A customer reported that they were having to run more compressors that they had previously needed, despite not having increased production. Factory pressure had been lost twice, causing lost production, despite apparently having plenty of compressor power available.

Air Technology investigated the situation and found anomalies in the stage temperatures and, on testing, the screw compressor was found to be producing no air and would only make pressure of 2.6barg. Further investigation revealed the cause of the problem - the first stage dump valve was stuck open and venting to the atmosphere, because of a corroded bolt. Once rectified the compressor operated as expected.

The compressor control panel, and the system controller, showed that the compressor was fully loaded. A simple fix, taking an hour, solved the problem. The site estimated that the issue had been present for five months, costing the company around £12,500.

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