment.com.

FTG Technical Tuesdays – Proper Air Filter Maintenance

FTG Technical Tuesday – Proper Air Filter Maintenance: It is extremely important to maintain the cleanliness of both the Engine and Compressor air filters. The air filters should be checked weekly at a minimum. On dirty, dusty (Sandblasting) environments, both engine and compressor air filters should be checked daily. If the Air Filter Clogged warning light comes on the unit should be shut down and both engine and compressor air filters should be checked immediately! Vacuum caused by a running compressor with a completely clogged air filter may cause dirt or debris to find a way around the filter resulting in a very expensive repair bill and excessive downtime. If you have a technical question contact (855) 303-7900 or email nick@ftgequipment.com

FTG Technical Tuesday – Minimum Generator Set Load/Capacity

Minimum generator set load/capacity: Running a generator set under light load can lead to engine damage, reducing reliability and cause “Wet Stacking”. FTG Equipment does not recommend running generator sets at less than 30-40 percent of rated load. Load banks should supplement the regular loads when loading falls below the recommended value. For technical help call (855) 303-7900 or email nick@ftgequipment.com.

FTG Technical Tuesday – On a generator, what is the difference between Prime kW and Standby kW?

Prime Power Rating – is the rating in kW that the generator can continuously run for without issue. Standby Power Rating – is the rating in kW that the generator can handle in a short term overload capacity, normally at 10% above Prime Power.

FTG is the exclusive distributor in the US for TecnoGen Generators which are considered Prime Power Generators. Have a technical question? Call (855) 303-7900 or email nick@ftgequipment.com