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Keys to the maintenance of an efficient compressed air system
Ask a question:
"What are the keys to maintain an efficient compressed air system?
Answer:
# 1: key PREVENTIVE MAINTENANCE
"What is the key to maintaining an efficient compressed air system?" The best answer would be – Preventive Maintenance.
WHAT is preventative maintenance?
According to Wikipedia: Preventive Maintenance (PM) have the following meanings:
"The care and service delivery by staff to maintain equipment and facilities
operate satisfactorily to provide for inspection systematic detection and correction of incipient failures either before they occur or before they become major defects.
Maintenance, including tests, measurements, adjustments and parts replacement, performed specifically to prevent faults occurring. "
* Source: from Standard federal 1037C and MIL-STD-188 and from the Department of Defense Dictionary of Military and Associated Terms
Preventive maintenance activities include revisions partial or total 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 a system failure.
The ideal program for maintenance Preventive prevent all equipment failure before it occurs.
BENEFITS OF PREVENTIVE MAINTENANCE:
-Improved reliability system and helps maintain work teams and / or extend the useful life of equipment.
Decreases downtime and system actively helps prevent unbudgeted maintenance costs of growing up.
-Reduces the cost of having to replace equipment as often.
"The operational records of data that can help solve an emerging problem (called "Data Trends")
Data trend is the record of the basic operating parameters such as pressures, temperatures and characteristics. For example, a slowly increasing temperature indicates a variety of maintenance requirements including cleaning cold core, the overhead system and possible mechanical problems. Another example might include gradually decreasing pressure, indicating increased flow system requirements, performance compressor reduces or leakage of the larger system. Make sure someone is looking at this data on a regular basis. If the data is checked then the benefit is lost.
THE VALUE OF PREVENTIVE MAINTENANCE:
To determine how valuable regular air compressor PM is for you and your business … you need to know what their "down-time" is worth it. In some operations, the downtime can cost hundreds, even thousands of dollars per hour.
There are many misconceptions about preventive maintenance … one being that it costs too much.
This line of thought is scheduled for downtime costs maintenance of computer operation until the repair is absolutely necessary … or until it breaks your computer. This may be true for some components, but do not forget to consider long-term benefits and savings associated with preventive maintenance that have been mentioned above.
If regular maintenance prevention can help reduce unexpected downtime results in lost production, time and materials or the ruin of a face plant process – then it's worth the investment. Not to mention that unscheduled closures may be extended if the parties the right equipment or repair technicians are not readily available.
"How effective is the program of the evening?"
The response is: "If your PM program is not finding problems is not effective."
Key # 2: Corrective maintenance
Corrective maintenance, usually called "restoration" is done to achieve team to work again
or solve the problems found during preventive maintenance.
The main objective of maintenance is to avoid or reduce the consequences of failure of compressed air equipment. PM is designed to preserve and restore equipment reliability by replacing worn components before they actually no.
Key # 3: EVALUATION OF YOUR EQUIPMENT: Maintain and when to change.
Here There are several factors to consider when assessing their compressed air equipment:
– How critical is your air compressed? If the computer fails, what is the impact production or safety.
-What is the age and history of your computer.
Team records show that most failures occur during childhood (Newly installed or overhauled recently) and age (self explanatory).
How many times has this team failed in the past?
– How much do you trust this team to perform as scheduled to run when?
– Need more new technology on your computer?
Evaluation answers to these questions will help you determine if your older computer repair or replacement needs. Preventive maintenance will help your team take longer, work better, and save a lot of money in the long term.
Key # 4: KNOW WHAT YOUR TEAM IS NEEDED:
"Every piece of equipment for compressed air must be accompanied by a set of instructions for maintenance and a certain type of operation and parts manual. Operators must review the information on your computer and keep it handy for future reference. If you purchased the equipment used and do not have the manuals, contact your equipment supplier for a copy.
– Follow the maintenance guidelines for your team.
