surgically remove rotors

8/18/2019 Surgically Remove Rotors

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The PROS Company

Professional Rebuild & Opmal Service, LLC

DOWN TIME IS LOST MONEY

Our equipment investments have allowed us to c

our lead mes in half. Call us for more details.

SPECIALIZING IN PROFURBISHING

Screw Compressors / Air Ends

Rotary Vane Compressors

Vacuum Pumps

Liquid Rings

Gear Boxes

Blowers

The PROS Company Also Provides:

Repair of Damaged Internal Parts

New Seals, Gaskets & O-rings

New and Reman Compressors

Repair of Sealing Strips/Tips

Dynamic Balancing

Quick Turnaround

Custom Engineering

Exchange Programs

ANY BRAND, MAKE, or

MODEL of COMPRESSOR

Mark Fie

806.316.2565

[email protected]

Ben Seymore

806.319.2770

[email protected]

Lee Levisay

405.830.0776

[email protected]

John Henry

806.789.6338

[email protected]

The PROS Company

601 Texas Avenue

Lubbock, TX 79401

www.thePROSco.com

Oce: 806.749.7761

The PROS Company has many rebuild capabilie

that other rebuilders do not.

The PROS Company has built a reputaon for th

ability to rebuild the worst compressors.

Please connue reading to learn

how The PROS Company can

surgically remove locked up roto

Has your compressor locked up?

Rotor or rotors welded to the housing?

Other rebuilders deemed your compressor

irreparable?



The male rotor in this unit was locked up. This was caused by excessive heat, which created metal exchange between the rotor and

inlet bearing seat (le). The excess heat literally creates a weld between the rotor and the housing. The rst step of repair is surgically

sawing out the locked up rotor (right).

The Surgical Removal of Seized Rotors

For some me, the main assumpon concerning seized rotors has been that the compressor is ruined, and

that a rebuild is out of the queson. The PROS Company has since been proving this assumpon wrongrebuilding locked up compressors since 2009. The overwhelming factor leading to a compressor locking up i

unwanted heat. When heat is generated inside the compressor the metal swells, which eliminates close

tolerances and leads to metal exchange. This exchange is the beginning of rudimentary welding within the

compressor. The excessive heat causes the metal to liquefy, and when the compressor does stop rotang, the

liqueed metal welds the rotor and rotor housing together.

When a locked up compressor arrives at The PROS Company, the rst step is to carefully teardown and

inspect the compressor to determine the locaon of the metal exchange. As the example photos show, the

main locaon of damage was on the inlet air collar and bearing seat. The alternave to our surgical remova

procedure would be simply to press the rotors out of the housing. Many mes this use of so much pressure

causes cracks in the housing, and these cracks could lead to irreparable damage. Instead of risking this damage

The PROS surgically saws out the seized rotor, which runs no risks of further damaging the compressor,

leaving only the inial damage caused by the metal exchange. The damage accrued during the inial meta

exchange is oen well within our rebuild capabilies.

Aer the rotor is sawed out of the housing, you can clearly see the eects of the metal exchange on the air collar of the male rotor

(le). This damage is repaired and machined back to OEM specicaons before the compressor is reassembled (right).



Aer the rotor is removed from the housing the

repairs on both the rotors and the housing can

begin. Because of the small tolerances between the

rotor and the bore in the inlet housing have been

removed, new sleeves for both the male and female

rotor are machined for the compressor. These new

sleeves are cooled down to approximately 4 degrees

Fahrenheit, while the housing itself is heated to

about 350 degrees Fahrenheit. This causes the metal

sleeves to shrink, and the housing to expand slightly.

Following the temperature regulaons of the two

components, the sleeves are carefully inserted into

the housing and all components are allowed to

return back to normal temperatures. This process

creates a new air collar surface to be machined back

to OEM specicaons. Aer the two parts return to

room temperature, the sleeves are welded into their

posions and the housing progresses onto the next

step of repair, the Blanchard grinder.

The Blanchard grinder is a machine which

machines down the weld on the two sleeves to a

at, nished surface. When the housing has nished

ts grind process, the sleeves can then be perfectly

machined back within OEM tolerances for the male

and female rotor. When the machining is complete,

the housing is ready to be reassembled.

The male and female sleeve are machined and prepared to be placed into

housing.

The two sleeves are inserted into the housing and allowed to return to no

temperatures.

The sleeves are then welded into the housing and prepped for th

Blanchard grinder.

The damage to the rotor is sprayed and prepared for machining

ack to OEM specicaons.



While the sleeves and housing are being repaired, the damage to the rotor is sprayed, using our thermal welding proc

his layer of metal will be machined back down to OEM specicaons and will ll in any scratches, dings, or other imperfec

hat occurred during the catastrophic failure. (This weld process allows us to repair damage that is deemed irreparable by ot

ebuilders.)

Aer the thermal welding repair is complete on the rotor, it is passed to a machinist for the spray to be machined b

within tolerances for the compressor. Both rotors will receive seal strip repair along with being dynamically balanced.

alancing of the rotors is essenal for opmal running situaons. Any added metal during the machining process could th

the balance of the rotor, causing vibraon, heat, and possibly bearing failure. Without dynamically balanced rotors, y

ompressor could be in the same situaon sooner rather than later.

Aer all components of the compressor are within OEM and PROS Company specicaons, the compressor is reassemb

nd shipped to you, ready for service. The PROS Company is commied to eecvely repairing seized compressors

eturning them to you in prisne running condion.

f you have a locked up compressor, don’t fall vicm to the assumpo

that your compressor is irreparable. Save me, money, and peace of

mind by sending your next locked up compressor to

The PROS Company!

e Blanchard grinder restores the parallelism between the inlet face and seat (le). Thereaer, the new sleeves for the male and female ro

e carefully machined back to OEM and PROS specicaons (right).

Both pictures are of the

same inlet housing from

a LeRoi 17 unit. The le

picture is of the damage

immediately aer the

rotor was surgically

removed, and the right

shows the housing aer

our machining process

was complete.

surgically remove rotors

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