Air End Rebuild - Before and After

Example
Our air end rebuild shop, Simple Air End Solutions, is a full service facility equipped to handle
total in-house rebuilds of stationary rotary air ends and blowers. Standard rebuilds (those not
requiring machining) are common, but this example shows an "extensive" rebuild recently
completed in our shop.
When we receive a unit, we take pictures and log on to our Work Sheet. Then, when
disassembled, we take pictures again. This particular unit showed that the rotor had welded to the
face plate (pictures taken after separation of rotor and plate).
The pictures (above) show the area of the face plate where the rotor had welded onto (plate
fractured after separation).
What caused the rotor to weld to the face plate?
Bearing failure will cause the rotor to drop and start running into the discharge housing. This
would cause the metal to liquify on extreme high temperature and the unit will shut down . Now
that the unit is off, the metal cools down and welds the two surfaces together. Remember the
clearance between the face of the rotor and plate is .003 and .005 mm.
Overheating, itself, should not cause the rotor to weld itself to the discharge plate as the high
temperature shut down should and will stop the machine. The main reason(s) for overheating
include:
 coolers have varnished or one of many other issues with oil coolers
 ambient temperature is too high (100 F or more)
 oil has broken down, lost viscosity
 thermal valve not working properly
If the unit is run backwards it can also cause the same issue. When the air end is not running it
will have the clearance (.003 to .005) between the face of the rotor and inlet plate (the end of the
rotor closest to the motor); when you power up the unit, you will have 0 PSIG on both ends of
the rotor. Now you start to make pressure (125 psig) on the discharge end of the rotor and
discharge plate (opposite end from the motor) and the rotors start to back up. That’s why you
need the clearance. If the unit runs backwards, the rotors will move in the wrong direction and
hit the discharge plate. This can make metal-to-metal contact and the rotor can weld itself to the
plate. And, of course, if the machine runs backwards, you have no oil pressure.
What steps are taken to remedy the issue and repair the unit?
In most cases, the rotor and faceplate can be pressed apart (as was done in this example).
However, there is always a risk of cracking the housing as the weld may now be stronger than
the housing. The risk is higher in some units than in other brands depending on the manufacturer.
We have a large inventory of OEM cores to draw upon when this occurs, but we also have the
ability to saw the rotor from the housing using a very high-tech tool for precise removal of the
weld.
From the pictures above, here are the finished rotor and faceplate after machining:
All machining and rotor balancing is done in-house. Rotor balancing (to 1/17th gram) is done on
every unit. We provide a detailed step-by-step update throughout the rebuild process. Digital
photos will be taken throughout the teardown, machining and rebuild process, all the way up to
crating and shipping of the unit. These digital photos will be kept on file throughout the warranty
period. After tearing down the air end, we will send you a firm quote and report of our findings
so that you can inform your customer of the exact cost before proceeding. Once the machining is
finished, the unit is cleaned, built and painted. We strap and wrap the pallet, take final pictures
and ship the unit back to you.
What sets us apart from other air end rebuild shops?
Several things that we do to assure your experience with us:
 Fast turnaround - 3 to 5 business days on Standard Rebuilds; 7 to 10 business days on
Extensive Rebuilds
 Total in-house service - all machining and rotor balancing performed in our shop
 Proactive Updates - continuous communication throughout every step of the rebuild
process to keep you and your customer informed of the status of the rebuild
 Warranty - 12 Month Standard Warranty period; 5 Year Extended Warranty available
  Quality Parts - we always use Timken or SKF bearings; never off-brand imports
 Core Inventory - we have a large (300+) inventory of Cores from All Major Brands

、Simple Air End Solutions is a specialized rotary screw air end

remanufacturing center, capable of handling all your oil flooded screw
compressor needs.  With over 40 years of combined experience in the air end
remanufacturing industry, the expert technicians at Simple Air End Solutions
deliver quality results, fast.  All machine work is done in house, ensuring every
step of the reman process is tightly monitored, right down to the rotor
balancing. 

