An air compressor is a device that intakes air and compresses it to deliver high-pressure compressed air to associated pneumatic systems. As an air compressor is a mechanical device, it requires a comprehensive maintenance schedule to ensure its safety, efficiency, and longevity. It also saves money, reduces downtime, improves air quality, and carries environmental obligations.
So, to inform you about the air compressor servicing schedule, we have crafted this comprehensive blog. The blog covers various important information, including why maintain air compressors, factors affecting maintenance, maintenance requirements for different compressor types, and much more.
A] Why Is Regular Air Compressor Maintenance Required?
An air compressor is mechanical equipment and requires time-to-time maintenance to maintain its optimal performance throughout its lifespan. It ensures the compressor remains free from potential wear and tear, mitigating any chances of further costlier repairs. It involves air compressor oil changes, replacing air filters, changing oil separators, changing of basic consumables spare parts and removing moisture buildups. Following a regular maintenance schedule, including all of the above, allows the compressor to prolong its life and safeguard businesses from potential downtime.
B] Factors Affecting Air Compressor Maintenance Schedule
1. Frequency of Use
Frequency of use is one of the top reasons that play a major role in determining air compressor preventive maintenance schedule. It is decided based on the usage patterns. If you use your compressor daily, it requires more frequent maintenance. On the other hand, occasional use needs less frequent maintenance but it must be maintained before and after each use.
2. Environmental Conditions
If you operate in high-humidity areas, it is obvious that moistures accumulate in these areas faster. In that case, you need to maintain your compressor frequently. It may involve frequent accumulated water drainage, the use of air dryers, or the integration of moisture separators. Similarly, a dusty environment clogs filters faster, needing more regular inspection and maintenance.
3. Workload & Pressure Levels
Not to mention, a higher PSI (a unit that measures pressure or stress) operation generates more heat and moisture, increasing maintenance needs. If the compressor continuously works without cooldown, it fosters wear and tear. Therefore, it is necessary to create a balance between workload and pressure level and adopt an adequate maintenance schedule.
4. Type of Air Compressor
Each type of compressor involves a different working mechanism and has different internal components. Whether it is an oil-free compressor or a lubricated compressor, all require different types of maintenance schedules. So, it is vital to assess your compressor type and adopt a tailored maintenance schedule based on your compressor type.
C] How Different Types Of Air Compressors Require Different Maintenance Schedules
1. Reciprocating Compressor
The reciprocating air compressor operates through a piston-cylinder mechanism. Due to the complex internal working mechanisms, frequent maintenance schedules are required to sustain its workability. It involves proper cleanliness, reducing vibration, maintaining temperature fluctuation, oiling, and detecting and repairing any wear and tear.
2. Oil-Free Reciprocating Compressor
An oil-free reciprocating compressor is one of the least-maintenance compressors, requiring minimal effort to prolong its workability. However, a scheduled maintenance arrangement is highly suggested even for an oil-free compressor as they are also mechanically built. It involves keeping the right pressure level, keeping an eye on leaks, and frequently checking their air filters.
3. Screw Air Compressor
Screw air compressors, also known as rotary screw compressors, consist of two helical rotors to compress air in continuous flow. Since the screw compressor involves a complex mechanism, it is necessary to adopt a frequent maintenance schedule to keep the mechanism intact. It requires replacing oil and filters, leak inspection, damage inspection, and compressor cleaning.
D] Air Compressor Maintenance Checklist
1. Oil Level
Air compressor oil lubricates, cools, and helps clean the compressor. So, it is necessary to keep on checking the oil level and change it when required. Doing so allows your compressor to work smoothly and prevents it from premature wear and tear. Regular oil changes also help reduce friction, minimise overheating, and keep internal components free from carbon buildup.
2. Air Leaks
Air leaks can waste up to 30% of the compressor’s output. So, it is vitally important to check any air leaks to maintain pressure within the air compressor. To check air leaks, you can listen for air leak sounds or use a soapy solution to detect any leaks. If found, repair it promptly.
3. Belt And Pulley
The belt and pulley work as power transmitters, transmitting power from the motor to the compressor pump. When checking these essential components, look for wear and tear, cracks, excessive looseness, or any visible damage. If find any defects or misalignments, replace them promptly or correct the alignment issues.
4. Air Filters
Industrial air compressor filters are air cleaning devices that are installed within air compression systems to eliminate contamination like dust, moisture, and oil from the air. So, it is vital to keep the air filters intact. It involves checking for wear signs, monitoring pressure drops, checking for changes in air quality, and enquiring about increased energy consumption.
5. Drain The Condensate
Condensation is a natural consequence of air compression. When condensation happens, it releases moisture in the form of water droplets which are eventually collected into the water container. The water container needs to be vacated from time to time to prevent the compressor from being corroded.
E] Maintenance of Varying Degrees
- Daily: The daily maintenance schedule should involve oil level checks, checking pressure switch workability, checking lubrication, visual damage, and emptying the water tank.
- Weekly: The weekly maintenance schedule involves checking oil levels, cleaning the air filters or replacing them, tightening the belt and pulley, and checking any signs of leaks and wear.
- Monthly: The monthly schedule should involve checking and cleaning the dryer, checking the drain valve, and cleaning filters.
- Quarterly: The quarterly maintenance schedule should comprise checking air filter elements, checking run hours, and cleaning the compressor motor.
- Annually: An annual maintenance schedule must involve getting professional expert help to inspect the internal and technical aspects of your compressor.
Conclusion
So far, we have understood the importance of an air compressor maintenance schedule and why it is needed. By considering the above-mentioned pointers, you can create a proactive maintenance routine that keeps your air compressor in top condition, ensuring safety, efficiency, and longevity.
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