Air compressor preventative maintenance (PM) (or predictive maintenance) is essential for the safe and efficient operation of your compressed air system, minimizing the risk of costly downtime and emergency repairs. However, most facility maintenance technicians don't know all the ins and outs of proper air compressor maintenance. Here's what building managers and maintenance staff should know — and how you can reduce the burden of compressed air system PMs.
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Preventative Maintenance Versus Standard: Key Differences in Air Compressor Care
When it comes to air compressor maintenance, distinguishing between standard maintenance and preventative/preventive maintenance is crucial for ensuring the long-term efficiency and reliability of the equipment. (Note: preventive maintenance and preventative maintenance are the same thing; these are just regional spelling and pronunciation differences.)
Here's a breakdown of the differences between standard maintenance and preventative maintenance for the air compressor system.
- Standard maintenance, also known as corrective maintenance, involves the repair or replacement of parts and components as they fail or after a failure occurs. This approach is reactive, meaning actions are taken only when there are evident problems or breakdowns. Standard maintenance tasks might include repairing or replacing failed components, troubleshooting specific issues (like leaks, noises or vibrations), or conducting inspections and services after a problem has been noticed.
- Preventative maintenance, on the other hand, is a proactive approach. It focuses on regular checks and the timely servicing of compressed air equipment to prevent failures before they occur. The goal of preventative maintenance is to extend the lifespan of the air compressor and minimize downtime by catching and addressing potential issues early. Preventative maintenance tasks typically include regularly scheduled inspections and servicing based on time or usage intervals, replacement of consumable parts before they fail (such as filters, belts and compressor oil), performance testing and analysis to anticipate wear and tear, and monitoring and adjusting operating conditions to ensure optimal performance.
There are key differences between standard maintenance and preventive maintenance, including the timing and approach, cost implications and operational impact. Standard maintenance is reactive and occurs after problems arise, while preventative maintenance is proactive and scheduled at regular intervals. With standard maintenance, there is a higher risk of downtime due to unexpected equipment failures. Preventative maintenance aims to minimize downtime by maintaining equipment in optimal condition. That's why preventative maintenance can help save money in the long run. Implementing a robust preventative maintenance program for industrial air compressor systems offers significant benefits in terms of reliability, energy savings and performance.
Why Air Compressor Maintenance Matters
A poorly maintained air compressor will end up costing your company money, both directly and indirectly. Regular preventive maintenance increases the life of your industrial compressed air system and ensures its safe, reliable and efficient operation. A regular maintenance schedule will help you catch little problems, such as a worn belt or an oil leak, before they become expensive emergencies. The time and costs associated with regular PMs are negligible when compared to the costs of an emergency repair that shuts your system down at a critical moment in your production processes. Here's why air compressor PMs are absolutely essential.
Reliability and Longevity
Preventative maintenance extends the equipment life of air compressors by preventing excessive wear and ensuring potential failures are addressed before they lead to significant damage. This proactive care avoids major breakdowns and ensures the compressor operates efficiently for a longer period.
Downtime Prevention
Unscheduled downtime can be costly in terms of both lost productivity and the expenses associated with emergency repairs. Regular maintenance helps identify and rectify potential issues before they lead to significant failures, ensuring that the equipment remains operational and minimizing compressor downtime.
Energy Savings
Proper maintenance of air compressors significantly enhances their energy efficiency. Issues like clogged filters, air leaks, and poor lubrication cause compressors to work harder, increasing energy consumption. Routine checks and maintenance activities ensure these issues are addressed, optimizing the compressor's operation and reducing energy use.
Safety
Air compressor PMs are also essential for safety. Air compressor accidents are not common, but poor maintenance, misuse or short-cycling can lead to a fire or explosion. Over-pressurization or failure of a pressure relief valve or other parts can lead to a dangerous rupture of the air receiver tank. These risks can be all but eliminated with regular inspection and maintenance of system components combined with proper operation.
