Air Compressor Preventative Maintenance Without the Hassle

Air compressor preventative upkeep (PM) is important for the protected and environment friendly operation of your compressed air system. However most facility upkeep technicians don’t know all of the ins and outs of correct air compressor gear upkeep. Right here’s what constructing managers and upkeep employees ought to know—and how one can cut back the burden of compressed air system PMs.

Why Air Compressor Upkeep Issues

A poorly maintained air compressor will find yourself costing your organization cash, each instantly and not directly. A few of these prices embrace:

  • Larger vitality prices as a result of overloaded filters, blockages, insufficient lubrication, and different issues that trigger your air compressor to work more durable than it ought to should.
  • Shorter gear life brought on by elevated put on and tear on the system.
  • Extra frequent emergency repairs, which is able to virtually at all times be far more costly than the preventative upkeep would have been.
  • Elevated danger of surprising downtime, which might result in 1000’s or tens of 1000’s of {dollars} in losses for firms who rely on compressed air to maintain manufacturing traces working.

Preventative upkeep will increase the lifetime of your air compressor and ensures its protected, dependable and environment friendly operation. A daily PM routine will show you how to catch little issues, akin to a worn belt or an oil leak, earlier than they develop into costly emergencies. The time and prices related to common PMs are negligible when in comparison with the prices of an emergency restore that shuts your system down at a vital second in your manufacturing processes.

Common PMs might help you keep away from different issues together with your compressed air system as nicely. Correct upkeep of filters, air traces, and different compressor elements will forestall buildup of fluids and particulates that may make their means into the airstream. Airstream contamination from corrosion or fluids within the compressed air system could cause issues for a lot of manufacturing processes. These issues might be averted with constant monitoring and mitigation on the first signal of an issue.

Air compressor PMs are additionally important for security. Air compressor accidents aren’t frequent, however poor upkeep or misuse can result in a fireplace or explosion. Quick-cycling of the air compressor motor could trigger a spark that creates a danger of a hearth. Over-pressurization or failure of aid valves or different elements can result in a harmful rupture of the air receiver tank. These dangers might be all however eradicated with common inspection and upkeep of system elements mixed with correct operation.

What Sort of Preventative Upkeep Does an Air Compressor Want?

Compressed air system house owners ought to observe all advisable preventative upkeep procedures of their proprietor’s handbook. A PM (preventative upkeep) for a compressed air system contains:

  • Drain extra fluids day by day from the air compressor and air receiver tank (if not utilizing an computerized drain valve).
  • Change the air filter frequently (will range relying on air compressor utilization and the atmosphere through which it’s working).
  • Change the oil and change the oil filter at advisable intervals, sometimes starting from 4,000 to eight,000 hours of use. The oil filter needs to be checked steadily and altered earlier if it exhibits indicators of extreme loading.
  • Examine lubrication of joints, bearings and shifting elements and reapply as wanted to forestall corrosion and put on.
  • Examine motor bearings steadily for indicators of wear and tear and corrosion and be certain that they’re correctly lubricated.
  • Examine belts for put on and be certain that they’ve correct stress ranges.
  • Examine and clear consumption vents to forestall filth from getting sucked into the system.
  • Examine the air compressor for indicators of oil leaks or air leaks.
  • Examine strain aid valves to make sure that they’re working accurately.

Whereas these will cowl the fundamentals, there are different issues to examine as nicely, together with strain drop, temperatures, vibration, voltage ranges, air dryer efficiency and the integrity of pipes, hoses and air receiver tanks. The precise guidelines and advisable intervals will likely be particular to the sort and mannequin of your air compressor and your utilization patterns.

Who Ought to Carry out Preventative Upkeep on a Compressed Air System?

Whereas many day by day and weekly upkeep actions can and needs to be carried out by facility upkeep employees (akin to draining fluids and checking motor oil and lubricants), it’s usually advisable to name within the specialists for a full PM checkup. Facility employees are typically not specialists in compressed air system upkeep. Whereas draining the air receiver tank and altering an air filter are pretty simple duties, there are lots of points that non-experts are more likely to miss when inspecting and sustaining your air compressor, air dryer and different system elements.

A few of these could embrace:

  • Diagnosing strain drop: Strain drop refers back to the lack of strain between the compressor and the endpoint the place the air is utilized. Whereas some lack of strain is inevitable, extreme strain drop could point out a leak or blockage someplace within the system. Ignoring the indicators of strain drop or rising working pressures to compensate will drive up vitality prices and put added pressure on the system. A licensed compressed air system technician can discover and repair compressed air leaks, clogged filters or different points inflicting extreme strain drop.
  • Security inspections: Periodically, your system needs to be shut down for an entire security inspection. The inspector will completely study all elements of the system to search for put on, corrosion, defective gauges and valves, electrical issues and different points that would current a security concern. This needs to be carried out by a licensed technician who understands what to search for.
  • Repairs: Whereas in-house upkeep employees can most likely change an air filter or belt, extra difficult repairs needs to be dealt with by a educated compressed air system specialist. A professional technician can determine and mitigate rising points—akin to frozen motor bearings or moisture within the air traces—earlier than they develop into a major problem. Caring for these probably minor repairs as they emerge, will show you how to keep away from a extra severe mechanical breakdown.

Lowering the Burden of Upkeep

When you don’t have somebody with particular experience in compressed air programs on employees, it is smart to achieve out to the specialists for assist. Fluid-Aire Dynamics has three ranges of PM service to fulfill your wants.

Reminder Service/On-Demand

As soon as we set up a service account in your operation, we merely ship you a reminder when regular upkeep is due. You may then determine to name us in for troubleshooting, repairs, elements and provides. If there’s a main situation or emergency down state of affairs, a name to our emergency response hotline may have a professional and educated service technician onsite inside 4 hours. This selection is finest for firms who’ve a educated particular person on employees who can carry out customary PM on the air compressor and system elements. There isn’t a cost for the reminders, and on-demand service calls are charged at the usual price.

Customary Upkeep Settlement

Our customary upkeep settlement establishes a hard and fast price for the traditional PM in your compressed air system. Your Fluid-Aire Dynamics service technician will go to your facility at common intervals, with a pre-arranged appointment, and carry out all advisable system checks and preventative upkeep. This retains your system clear and working at prime effectivity with no burden in your upkeep employees. All customary PM actions are included for one mounted price, so that you gained’t have any surprises. Repairs are charged at the usual price. This can be a nice possibility for firms who do not need certified upkeep technicians or who merely need the peace of thoughts of figuring out that PM is at all times carried out proper.

Month-to-month Service Subscription

For optimum peace of thoughts, contemplate a month-to-month service subscription. This plan contains not solely common PM but additionally restore protection so that you don’t have to fret about surprising prices and surprises. It’s like an prolonged guarantee in your total system, together with compressors, dryers and filtration. The Fluid-Aire Dynamics Month-to-month Service Subscription Package deal gives ‘bumper to bumper’ protection for a predictable month-to-month price, 50% reductions on gear leases, and honest market worth on gear trade-ins. It’s the hassle-free technique to assure clear, dry, dependable compressed air in your operation.

Need to take the trouble out of compressed air preventative upkeep? Ask us about our service agreements!

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