Discover useful PDF charts and learn about the basics of air compressor maintenance below. Ask a Question: "What are the keys to maintaining an efficient compressed air system?
According to "Wikipedia": Preventive maintenance PM has the following meanings:. Maintenance, including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring.
Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on.
In addition, workers can record equipment information and deterioration so they know to replace or repair worn parts before they cause system failure. The ideal preventive maintenance program would prevent all equipment failure before it occurs. For example, a slowly increasing temperature indicates a variety of maintenance requirements including cooler core cleaning, overloading of system and possible mechanical problems. Another example might include slowly decreasing pressure, indicating increased system flow requirements, reduced compressor performance or increased system leakage.
Make sure someone is looking at this data on a regular basis. If the data is never reviewed then the benefit is lost. In some operations, down-time can cost hundreds, even thousands of dollars an hour. There are many misconceptions about preventive maintenance This line of thinking says regularly scheduled downtime for maintenance costs more than operating the equipment until repair is absolutely necessary This may be true for some components, but don't forget to consider the long-term benefits and savings associated with preventive maintenance that have been previously mentioned.
If regular Preventive Maintenance can help reduce unexpected downtime that results in loss of production, time and materials or the ruining of an expensive plant process--then it is well worth the investment. Not to mention that unscheduled shut-downs can be extended if the correct equipment parts or repair technicians are not readily available.
The primary goal of maintenance is to avoid or reduce the consequences of failure of your compressed air equipment. PM is designed to preserve and restore equipment reliability by replacing worn components before they actually fail.
Here are several factors to consider when assessing your compressed air equipment: -How critical is your compressed air equipment? If equipment fails, what is the impact on production or safety. Equipment histories will prove that most failures occur during infancy newly installed or recently overhauled and old-age self-explanatory. How many times has this equipment failed in the past?
Assessing the answers to these questions will help you determine when your older equipment needs fixing or replacing.
Preventive Maintenance will help your equipment last longer, run better, and save you loads of money in the long haul.
Your operators should review the equipment information and keep it handy for future reference. Before performing any maintenance function, switch main disconnect switch to "off" position to assure no power is entering unit.Nothing will stop your business cold like a refrigeration equipment meltdown. Having a refrigeration preventative maintenance checklist will help you complete routine commercial refrigerator maintenance tasks that will prevent untimely breakdowns and headaches.
Clean the equipment. Though the fast pace of your kitchen lends itself to food and beverage spills and little time for prompt cleanup, it is an imperative that you clean drips and splatters on a timely basis as part of your daily commercial refrigerator maintenance program. The longer you let a spill settle, the harder it will be for you to clean it without the use of a potentially harmful cleaning agent.
Uncleaned spills can lead to unpleasant odors effecting the quality of your ingredients and mold growth that can jeopardize the safety of your food. Check settings. Another simple item on your refrigeration preventative maintenance checklist is to check your temperature and defrost frequency settings daily. If the temperature is set lower than necessary, your system will be working too hard, which can shorten its life.
If the unit is too cold, ice could form, especially on liquids. On the other hand, if your temperature is not cool enough, your food could spoil. Defrost on schedule. Defrosting your unit too often is creating unnecessary work for your refrigerator. Clean out units to prevent crowding. No one likes to be packed in like sardines; even the sardines. When coming up with a refrigeration preventative maintenance checklist, make sure to include a reminder on overcrowding.
The air will not be able to freely circulate in a refrigerator packed to the gills, which will make the unit work harder to maintain its set temperature.
Clear the area to maximize airflow. Besides the proper interior airflow, do not overlook exterior airflow issues. Unfortunately, kitchens are often cramped spaces. If you do, your unit will have to work harder to cool the food stored inside. This not only chews up electricity, it could bring about the premature end to your system.
Inspect seals and fix leaks. Another regularly performed task on your refrigeration preventative maintenance checklist should be air leak inspections.
When the gaskets or seals on your doors are ripped or loose, air can escape, which is another reason why your unit might be overworked and your electric bill on the rise. Minor gasket leaks can be repaired with silicone caulk. If the doors are not properly aligned, cool air is likely escaping.