Cost Savings
Although air compressor maintenance requires an upfront investment in time and resources, it can lead to substantial cost savings. Preventing major breakdowns, optimizing energy use, and extending the equipment life all contribute to reduced total ownership costs. Regular maintenance can prevent costly repairs and the need for premature replacement of the compressor or its components.
Compressed Air Quality
The quality of air produced by compressors can directly affect the processes they facilitate. Contaminants like compressor oil, moisture and particulates must be regularly removed to prevent damage to the air tools and products being manufactured. Compressed air contaminants may also put facilities out of compliance with industry regulations for compressed air quality, such as those governing the pharmaceutical and food and beverage industries. Regular compressed air testing and proper maintenance of filters, air lines and other compressor components will prevent buildup of fluids and particulates that can make their way into the airstream.
Air Compressor Maintenance Checklist
It helps to have a checklist to follow for routine maintenance (daily, weekly and monthly) and a full air compressor PM. Always check your user's manual for specific recommendations for your make and model. Download the basic checklists below or see our detailed compressed air system maintenance checklists.
Rather not do it yourself? Contact us for PM service on all industrial air compressor makes and models!
Downloads:
- Rotary Screw/Rotary Vane Compressor Maintenance Checklist
- Reciprocating Compressor Maintenance Checklist
- Refrigerated Air Dryer Maintenance Checklist
- Desiccant Air Dryer Maintenance Checklist
- Oil/Water Separator
Daily Maintenance
- Drain Condensate: Water accumulating in the compressor, air receiver tank, dryers and distribution system should be drained daily to prevent rust and corrosion. An automated condensate drain or zero-loss drain can eliminate this daily step.
- Monitor Operating Temperatures: Ensure that the compressor is not overheating and that cooling systems are functioning properly.
- Verify Pressure Readings: Check pressure gauges to ensure they are within the recommended range and that the compressor is not operating under undue stress.
- Check Oil Level (For Oil-Lubricated Compressors): Check the oil level and top up if necessary to prevent damage from low oil levels.
Weekly Maintenance
- Check and Clean Intake Vents and Inlet Air Filters: A dirty inlet filter can strain the operation of the compressor, leading to inefficiency and increased energy use. Clean or change the air filter as needed.
- Inspect Belts and Couplings: Look for signs of wear or damage on drive belts and couplings. Adjust or replace them if necessary to avoid breakdowns.
- Test Safety Systems: Ensure that all safety valves (e.g., pressure relief valve) and the safety shutdown system are operational to prevent accidents and equipment damage.
- Check automatic drain valves: If using automatic drain valves, check them weekly to make sure they are operational.
Monthly Maintenance
- Check for Air Leaks: Inspect the entire system for any signs of air leaks, which can reduce efficiency and increase operating costs.
- Change or Clean Air Filters (If Not Replaced During Weekly Checks): A clean air filter ensures efficient operation and prevents contamination of the air supply.
- Inspect Hoses and Connections: Check for cracks, wear and leaks in hoses and connections, and replace any damaged parts to maintain system integrity.
- Review Maintenance Logs: Check logs to track any recurrent issues or upcoming maintenance tasks that need addressing.
Full Compressor PM Checklist
The maintenance schedule for a full preventive maintenance (PM) service for an air compressor and the tasks included can vary based on the type of compressor, its usage patterns, and environmental conditions. A full PM is generally recommended for an oil-flooded industrial rotary screw compressor every 2,000 to 4,000 operating hours or at least annually for compressors that run less often. Reciprocating compressors may require maintenance more often, typically every 1,000 hours or six months. A comprehensive PM service for an air compressor typically includes several key tasks:
- Oil Change: Replace the compressor oil and oil filter in oil-lubricated compressors to ensure smooth operation and protect internal components.
- Filter Replacement: Change the panel filters, air inlet filters, oil filters and air/oil separator as needed. Clean or replace other filters like inline coalescing or particulate filters.
