Major Preventative Maintenance – Air Compressor
Major PM’s are usually scheduled every 1-2 years, depending on the number of hours the compressor runs, and how dirty the ambient conditions are.
A Major PM generally consists of:
- Changing Air Filter – The air filter will capture particulate matter, such as pollen, dust, dirt and other contaminates. For most units, this will need to be changed every 2,000 hours. After the air is filtered, it can then travel into the inlet on the air-end for pressurization.
- Changing Oil Filter – The oil filter will capture dirt and grime so that it can be reused in the system. The oil comes through the oil filter after the oil passes through the air-end then the separator. At this point the oil lubricated and cleaned the air-end and needs to be cleaned before it can be recycled through the unit.
- Take Oil Sample for Analysis – A detailed Oil Analysis Report will give information regarding external contamination, which will give an insight to the ambient conditions that affect the lubricant and running of the compressor, or internal contamination that would give an early warning regarding malfunctioning of components.
- Evaluate Dryer – Even though the dryer is not typically serviced at this time, it is vital to check its overall health to make sure it is operating correctly.
- Cleaning of Cooler – The cooler is one of the most overlooked parts by our customers, yet the easiest to evaluate and clean. Without a clean cooler, your oil temperature will rise (causing a shutdown) and your air temperature will rise (causing water carryover) and potential damage downstream.
- Inspect & Tighten Electrical Connections – An air compressor runs at 2500-9000 RPMs, sometimes 24/7. This constant vibration can cause wires to wiggle lose, causing shortages or shutdowns. Examining and tightening these connections will prevent such issues.
- Inspect Drains & Inline Filters – We will want to verify that all drains are working and flowing to ensure moisture does not unnecessarily build up in your system. Additionally, we will want to make sure all inline filters have a proper delta P (pressure drop) indicating they are not clogged and free of any restriction.
- Cleaning of Condenser (if applicable) – much like the cooler, you will want to ensure the condenser is clean, otherwise with won’t be able to properly cool the air.
- Changing Cabinet Mat (if applicable) – We will want to make sure the cabinet mat (if applicable is clean and free of any restrictions. A clogged mat will result in overheating and restricted air flow.
- Check Controls for Maintenance Reminders – You will want to resent any maintenance reminders as well and check for any error alerts.
- Changing Oil/Coolant – Depending on your unit, and whether it is under warranty, you will want to change your air compressor oil every year, every 8,000 hours, or when your oil analysis says you should. Consult with your service provider to determine the exact time.
- Changing Air/Oil Separator – The Air/Oil Separator acts to remove the oil from the air stream. In a larger chamber, the oil-soaked air swirls around, goes through the separator, separating the 2, and then the oil is returned to the oil sump via a scavenger line. The air in turn then goes down stream, for further cooling and filtration. If the Separator is neglected and not maintained, it will clog, or worse, collapse. A clogged separator will result in oil carryover and pressure drop, and a collapse will result in oil carryover and possibly a fire.
- Grease Motor – You will want to inspect and grease the motor on a regular basis. Check with the manufacturer of your equipment to find the recommended intervals.
- Test Safety Valve – Test all safety valves to ensure they are working properly. A failed safety valve can result in pressure buildup in your system and having your lines or storage tanks burst from over-pressurization.
- Examine Hoses and Piping – cracked hoses and pipes will rob you of money and production. Examining these lines on a regular basis is a sure way to ensure all of the hard work your compressor does is properly realized.
Just like with the Minor PM, the technician will inspect your system, and provide a service recommendation to our service staff if any issues are detected.