Maintenance For Compressor

Establishing a regular, well -organized maintenance program and strictly following it is critical to maintaining the performance of a compressed air system. One person should be given the responsibility of ensuring that all maintenance is performed properly, on schedule and is adequately documented.

The following are typical recommended minimum maintenance procedures for reciprocating compressors and screw compressors.

Routine Maintenance for Reciprocating Compressors:

Every 8 Hours (or Daily)

1) Maintain lubricant level between high and low level mark on bayonet gauge. If lubricant is contaminated, drain and replace;
2) Give compressor an overall visual inspection and be sure safety guards are in place;
3) Check for any unusual noise or vibration;
4) Check lubricant pressure on pressure lubricated units.
5) Check for lubricant leaks;

Every 40 Hours (or Weekly)

1) Be certain pressure relief valves are working;
2) Clean the cooling surfaces of the intercooler and compressor;
3) Check the compressor for air leaks;
4) Check the compressed air distribution system for leaks;
5) Inspect lubricant for contamination and change if necessary;
6) Clean or replace the air filter. Check more often under humid or dusty condition;

Every 160 Hours (or Monthly)

1) Check belt tension;

Every 500 Hours (or 3 Months)

1) Change lubricant;
2) Torque pulley-clamp screws or jam-nut;

Every 1000 Hours (or 6 Months)

1) When synthetic lubricant is used, lubricant change intervals may be extended to every 1000 hours or every 6 months, which ever occurs first;
2) Inspect compressor valves for leakage and/or carton build-up; If excessive sludge build-up exists inside the crankcase, clean the inside of the crankcase.

Lubrication

Compressors may be shipped without lubricant in the crankcase. Before starting the compressor, add enough lubricant to the crankcase. Use the specified lubricant or consult the manufacturer for recommendations.

Routine Maintenance for Screw Compressors:

The following are typical minimum requirements for this type of compressor. Routine maintenance is relatively minimal. The microprocessor control panel monitors the status of the air and lubricant filters. When Maintenance to either device is required, the control panel may display the appropriate maintenance message and flash the location on the display as a visual remainder.

Do not move caps, plugs and other components when compressor is running or pressurized. Stop the compressor and relieve all internal pressure before doing so.

Daily

Following a routine start, observe the various control panel display and local gauges to check that normal readings are being displayed. Previous records are very helpful in determining the normalcy of the measurements. These observations should be made during all expected modes of operation.

After Initial 50 Hours of Operation

Upon completion of the first 50 hours of operation, essential readings of operating conditions should be verified and any necessary adjustments made.

Every 3000 Hours of Operation

The following items should be checked every 3000 hours of operation, although service conditions, such as relative cleanliness of process air or quality of cooling water, may require shorter inspection intervals.
1) Check/change lubricant charge and filter element;
2) Check/change air filter element;
3) Check/change control line filter element;
4) Check/clean condensate drain valve;
5) Check condition of shaft coupling element and tightness of fasteners;
6) Measure and record vibration signatures on compressor, gearbox, and motor;
7) Annual rebuilding of the inlet valve is normally recommended;

Note: Please refer to the motor manufacturer’s documentation for recommended maintenance.

Every 15000 Hours of Operation

In addition to those items covered in the 3000 hours Maintenance interval, the following items must also be checked every 15000 hours of operation, depending upon conditions of service.
1) Operate /test all safety devices;
2) Check/clean heat exchangers;
3) Check/clean blowdown valve;
4) Check/operation of balancing switch/valve assembly;
5) Check/clean check valve;
6) Check/clean galvanized interstage pipe work;
7) Check condition of isolation mounts under compressor unit and motor;

Parts Replacement and Adjustment Procedures

Familiarize yourself with the safety guidelines offered in the safety section of the manufacture’s manual before attempting any maintenance on the package.