- Condensate System Maintenance: Inspect, clean, and, if necessary, repair or replace components of the condensate trap and drains.
- Safety and Control Systems Check: Test safety shutoffs, pressure gauges, thermostats, pressure relief valves, and control systems to ensure they are operating correctly and safely.
- Cooling System Maintenance: Clean and inspect coolers, fans, and heat exchangers to prevent overheating and ensure efficient operation.
- Drive System Check: For belt-driven compressors, check belt tension and alignment, adjusting or replacing belts as needed. For direct-drive systems, inspect the coupling and ensure it is secure.
- Overall Inspection: Check for any unusual noise, vibrations, or signs of wear and tear on mechanical parts and address as needed.
Fluid-Air Dynamics uses a 45-point inspection and maintenance checklist for our professional maintenance service. Download now!
Best Practices in Compressed Air System Preventative Maintenance & Servicing
Effective preventive maintenance of the air compressor and other system components, such as air dryers and inline filtration, is essential to maximize the efficiency, longevity, and reliability of industrial compressed air systems. Here are some best practices in compressed air maintenance and servicing.
Regular Inspections
Conduct routine inspections of air compressors, air dryers and tanks to identify leaks, wear, and potential failures early. This can include listening for unusual noises, checking for vibration, and visually inspecting for oil leaks or damaged parts.
Maintain Air Quality
Keep air intake areas clean and replace intake air filters and inline filters regularly to prevent contaminants from entering the air lines. This is crucial for maintaining the quality of the compressed air and the efficiency of the compressor.
Monitor and Replace Consumables
Regularly check and replace consumable parts such as oil filters, inlet air filters and lubricants. In oil-injected systems, maintaining the proper oil level is essential for the health of the compressor and the quality of the air produced.
Manage Moisture
Water condensate can accumulate in various parts of the system, particularly in air tanks and air dryers, as water vapor condenses back into liquid water. Regularly draining the air compressor system prevents corrosion and damage to the air system.
Test Safety and Control Systems
Ensure that all safety shutoffs, alarms and controls are functioning correctly. Regular testing helps to prevent accidents and ensures the system operates within safe parameters.
Maintain Cooling Systems
For compressors that generate significant heat, maintaining the cooling system and heat exchangers is vital. Check coolant levels, clean radiators, and ensure fans are functioning properly to prevent overheating.
Keep a Maintenance Log
Document all inspections, tests and replacements and collect data on operating temperature, pressure and other aspects of system performance. A detailed log can help track the performance of the system over time and plan future maintenance more effectively.
Follow the Owner's Manual
Each compressor model may have specific needs based on its design and operational capacity — for example, rotary screw air compressors will have different maintenance requirements than reciprocating air compressors. The manual will detail the appropriate maintenance schedule, recommended parts for replacement, and special considerations unique to that model.
Common Mistakes in Air Compressor Maintenance
Maintaining air compressors is essential for reliable operation, but common mistakes can compromise their efficiency and longevity. Here are some frequent errors to avoid.
Neglecting Regular Inspections
One of the most common mistakes is not performing regular inspections. Skipping these can lead to undetected leaks, worn parts and other issues that can escalate into costly repairs.
Ignoring Leak Repairs
Compressed air leaks are often underestimated in their impact on system efficiency. Failing to promptly identify and repair leaks can lead to significant energy losses and higher operational costs.
Inadequate Lubrication
Under-lubricating or using incorrect lubricants in an oil-flooded rotary screw or reciprocating compressor can cause increased friction and wear in moving parts, leading to premature failure. Conversely, over-lubrication can cause oil carryover. A dirty oil filter can also cause problems such as restricted oil flow and contaminant buildup.
Not Draining Condensate
Failing to regularly drain condensate from tanks and separators can lead to water accumulating in the system. This can cause rust and corrosion, which compromise the integrity and efficiency of the compressor.
