Minor and Major Turnaround Overhauling
Minor and Major Turnaround Overhauling
An air compressor minor turnaround involves routine, often scheduled, maintenance such as filter replacement and diagnostics to address emerging issues and maintain operational efficiency. In contrast, a major turnaround (or overhaul) is a comprehensive, less frequent procedure involving full compressor disassembly, cleaning, and replacement of worn parts to restore it to near-original factory specifications or even improve its design. The choice depends on the compressor’s age, operating hours, and performance, with minor overhauls performed every few thousand hours like 2000, 4000, 8000 16,000 running hours and major overhauls every 24,000, 40,000 of hours.
Minor Turnaround (Service)
Purpose:
- Preventive maintenance to catch and address early signs of wear and tear and restore optimal flow and thermal balance.
Frequency:
- Typically scheduled every 6 to 12 months or after a specific number of operating hours.
Tasks:
- Cleaning or replacing suction and oil filters.
- Checking and calibrating the pressure switch.
- Monitoring vital signs like pressure, temperature, and vibration levels.
- Inspecting belt tension/coupling element condition.
- Diagnosing issues and restoring component function without full disassembly.
Outcome:
- Prevents minor issues from accelerating into major failures and extends the compressor's overall lifespan.
Major Turnaround (Overhaul)
Purpose:
- A complete restoration of the compressor's internal components and functionality to restore its original operating standards.
Frequency:
- Performed after many thousands of running hours (e.g., every 20,000 or 40,000 hours), as recommended by the manufacturer.
Tasks:
- Complete disassembly:of the compressor.
- Thorough cleaning: of all internal parts.
- Inspection: of all components for wear and damage.
- Replacement: of worn-out parts, such as bearings, seals, and gaskets, with new or OEM-certified components.
- Testing: the restored unit for functional aspects like discharge pressure and vibration.