Tank Air
Keys to maintaining a compressed air system efficient
Ask a question
"What factors essential to ensure an effective system of compressed air?
Answer:
Key # 1: Preventive Maintenance
"What is the key to maintaining an effective system of compressed air?" The best answer would to be – Preventive Maintenance.
WHAT IS PREVENTIVE MAINTENANCE?
According to "Wikipedia": Preventive Maintenance (PM) has the following meanings:
"The care and service by staff for maintenance of equipment and facilities in
operating satisfactorily, by providing systematic inspection, detection and correction of failures emerging either before they occur or before they become major defects.
Maintenance, including tests, measurements, adjustments and spare parts, performed specifically to prevent faults from occurring. "
* Source: from the standard Federal 1037C and MIL-STD-188 and the Department of Defense Dictionary of Military and Associated Terms
Maintenance activities Preventive revisions include partial or complete specified periods, oil changes, lubrication and so on. Furthermore, workers can record information and equipment deterioration so they know to replace or repair parts waste before they cause system failure.
The ideal program of preventive maintenance would avoid any equipment failure before it occurs.
BENEFITS OF PREVENTIVE MAINTENANCE:
-Improves reliability system and keeps the equipment working and / or prolong the life of the equipment.
Reduces system downtime and helps actively to prevent spending unbudgeted maintenance crop up.
Reduces the cost of having to replace equipment as often.
The operational data records that can help you solve an emerging problem (called "Trending Data")
Data trend recording of operating parameters including core pressures, temperatures, and electrical data. For example, temperature increases slowly shows a variety of maintenance requirements, including costs of cleanup, overloading the system and possible mechanical problems. Another example might include pressure slowly decreases, indicating an increase in needs drainage, reduces performance compression or tightness of the system increased. Make sure someone is looking at these data on a regular basis. If data are never revised when the advantage is lost.
THE VALUE OF Preventive maintenance
To determine how precious air compressor Regular PM is you and your company … you need to know what your down-time "applies. In some operations, the downtime can cost hundreds or even thousands of dollars an hour.
There are many misconceptions about the maintenance Preventive … one being that it costs too much.
This line of thought says regular downtime for costs more maintenance to operate equipment until repair is absolutely necessary … or to failure of equipment. This may be true for some components, but do not forget to consider long-term benefits and savings associated with preventive maintenance that been mentioned previously.
If the regular preventive maintenance can help reduce downtime unexpected result in loss of production time and materials or ruin an expensive process facilities – it is well worth the investment. Besides the unplanned outages may be extended if the equipment parts correct and repair technicians are not readily available.
"What is the effectiveness of your PM program?
The answer is: "If your PM program is not to find problems, it is not effective. "
Key # 2: Corrective maintenance
Corrective maintenance, generally called "relief" is conducted to get equipment working again
or correct the problems detected during preventive maintenance.
The main objective of maintenance is to avoid or reduce the consequences of failure your compressed air equipment. PM is designed to preserve and restore equipment reliability by replacing worn parts before they not fail really.
Key # 3: ASSESSING YOUR EQUIPMENT: When to keep and when to replace.
Here are some factors to consider when assessing your Compressed Air Equipment:
-How important is your compressed air equipment? If the equipment fails, what is the impact on production or safety.
-What is the age and history of your equipment.
Equipment history prove that most failures occur during early childhood (newly installed or newly revised) and old (self-explanatory).
How many times this equipment has failed in the past?
-How much did you trust this equipment to perform as expected during planning to run?
-Do you need a newer technology on your equipment?
Evaluate responses to these questions will help you determine when your old equipment must be repaired or replaced. Preventive maintenance will help your equipment last longer, operate better and save you a lot of money in the long term.
Key # 4: Know your EQUIPMENT what it needs:
-Each piece of equipment, compressed air must come with a set of instructions for maintenance and certain type of operation and parts manual. Your operators should review the information and keep equipment on hand for reference Later. If you purchased the equipment used and have no manuals, contact your equipment dealer for a copy.
– Follow care instructions for your equipment.