This should be a monthly activity. Check interior lights. A lights-out refrigeration preventative maintenance checklist item is remembering to shut off the lights in your freezer or cooler. It may seem trivial, but lights generate heat, which again is another reason your refrigeration units might be working harder than necessary.
However most busy restaurant managers choose to assign these tasks to a professional, who can do the job better with the proper equipment and supplies to do the work safely and efficiently.
Clean coils. Coil cleaning is critical to the efficient operation of your system and should be on every refrigeration preventative maintenance checklist. If your coils are caked in dirt and grime, it will interfere with the transfer of heat from your system. This is yet another cause of inefficiency and your system working overtime, which will accelerate repairs.Weekly air compressor preventive maintenance checks with KAESER
Clean fan blades.Air compressor maintenance is not a tiresome job but obviously to many it is the most irritating job. Do you know you can extend the life of the compressor twice just by little maintenance once or twice in a year. I have given here some air compressor daily checklist, read it, take your compressor and start your maintenance job.
The pump of an air compressor is the center component of an air compresses; it sucks air and drain it to a receiver or air tank. This pump can be either oil-lubricated or oil-free. Industrial grade compressors are generally found to be featured with oiled pump. However, for oil-free pump there is no maintenance.
After long use the Teflon piston ring decay and fail to build pressure perfectly. The reason is the Teflon ring can seal the cylinder properly and leaks air. Many users can change the ring by themselves and you need not to be expert on that. Though this is critical but with the help of YouTube videos you can do it. For oil-lubricated pump, you have to change the oil after certain period of use. This is quite easy and you can do it by yourself. Many compressors have oil-sight glass like Makita Mac that will let you know when to change oil of your compressor pump.
By the color of oil, you will understand whether to change oil or not. There are few records of tank explosion and it happens when the tank grows old and rusty.
When you are done with your job, remove the drain valve to flow out water inside the tank. To reduce the tank pressure, open the safety relief valve manually and now you are safe. Keep the drain valve open for 5 minutes and let the tank dry. You can also keep it open until you start working next day. Why should you do that? This is a simple science.
Water creates rust in iron. When water deposits for long time under the tank, the tank starts to decay thus gets premature damage. There are different material built air compressors tank e. With cast iron manufactured tank, you should drain the tank after every single use; for the rest two types once in a week will do well. The function of an air filter is to block dirt from the air to ensure clean air flowing into the pump. So the filter becomes dirty very soon and requires periodic cleaning.
Either you can wash it or blow it out.Compressor 1. Have a lubrication regime, your lubrication regime should include greasing motorsoil top-up compressor, in-line lubricators etc and oil replacement compre ssor 2. Check and replace filters 3. Check drive belts where fitted 4. Check the tension and condition of drive belts 5. Clean air and oil filters Ensure air and oil filters are kept free of dirt and debris. Compressed Air System 1.
Check for leaks or damage 2.
Have a lubrication regime including greasing, oil top-up and oil replacement 3. Check the operation of valves 4. Check condensate traps and ensure that manually operated ones have not been left open 5. Learn more about Scribd Membership Home. Read Free For 30 Days. Much more than documents. Discover everything Scribd has to offer, including books and audiobooks from major publishers.
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Standard Maintenance Tasks
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Flag for inappropriate content. Download Now. Related titles. Carousel Previous Carousel Next. Jump to Page. Search inside document. Documents Similar To Mohammed Jahir Husain. Satheesh Kumar.When it comes to an air compressor, maintenance in the standard form is never enough. To ensure the smooth running of operations and avoid interruptions and unexpected downtime, it is crucial to have a compressor maintenance program in place that prevents — rather than reacts to — problems with the air compressor and all attached tools and machinery.
In smaller businesses, maintenance is a standard procedure that amounts to toner refills and software and hardware upgrades. Essentially, standard maintenance is what you perform on equipment that works consistently until it expires or becomes outmoded by newer technology. At facilities that employ high-tech machinery, you must perform more than just standard maintenance to ensure the operability and longevity of all the expensive equipment on hand.
With air compressors, for example, you need to implement a preventive maintenance program where you get the compressor and its system peripherals inspected routinely to ensure everything is in optimal running condition.
The purpose of preventive maintenance is to catch mechanical problems before they spread and necessitate costly repairs and system downtime. As such, preventive maintenance consists of inspections of all consequential system components — some according to a daily schedule, others on a weekly, monthly, quarterly or annual basis — to ensure everything works as it should.
