Like other machinery, screw air compressors have a break-in period. During the break-in period, friction pairs undergo surface material transfer with the aid of lubricants, reaching a state suitable for optimal friction. This is the traditional concept of break-in, a narrow definition.

The new broader concept of break-in refers to the manifestation of unsuitability in basic components, connecting parts, containers, auxiliary systems, control systems, and other components or subsystems during the break-in, the exposure of design and manufacturing errors, and the appearance of other unreasonable factors, which are further corrected or self-corrected, thereby achieving an adaptation and self-adaptation process.

This process is necessary for mechanical products. The consequences of skipping or inadequately performing the break-in process can sometimes be painful for manufacturers, distributors, and owners.

For example, a well-known manufacturer’s large piston compressor with a power of 5500 kilowatts experienced incidents within a year including coupling fracture, main shaft fracture, connecting rod fracture, piston rupture, and piston rod fracture. Some fertilizer compressors even exploded, causing casualties.

Cylinder roughening, abnormal piston ring leakage, and severe stuffing box leakage are not uncommon.

Screw air compressors sometimes experience abnormal noises, high temperatures, excessive vibration, or even complete failure to operate; single-screw compressors also occasionally suffer star wheel damage.

Whether these issues can be detected early and addressed under a quality assurance system before an accident or disaster occurs is crucial. Even the zero-tolerance, zero-error standards of the US military cannot prevent space shuttle disasters. Therefore, identifying potential errors or unforeseen hazards early during equipment commissioning and break-in stages is both highly profitable and the safest approach.

Different manufacturers have different methods for the break-in period. I remember in the 1980s, Ms. Feng Yaoping, then Chief Engineer of the Mechanical Planning Institute, said after visiting Germany: Heidelberg printing machines leave the factory with the print counter displaying 4000, meaning each Heidelberg press has undergone break-in and inspection with 4000 sheets of paper in the factory. The reputation of the domestic and international compressor industry indeed does not surpass that of Heidelberg printing machinery.

Compressor manufacturers should seriously study how to handle compressor break-in and actual inspection to minimize wear losses. How manufacturers approach compressor break-in and inspection affects not only the interests of manufacturers and distributors but also those of owners, especially new project owners.

Some compressor manufacturers do not take break-in seriously and consider it unnecessary; however, neglecting it can sometimes cost manufacturers huge losses.