we are using 6 no's Atlas copco ZR-250 (0-15 Bar range) screw compressors in that recently one of the compressor while starting and compressor in unloading condition(approximately 15 minutes, because there is no air requirement).

Observed that noise & smoking with sparks coming through the enclosure at outlet air line surroundings and stops the machine immediately. After opened & inspecting the service person and found that Hp element screws are not rotating and he said element is damaged due to mal-function of IC drain valves, moisture is carryover in to the element.

My observations:

Running Hrs:19968

Loading Hrs:13064

Load/Unload times:1,49,000

Slight Bearing Clearance observed in drive bearing(which the shaft pinion gear is placed) as compared to other bearing.

Is it possible to carryover the moisture during unloading condition? and i am not agree with his reason.

so please give your probable reasons for failure of HP Element & also give the allowable clearances for Hp element Bearings.

And also give suggestions for smooth operation.