When you choose to work with Simple Air End Solutions, you receive
continuous customer support throughout the entire reman process, and peace
of mind knowing that we only rebuild for the air compressor distributor, and
never sell to the end user.  Advantages to choosing Simple Air End Solutions
for your air end reman needs, include:
Quality Parts
Exclusive use of high quality, industry recognized brands, such as Timken or SKF;  never
off-brand imports. 

Core Inventory
Availability of large (300+) inventory of cores from all major brands, stored indoors.
 
In-House Machining
Comprehensive, in-house machining capabilities include a state of the art IRD Balancing
machine, capable of balancing rotors within one-seventeenth  of a gram, and a Thermach,
thermal spray coating system used for rotor repair.
What is a thermal spray coating?
A coating produced by a process in which molten or semi-molten particles are applied by impact
onto a substrate. A common feature of all thermal spray coatings is their lenticular or lamellar grain
structure resulting from the rapid solidification of small globules, flattened from striking a cold surface
at high velocities.
Proactive Communication
Simple Air End Solutions will take all the guesswork out of how your job is progressing by
providing  updates from the time your air end is received, up to the day your unit is shipped
with a tracking number.  Digital pictures on every unit are kept on file from the time a unit is
received, through the reman process, until it is loaded for return shipment to customers.

Fast Turnaround TImes

We continuosly outpace the competition with the fastest turnaround times in the industry.
Contact us today for an estimate on your rebuild.

Exclusive Warranty Program

Warranty Program available through SA Performance includes; a 12 month standard
warranty period and 5 year extended warranty for qualified customers.
 
Cash For Cores Program
In addition to providing outstanding air end rebuilding services, Simple Air End Solutions will
purchase used cores for a minimum of three times the national scrap price and pay the
freight to move them!

Before / After Examples

AIREND REBUILDING PROCEDURE

Once we receive your airend, it is taken to the disassembly area, which contains a mounting
stand, overhead crane and oil pit for collecting waste oil.

The airend is then assigned a work order number, and a job folder is generated to hold all
documents related to disassembly, teardown and dimensional specs.

This folder stays with the airend through the entire rebuilding process to ensure accurate
documentation from start to finish.

Once the airend is completely disassembled, the rotors, bearing carriers and end plates are
checked for wear & all measurements are recorded.

Pictures are taken identifying the problem areas.

The disassembled airend is then placed in a self contained cleaning system to remove all grease,
sludge and debris.

After the airend is completely cleaned & degreased, any parts that require machine work are
brought to various areas of the shop and the repairs begin.

If necessary, the following repairs will be made

The front and rear covers can be metalized using a thermal ARC system. Finish machining is
done on the appropriate Blanchard grinder.

The rotors are be mounted and turned on a lathe.

Bearing journals can be metalized and ground according to OEM specs.

Disassembled Airend

Polished End Plate

End Plate

Sealing Strip

The main bore areas can be metalized and bored on a vertical boring mill.  

Sealing strips can be built up and re-cut on our custom jig.

Depending on the extent of the damage, the above work normally takes 1 to 2 days to complete.

Shaft Before Repair

Shaft After Repair

Complete Air End Rebuild

All components are then cleaned again and taken to the assembly area, where all bearings, seals,
gaskets, and related materials needed to complete the assembly are pulled from inventory.

Before assembly takes place all the dimensions are rechecked including the bearing pockets,
bores and alignments. 

Both rotors are also checked for proper balance and alignment. The new bearings are measured
for proper fit before installing.

The airend is then completely re-assembled. After assembly the airend is spun unloaded for a
final check. 

To insure that the OEM specs are being met, the unit is continually measured and rechecked for
accuracy during the entire rebuilding process.

Upon completion, all open ports are plugged with plastic caps and the inlet is sealed shut. 

The airend is now ready to be skid mounted and painted the original OEM color.
As units enter the shipping area, all necessary shipping documents and startup procedures are
attached to the unit, and trucking details are arranged.

This whole process normally takes 5 to 7 working days, depending on the size of the airend and
the degree of damage. 

We have set up our shop so the work flows through on an orderly path to insure that all our
inspection steps and quality controls are adhered to.

All rebuilds are backed by our standard 400 Day warranty. Ask us how you can extend this
warranty to two years at no additional cost.

See our airend warranty sheet for complete details.