Importance of Preventative Maintenance to Industrial Air Compressors

Many people ask us about the Importance of Preventative Maintenance to Industrial Air Compressors.

Rotary screw, industrial air compressors are used in various manufacturing, and service sectors, across the country. The air compressor station plays a vital role in powering tools, valves, cylinders, and other applications in food, pharmaceutical, brewing, dairy, aerospace, healthcare, automotive, chemical, textile, beverage, and electronic production. Like all machinery and equipment, they require regular service and attention.

This preventative maintenance blog post, we will explore the importance of performing, daily checks, regular inspections, minor, and major services, and overhauls. If you choose to conduct these tasks “in house,” you may require some advice, or even training. Air Solutions Canada’s compressor service training is a reliable source for on site and off site training sessions for all manner of compressed air service roles.

We asked one of our lead service technicians “what are your primary focuses, and concerns – when it comes to checks and balances in front of a rotary screw compressor?” 

Alain told us “As a technician, my focus for all of my customers, has always centred around being proactive and keeping them running smoothly.

Sometimes when discussing upcoming services, such as filter, and oil changes, customers tend to shy away from the topic, often based on time and/or budget restrictions. I always remind them that "preventative maintenance" should be looked at as "failure prevention".

Unfortunately, there will always be failures, but the name of the game is to limit these, as best we can, and maximize up times.

The best way to do this, just like your personal automobile, is to perform regular service.  This allows qualified technicians to go over your entire compressor looking for any indication that an event is looming. If there is something irregular, it can be addressed in a controlled, and timely manner.

The best way to do this is to produce a game plan right from the get go. Design redundancy and contingency into the system, by adding shut-off, and 3 valve service by pass arrangements around critical items to enable service availability, without a compressed air shutdown. If possible, the installation of redundant, stand by back up equipment, and emergency, temporary rental hook up couplings and valves are service critical enhancements to a system. During start up and commissioning, make calendar placeholders for checks, inspections, and services, so these are performed on time, every time.

One “service plan” size will not fit all, as run times, environmental conditions, shift patterns, temperatures, and availability will all need to be considered.” 

Daily checks

Preventative maintenance is the key to trouble free air compression, enhancing the service life, and reliability of an industrial air compressor.

Daily compressor checks, should include:

• A visual check of the compressor station and equipment.
• Inspect all hoses, pipes and fittings for air and oil leaks.
• Clean the equipment, and in particular the air and oil coolers of air cooled machines.
• Track, and trend the running and cooling temperature.
• Check the oil levels.
• Listen for unusual sounds, knocking or vibrations.
• Test the auto drains for discharge function.
• Replace the air intake filters on the walls, louvers, and compressor cabinet as required. 
  
  

Monthly inspections

Compressor inspections are recommended by all major air compressor manufacturers, such as Kaeser Canada to increase the efficiency and reliability of your compressed air equipment. 

Compressor inspections, should include:

• Compare the psig (barg) pressures between generation, tank(s), dryers and point of use. Pressure drops are an expensive waste of energy and should be avoided.
• *Qualified personnel should ensure the electrical connections, and terminals are sound.
• *Test the electrical amp draw, voltage and current.
• Inspect all hoses and fittings for air and oil leaks.
• Check the oil levels and top up as required.
• Sample compressor lubricant.
• Track and trend the running and cooling temperature.
• Ensure that the equipment is clean, particularly the air and oil coolers of air cooled machines.
• Ensure that all louvers and duct work dampers are in the correct “seasonal” positions, to optimize fresh air cooling, and hot air discharge. The heat of compression can be captured for #heatrecovery, and massive energy savings.
• Ensure the rotation direction and operation of all cooling fans.
• Listen for unusual sounds, knocking or vibrations. (Vibration tests are invaluable).
• Test the auto drains for correct discharge function.
• Replace the air intake filters on the walls, louvers, and compressor cabinet as required.
• Sample and inspect the oil/water condensate discharge. It should be clear, and not milky colored. Condensate sample testing, and test kits are available from #airsolcan.com free of charge, in the GTA.