If you detect problems early, you can take steps to rectify matters. In some cases, preventive maintenance involves low-cost measures that help avoid costlier situations down the line. For example, when a maintenance staffer notices a compressor belt has a minor crack, replacing the belt then and there helps your company prevent a costlier scenario in which the belt snaps, the compressor stops working and productions grind to a halt as staff work to identify the problem and take the necessary steps to get the system back up and running.
Regardless of the size or scope of your compressor operation, it is vital to have someone on staff, or work with a qualified service provider, to oversee preventive maintenance work on a timely and consistent schedule.
Only with preventive maintenance can you ensure the machines will work hour by hour, day after day, and continue to operate to their full life expectancy. One of the foremost benefits of air compressor maintenance is that it makes the equipment run smoothly and more efficiently and decreases occurrences of system downtime.
As anyone who runs an air compressor facility knows, downtime can be a very costly problem because when the machines fail to function, it halts production. A company that fails to enact timely maintenance protocols runs the risk of encountering performance issues with greater frequency.
Such occurrences are hard to predict, but can arise at the worst moments, such as when a high-cost production is underway with a set deadline. To be on the safe side, you need to perform maintenance as scheduled without skipping a date, even on days when everything seems to be running flawlessly with no conceivable problems in sight. With reduced occurrences of downtime and parts failure in your air compressor system, you save money.
As such, you profit both ways — through increased productivity and reduced overhead. The money you save through timely compressor maintenance allows you to invest more in better equipment as innovations reach the market. When you perform air compressor maintenance on a regular schedule, it allows you to catch instances where a function within the system is over-exerting or struggling to maintain an expected rate of production.
When such issues do arise, it is often down to a part that needs cleaning, replacement or lubrication. By spotting these problems before they grow out of hand, the machine runs smoother and more efficiently, which translates to energy savings. Of course, energy savings also amount to money saved in your overall production costs.
With lower monthly energy costs, you can invest the money back into the infrastructure of your company. Of course, the greatest benefit of air compressor maintenance is that it increases the life and efficiency of the machine itself and the system as a whole. When you add up the initial cost of investment in an air compressor and all the attached pneumatic tools, you want to ensure a return on that investment through years of optimal performance.
Ideally, the money you spend on your compressor system should reward you thousands and thousands of times over through productivity. Without maintenance, an air compressor and its peripheral components will not last as long as it otherwise could with regular checkups, tuneups and cleanups.
When you compare the profits of companies that implement responsible system maintenance with those that do not, you are liable to see major differences in productivity. On an industrial air compressor, preventive maintenance is crucial to ensure the functionality of the system and its various attachments.
The key parts to check include the filters, vents, belts and bearings, all of which could become troublesome to the system if dirt and grime build up. Moreover, you must apply and reapply lubricant at timely intervals on all applicable parts of an air compressor. The purpose of an air compressor is to produce clean, pure, compressed air that will ultimately power numerous functions. To ensure the quality of air that comes out at the end, the ambient air that goes into the compressor must be filtered of impurities before it leaves the machines.
None of that could be possible without a clean air filter. If the air filter is dirty, impurities and particulates could corrupt the compressed air and degrade the quality of end-point applications. Therefore, clean the air filter regularly.
Change it out at regular intervals, which vary based on the environment.Tasks are organized by equipment category within individual Excel workbooks. User configurable. Purchases delivered to buyer via email.
Purchase also includes the following two Excel spreadsheets:. Overlooked or ignored welding safety measures may result in serious health issues, accidental death, safety violations, lawsuits, and downtime.
Let our Welding Inspection Checklist help you to avoid welding hazards in the work environment. Here are some additional online welding safety resources:. Worth the Cost? What Our Customers Say. Are Your Welding Practices Safe? Do you have an Energy Control Program to protect employees from hazardous energy sources on machines and equipment during service and maintenance?
Advantages of Preventive Maintenance. Increased component life cycle Reduced equipment or process failure Manual workload is reduced Quicker response to unplanned maintenance Energy savings Improved employee performance Built-in safety and compliance Data enhances productivity Significant cost savings.
Maintenance Management Resources.