BASIC PREVENTIVE MAINTENANCE OF CONTROL FOR
Reciprocating (piston) Compressors:
Before performing any maintenance function, switch the main switch to "OFF" position to avoid any power input is unity. "Lock Out" or "tag out" all sources of energy. Make sure any air pressure in the unit is relieved. Do not do it May cause injury or property damage.
DAILY MAINTENANCE
1. Check the oil level of compressor and motor in both so equipped. Add quality air compressor lubricant as needed.
2. Drain the water from the reservoir by opening valve tank drain located bottom of the tank. Do not open drain valve if the tank pressure exceeds 25 psi.
3. Stop, Look & Listen for any unusual noise, Compression error, overheating, vibration or slippage of belts and correct before the damage of a serious nature develops.
4. Turn off compressor the end of each workday. Turn off power supply.
Weekly Maintenance
1. Clean dust and foreign matter from the cylinder head, engine, fan blades, airlines, intercooler and reservoir.
2. Remove and clean Filters Air Intake
WARNING
Do not exceed 15 PSIG pressure of the nozzle when cleaning component parts with air tablet. Do not direct compressed air against the human skin. Serious injury could result. Never wash items of oil, gasoline or flammable solvents.
3. Check V-belts for tightness. The V-belts should be tight enough to transmit power required to
compressor. Adjust the V-belts as follows:
a. Remove the bolts and keep them for access to drive the compressor.
b. Loosen mounting hardware ensures that motor at the base. Slide motor inside the slots base plate to the desired position.
c. Check the manufacturer's specifications for proper belt tension. Apply pressure with Checker belt tension of a belt in the middle span. Make further adjustments if necessary.
d. Check alignment of pulleys. Adjust if necessary.
e. Tighten the mounting hardware to ensure motor on the base.
f. Re-install guard and secure with bolts.
WARNING
Never operate the unit without belt guard up. Removal exhibit rotating parts that can cause injury or property damage.
All 90 days or 500 hours of maintenance
1. Change crankcase oil. Use type and oil quality as specified.
2. Check entire system for detecting air leaks around the fittings, connections and seals, using a detector Ultrasonic leak or using a soap solution and a brush.
3. Tighten the nut and screw-Cap as necessary.
4. Inspect and clean compressor valves, ASSEMBLY valve seal replace when worn or damaged.
CAUTION
Valves must be reinstalled in the original position. Valve seals must be replaced whenever the valves are serviced.
5. Pull ring on all relief valves to ensure proper operation.
GENERAL MAINTENANCE NOTES:
PRESSURE safety valve: The valve Pressure relief valve is an automatic pop. Each valve is well adapted to the maximum pressure allowed by the specifications of tank and pressure of work the body on which it is installed. If pop, it will be necessary to empty all the air in the tank to reinstall properly. Do not be rehabilitated.
TANK DRAIN VALVE: drain valve is located at the bottom of the tank. Open the drain valve to drain daily condensation.
Do not open drain valve, if the reservoir pressure exceeds 25 PSIG. The auto drain the Compressor Tank requires drain fitted manually once a week.
PRESSURE SWITCH: The switch is automatic and will start at low pressure compressor, and stops when the maximum pressure is reached. It is adjusted to start and stop compression pressure adequate for the unit to which it is installed. Do not be rehabilitated.
BELTS: Drive belts must be kept tight enough to prevent slipping. If belts slip or squeak, see V-belt maintenance 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 fails to pump air or appears slow to fill tank, disconnect the unit from power source, drain air tank and remove the valves and cleaned thoroughly in using compressed air and a soft wire brush.
After cleaning exceptional care must be taken that all parts are replaced in exactly the same position and all joints must be sealed and the compressor will not work correctly.
When all valves are replaced, perform a timed pump-up test and verify that it meets factory specifications.
Valve seals must be replaced whenever the valves are removed from the pump.
Bottom Line: One of the keys to maintaining an effective system of compressed air was and still is "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
Learn more about Industrial Air Compressors www.industrialaircompressors.biz
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