Quarterly minor service

Preventative maintenance is the key to a trouble free air compressor station, negating the risk of unplanned failures, expensive repairs, and downtime. Air compressor service, should include:

• Inspect and replace the air filter element.
• Replace the oil filter element.
• Replacement of compressor canopy filtration, if applicable.
• Top up/replacement of lubricant.
• Grease all bearings, as required.
• Inspect and check the flow of oil through the separator scavenge line.
• Inspect and test the operation of: Combination Valve, Vent Valve, Thermostat, Minimum Pressure Valve and Inlet Valve.
• Blow through of air cooled compressed air and oil coolers.
• Inspect the condition of Drive Couplings, Belts and Pulleys.
• Check electrical circuits and amp draw readings.
• Re-set control board hours.
• Replace the air intake filters on the walls, louvers, and compressor cabinet as required. 

Annual major service

Major compressor service is recommended for machines that operate continuously for more than 4,000 hours per year. An air compressor oil change is important, and will ensure cooling, sealing and lubrication – while increasing the service life, & reliability of an industrial air compressor. Annual compressor maintenance, should include:

• Cleaning of the equipment, and particularly the air & oil coolers of air cooled machines.
• Ensure that the ductwork dampers and cooling air louvers are in the correct position. Adjust to match the environmental season time, winter summer.
• Track and trend the running and cooling temperature.
• Replace the compressor lubricant.
• Inspect all hoses and fittings for air and oil leaks.
• Listen for unusual sounds, knocking or vibrations.
• Perform vibration analysis.
• Test the auto drains for discharge function.
• Replace the air intake filters on the walls, louvers, and compressor cabinet as required.
• Replacement of the oil filter element.
• Replacement of the air filter element.
• Grease all bearings, as required.
• Replacement, as per service schedule, of air/oil separator element.
• Cleaning and regular maintenance of the separator scavenge line.
• Inspect and test the operation of: Combination Valve, Vent Valve, Thermostat, Minimum Pressure Valve and Inlet Valve.
• Blow through of air and oil coolers.
• Inspect the condition of Drive Couplings, Belts and Pulleys.
• Check electrical circuits and amp draw readings.
• Re-set control board hours.

How often should I service my air compressor?

Service intervals are dictated by how often you are running your compressor(s). Annual service would be adequate, if run hours are <2,000. Quarterly service is recommended for systems that run continuously, >4,000 hours. Diligent service will protect your equipment and warranty coverage, but also help prevent unexpected downtime. 

Increasing energy efficiency

When a compressed air system is running efficiently, this will directly translate into cost savings, by virtue of uptime, lower pressure drops, cooler running temperatures, and energy consumption. Compressor stations that are not serviced regularly tend to suffer from oil leaks, component fatigue, or failures, wear and tear, costly air leaks, inefficient controls, and ultimately wasted energy and increased repair, and utility bills.

Regular maintenance optimizes the compressor’s performance, ensuring it operates at its peak efficiency, lowering operational costs, and contributing to a greener and more sustainable operation.

By adhering to a maintenance schedule, businesses can extend their compressed air equipment service life, saving on premature replacements and capital expenditures.  

Being proactive will increase “up time,” ensure that the compressors are operating correctly, and this will reduce unexpected/unwanted “downtime,” and the expenses associated with equipment and production failure.

Sustaining and ensuring compressed air quality

In industries where compressed air quality is critical, such as food and pharmaceutical facilities, the upkeep of the clean air treatment equipment is crucial. Preventative maintenance guarantees that the plant and its points of use receive clean, dry and contaminant free compressed air. 

Filter element replacement is important, and so is the testing of automatic drain trap functionality. The cost of filter element replacement far outweighs the increased power consumption required to overcome the increased differential pressure drop, which occurs as filter elements plug, or blind.

Faulty drain traps mean that the item, or equipment that they are fitted to, is in essence; redundant. It is essential to remove unwanted oil/water condensate from a compressed air system, as liquid levels will increase inside tanks, dryers, coolers, and filters and eventually carryover downstream. 

Oil/water condensate discharge should be sent to an oil/water condensate management separator, to protect the environment, and safeguard the integrity of business disposing liquid waste to drain. Regular checks on the oil/water condensate management separator are important, along with semi-annual, and/or annual overhaul and maintenance of these units. Failure to meet and comply with municipal discharge limits may lead to severe fines and, in extreme cases, prosecution. Sample your condensate discharge on a regular basis.