Using Worn-Out Components
Continuing to use worn-out components like filters, belts and separators beyond their service life can reduce compressor efficiency and lead to other parts being damaged due to increased strain on the system.
Overlooking Environmental Factors
Not considering the environmental conditions (like dust, temperature and humidity) in which the compressor operates can lead to inappropriate maintenance schedules and procedures.
Poor Record Keeping
Not keeping accurate maintenance records can result in irregular maintenance schedules and missed service intervals, reducing the compressor's efficiency and service life.
Who Should Perform Preventative Maintenance on a Compressed Air System?
While many daily and weekly routine maintenance activities can and should be performed by facility maintenance staff (such as draining fluids and checking motor oil and lubricants), it is often advisable to call in the experts for a full PM checkup. Professional maintenance for industrial air compressor systems is often helpful in detecting and diagnosing emerging issues that facility maintenance staff may miss and ensuring that all essential PM activities are performed correctly.
Some issues that may require professional maintenance and repair include:
- Diagnosing Pressure Drop: Pressure drop refers to the loss of pressure between the compressor and the endpoint where the air is utilized. While some loss of pressure is inevitable, excessive pressure drop may indicate a leak or blockage somewhere in the system. Ignoring the signs of pressure drop or increasing operating pressures to compensate will drive up energy costs and put added strain on the system. A certified compressed air system technician can find and fix compressed air leaks, clogged inline filters or other issues causing excessive pressure drop.
- Safety Inspections: Periodically, your system should be shut down for a complete safety inspection. The inspector will thoroughly examine all parts of the system to look for wear, corrosion, faulty gauges and valves, electrical problems and other issues that could present a safety concern. This should be done by a certified technician who understands what to look for.
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Repairs: While in-house maintenance staff can probably change air filters or change compressor oil, more complicated repairs should be handled by a trained compressed air system specialist. A qualified technician can identify and mitigate emerging issues — such as damaged motor bearings or moisture in the air lines — before they become a serious problem. Taking care of these potentially minor repairs as they emerge will help you avoid a more serious mechanical breakdown.
Reducing the Burden of Compressor Maintenance
If you don't have someone with specific expertise in compressed air systems on staff, it makes sense to reach out to the experts for help. Fluid-Aire Dynamics has three levels of Compressed Air Preventative Maintenance Plans to meet your needs.
Contact us for service.
Reminder Service/On-Demand
Once we establish a service account for your operation, we simply send you a reminder when normal maintenance is due. You can then decide to call us in for troubleshooting, repairs, parts and supplies. If there is a major issue or emergency down situation, a call to our emergency response hotline will have a qualified and knowledgeable service technician onsite within four hours. This option is best for companies that have a knowledgeable person on staff who can perform standard PM on the air compressor and system components. There is no charge for the reminders, and on-demand service calls are charged at the standard rate.
Standard Maintenance Agreement
Our standard maintenance agreement establishes a fixed cost for the normal PM on your compressed air system. Your Fluid-Aire Dynamics service technician will visit your facility at regular intervals, with a pre-arranged appointment, and perform all recommended system checks and preventative maintenance. This keeps your system clean and operating at top efficiency with no burden on your maintenance staff. All standard PM activities are included for one fixed cost, so you won't have any surprises. Repairs are charged at the standard rate. This is a great option for companies who do not have qualified maintenance technicians or who simply want the peace of mind of knowing that PM is always done right.
Monthly Service Subscription
For maximum peace of mind, consider a monthly service subscription. This plan includes not only regular PM but also repair coverage, so you don't have to worry about unexpected costs and surprises. It's like an extended warranty on your entire system, including compressors, dryers and filtration. The Fluid-Aire Dynamics Monthly Service Subscription Package offers 'bumper to bumper' coverage for a predictable monthly rate, 50% discounts on equipment rentals, and fair market value on equipment trade-ins. It's the hassle-free way to guarantee clean, dry, reliable compressed air for your operation.
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