BASIC PREVENTIVE MAINTENANCE Checklist
SABLE (piston) Air Compressors:
Before performing any maintenance function, disconnect the main switch in the off position to ensure that no power is entering the unit. "Label Block" or "Out" all power sources. Make sure that all pressure air into the unit is relieved. Doing so may cause injury or damage to equipment.
DAILY MAINTENANCE
1. Check compressor oil level and engine, whether it is equipped. Add the quality of air compressor lubricant as needed.
2. Drain moisture tank by opening the tank drain valve located at the bottom of the tank. No drain valve open if the tank pressure exceeds 25 PSIG.
3. Stop, Look & Listen for any unusual noise, lack of compression, overheating, vibration or belt slippage and corrected before serious damage occurs in nature, develops.
4. Turn the compressor on the end of the operation of each day. Turn off the electricity supply.
WEEKLY MAINTENANCE
1. Clean dust and foreign material of the cylinder head, engine, propeller, air lines, intercooler and tank.
2. Remove and clean filters intake air
WARNING
Do not exceed the nozzle pressure 15 PSIG to clean the parts with compressed air element. Do not point compressed air against the human skin. serious injury could result. Never wash the items in the fuel oil, gasoline or flammable solvents.
3. Check V-belts are tightened. The V-belts should be tight enough to transmit the energy requirement
compressor. Adjust the V-belts as follows:
a. Remove the bolts and guard access to the compressor unit.
b. Loosen motor mount that secures the base. Motor slide into slots on the motherboard to the desired position.
c. Check the manufacturer's specifications for proper belt tension. Apply pressure to the inspector belt tension of a belt around the peak medium. Make adjustments if necessary.
d. Check alignment of pulleys. Adjust if necessary.
e. Tighten the mounting hardware to secure the base engine.
f. Replace the guard and secure with screws.
WARNING
Never operate the unit without belt guard in place. Exposed Removal rotating parts can cause injury or equipment damage.
Every 90 days or 500 hours of maintenance
1. Change crankcase oil. Use the type and grade of oil as specified.
2. Check the complete system for air leaks around fittings, connections and gaskets, using an ultrasonic leak detector or soap solution and brush.
3. Tighten the nuts and bolts of the cover as required.
4. Inspect and clean compressor valves, replace the valve packing Asssembly when used or damaged.
CAUTION
Return valves replaced in its original position. valve seals must be replaced each time are the service valves.
5. Pull ring on all valves pressure relief to ensure proper operation.
GENERAL MAINTENANCE TIPS:
Safety valve PRESSURE: The pressure relief valve is an automatic valve to pop. Each valve is properly adjusted maximum pressure allowed by the specifications of the tank and working pressure of the body on which it is installed. If you must leave, it will be necessary to drain all air from the tank to replace properly. No adjustment.
Tank Drain Valve: valve drainage at the bottom of the tank. Open the drain valve every day to drain the condensation.
Do not open the drain valve if the pressure of tank exceeds 25 PSIG. The compressor tank drain equipped automatic drain requires manually once a week.
PRESSURE: The pressure switch is automatic and will start the compressor at low pressure and stop when the maximum pressure is reached. Conforms to start and stop the compressor to the proper pressure for the unit is installed. No adjustment.
BELTS: Drive belts should be kept as tight enough to prevent slipping. If belts slip or squeal, see maintenance V-belt in the previous section.
CAUTION
If belts are too tight, the surcharge will be placed on the engine and engine bearings.
COMPRESSOR VALVES: If the compressor stops pumping air or seems slow in filling the tank, disconnect the unit from the power supply, drainage valves air tank, and remove and thoroughly clean, using compressed air and a soft wire brush.
After cleaning, exceptional care must be taken that all parts are replaced in the same position and all Joints must be tight or the compressor will not work correctly.
When all valves are replaced, perform a time trial of the pump and check meets factory specifications.
Valve seals should be replaced each time the valves are removed from the pump.
Conclusion: One of the main keys to maintaining an efficient compressed air system has been and remains "preventive maintenance."
About the Author
1-888-229-9999
Tommy McGuire
McGuire Air Compressors, Inc.
“Real People with Real Air Compressor Experience”
P.O. Box 1100
Graham NC 27253
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