- Compressor core arrives and is logged into our database system for complete traceability
- Complete teardown begins
- All teardown analysis is stored in our database and is available upon request.
- All critical wearing parts are discarded.
- These include bearings, piston rings, suction and discharge valve reeds, wrist pins snap rings, name plate
- Hydraulic unloaders mechanisms are completely disassembled
Inspection and Cleaning
- All crankcase and parts are inspected and cleaned.
- These include pistons, connecting rods, valve plates, wrist pins, heads, etc.
- All oil lines leading to bearing, crankshaft, unloader, and shaft seals are pressure tested and replaced if required.
- Environmentally friendly chemicals are used throughout the cleaning process to thoroughly clean all components of grease and other contaminants.
- To ensure the consistency and reliability of the finished product, our facility is kept meticulously clean and climate controlled to maintain a constant year round temperature.
- The cleanliness of our facility provides additional safety to the work environment.
- Any parts that can’t be brought to original specification are discarded.
- Every crankshaft is inspected for dimensions, manga fluxed and brought back to original specification.
- All recycled parts are restored to optimum tolerances on high quality machine tool, computer controlled machines.
- All cylinder walls are honed.
- Surface finishes are monitored with a profilometer.
- All stators showing signs of defect are stripped and burned.
- Salvageable stators have to sustain a dielectric insulation test of 3000 volts also known as hy‐pot test.
- All stator irons are cleaned and core loss tested.
- All stator testing and rewinding are executed in strict accordance with N.E.M.A and I.E.E.E.
- All winding insulation and materials must meet class H (180 °) including the epoxy.
- Rewound stators are impregnated using a trickled process.
- All rewound stators as well as all re-qualified stators are tested and identified, test results are recorded.
- Rotors are tested and identified.
- All rewound and re-qualified stators are fixed with a new set of thermal protection.
- All parts, sub-assemblies and components conform to original equipment specifications.
- 100% of all parts replaced are new or remanufactured.
- Crankcase (housing) is visually inspected to ensure no residual particles are trapped.
- Crankshaft end play is adjusted, dead center is verified to be within tolerance, thrust bearings are pre– lubricated.
- Sub‐assembly piston and rod, unloader power elements are installed to specification.
- Each individual compressor is fully tested under actual load conditions, all results are logged into our database.
- Each individual compressor has its own performance record document, available upon request.
- Each compressor is test run at design RPM in both directions to ensure proper oil pump reversing element function.
- Hydraulic unloader operation is verified to assure sequence and confirm proper performance.
- With the use of dry nitrogen and adjustable suction and discharge pressure regulators while in operation, the following data is recorded step by step. Actual suction pressure, discharge pressure, amperage draw on L1 L2 and L3, oil pressure over suction pressure, full load and partially loaded.
- The rotation is reversed by changing one of the incoming phases in the opposite rotation. The suction, discharge and net oil pressure are all recorded. The amperage draw on all 3 phases are recorded and compared. All must be balanced +/‐ 1 psig, +/‐ 1 amp.
- The temperature is closely monitored at the crankcase, head covers, and at the suction inlet, 3 specific locations on stator housing must be within designed criteria.
- On open type compressors, shaft seal temperature is measured and recorded. It must remain below 145°.
- Once all temperatures, pressures, amperage are checked, we put the compressor under vacuum (minimum 15 inches). It has to hold the vacuum. This is to verify there is no internal leak back.
- Once the efficiency test is complete, all covers are re-torqued to specifications.
- Each compressor is pressure tested with nitrogen to 350 psig, and is subject to 1st a gas leak detector and 2nd a hydrostatic leak detector, ensuring the lightness of the entire unit.
- Compressor is attached to pallet.
- All necessary tags are attached to the compressor to ensure it arrives safely at its proper destination.
- All required accessories are attached to the compressor.
- All paperwork (Start Up Report, Core Return Documents, etc.) are placed in an envelope and attached to the compressor.
- Finally compressor is shrink wrapped and ready for shipment.