How to handle gumming in screw air compressors?

Causes of gumming

During operation, screw-type air compressors can experience resin buildup, which often leads to head seizure, increased energy consumption, and even equipment damage. The primary causes of resin formation include prolonged use of degraded lubricating oil, excessively high operating temperatures, cooling system malfunctions, and the use of low‑quality lubricants. High temperatures accelerate the oxidation of the lubricant, resulting in sludge and carbon deposits that eventually adhere to the rotor, oil passages, and the interior of the cooler.

Emergency Procedures and Cleaning Steps After Gelation

Upon detecting gumming in the air compressor, immediately shut down the unit for inspection to prevent forced startup, which could lead to severe wear on the compressor head or motor burnout. The specific cleaning and troubleshooting steps are as follows:

• Draining old oil and disassembly: Drain the degraded lubricating oil from the system, and remove the oil–gas separator, the oil filter, and the cooler. For compressor heads with severe gumming, disassembly and thorough cleaning are required.
• Use a dedicated cleaning agent.: Use a carbon‑detergent specifically formulated for air compressors, or a safe, environmentally friendly cleaning solvent. Inject the cleaner into the system or soak the removed components to dissolve oil sludge and resinous deposits through chemical action.
• Physical Cleaning and FlushingFor stubborn resin buildup, a soft-bristled brush or high-pressure air can be used to assist with cleaning. After cleaning is complete, thoroughly rinse with clean compressed air to ensure no residue remains.
• Drying and AssemblyAfter cleaning, thoroughly dry or blow-dry all components to prevent moisture from entering the system. Once you have confirmed that no damage is present, reassemble the components to the specified torque values.

Replacement of Consumables and System Recovery

After cleaning is complete, the lubricating oil, oil filter, and oil‑air separator element must all be replaced with new components. Before adding fresh oil, it is recommended to first introduce a small quantity of new oil to circulate through the system for flushing; run the system briefly, then drain it again to ensure thorough internal cleanliness. Subsequently, add the specified amount of new lubricating oil, start up the equipment for a trial run, and closely monitor oil temperature, oil pressure, and operating noise to confirm they are within normal ranges.

Daily Maintenance Tips to Prevent Gelation

Once the adhesive failure has been resolved, routine maintenance is key to preventing recurrence.

• Regularly change the lubricating oil.: Replace the lubricating oil strictly according to the equipment’s operating hours or the manufacturer’s recommended service intervals; never exceed the prescribed service life.
• Monitor operating temperature: Regularly inspect the cooling system, clean dust from the radiator surface, ensure the thermostat and fan are functioning properly, and prevent exhaust temperatures from becoming excessively high.
• Use genuine consumables.: Use genuine lubricants and filtration consumables that meet the equipment’s specifications, and avoid using low-quality oils.
• Regular inspectionsEstablish a comprehensive equipment inspection system, conduct regular sampling and analysis of lubricant quality, and promptly address any signs of emulsification or darkening in the oil.