When a legacy centrifugal compressor began showing high vibration at a large U.S. tire manufacturing facility, the supplier needed a reliable solution to prevent operational disruption. Rather than replacing the 1,000 HP unit, Rasmussen Air & Gas Energy preformend a comprehensive airend overhaul.
By diagnosing the system as a whole, repairing heavily worn internal components, and troubleshooting an unexepected startup issues, the team successfully restored the compressor to its designed operation and extended the equipment's lifespan.
A major tire supplier relies on dependable compressed air to support demanding manufacturing operations at one of its large U.S. production facilities. Because critical equipment operates throughout the plant to meet high production requirements, maintaining continuous, reliable compressed air is essential to minimizing operational disruption and ensuring productivity.
After years of service, a Joy TA 40HZ industrial centrifugal compressor, rated for 4,000 ICFM and powered by a 1,000 HP motor, began exhibiting high vibration.
Because the compressor supports a major manufacturing operation, the tire supplier needed a dependable solution that addressed the underlying mechanical condition of the machine rather than simply treating the vibration symptom.
Rasmussen Air & Gas Energy evaluated the system and presented the client with several options and quotes for a new compressor or comprehensive rebuild. The customer opted for the more cost-effective path: a complete overhaul and rebuild of the existing unit.
Rasmussen Air & Gas Energy removed the airend and transported it to their shop. The teardown showed that years of operation had taken a significant toll. It revealed that the bearing pads were worn, rubbing, and heat-spotted, which was deemed the likely source of the vibration, with one bearing beginning to delaminate.
Across all three stages, the impellers, diffuser vanes, and inlets showed heavy erosion. Rust and erosion were so extensive that inlets were stuck inside the scrolls, and most bolts required drilling and machining during disassembly.
With the internal condition fully documented, Rasmussen Air & Gas Energy went beyond the most visible failure points: the team weld-repaired and recontoured the impellers and inlets and installed new bearings, seals, and stainless steel diffuser vane plates throughout the airend. Worn pinion journals were chrome-restored, vibration probes were reground, and bearing procurement was expedited at no additional cost.
Because the bullgear showed little damage, it was cleaned, inspected, and retained. Extensive nondestructive dye penetrant testing confirmed no linear or surface-breaking indications.
While the airend was being overhauled, the customer installed a new oil cooler on site. The replacement cooler was a different size than the original.
This change was unrelated to the vibration issue and outside the original overhaul scope, but it introduced a new operating condition during commissioning.
When the rebuilt air compressor was reassembled and started, the system did not immediately operate as expected. Rather than treating the startup problem as a continuation of the original failure, Rasmussen Air & Gas Energy worked through the new operating conditions and traced the issue to the oil cooler mismatch.
The team of engineers and technicians regulated the incoming water flow to bring the system into the correct operating range and successfully completed startup.
The extensive wear uncovered during the teardown indicated the compressor had likely been operating below its designed capacity and efficiency for an extended period. Following the overhaul and startup adjustments, the unit returned to its fully designed operation.
Approximately one year after the overhaul, the centrifugal compressor continues to run smoothly as designed.
By overhauling the existing equipment instead of immediately replacing it, the tire supplier successfully extended the useful life of a critical asset while resolving the underlying mechanical conditions.
This project demonstrates the value of diagnosing a centrifugal compressor as a complete system.
Rasmussen Air & Gas Energy identified the likely root cause of the vibration, helped the tire supplier pursue a cost-effective alternative to replacement, restored heavily worn components, and remained engaged when an unrelated on-site change created a second startup challenge.
By combining technical depth, responsiveness and practical decision-making, Rasmussen Air & Gas Energy helped the customer extend the useful life of critical compressed air equipment and return the industrial compressor to dependable service.
The successful overhaul and collaborative troubleshooting not only restored the critical equipment but also solidified a strong working relationship. Reflecting on the project's success, the tire supplier noted:
"We were glad to have the RAGE team on site with us, we worked together very well and fixed the issue. They have an incredibly talented team, we will continue to lean on them in the future when issues arise that are beyond our normal scope of repairs."
Reach out to speak with a compressed air expert about your compressed air system today.