When I was seventeen my grandfather took me to a used are dealership and helped me buy my first car. It wasn’t anything special, as it was a 1996 Chevrolet Lumina. It had its fair share of bumps and bruises, but the bones were solid. We took it home and he taught me how to do all the basics, we changed the oil, oil filter, air filter, brakes, pretty much every fluid we could, we changed.
You see my grandfather retired from Ford Motor Company after 50+ years of service. And he always said, “If you treat it right, it will treat you right.”; and I’ve lived by that ever since.
Just like a car, air compressors require regular maintenance to run at peak performance and minimize unscheduled downtime. Inadequate maintenance can have a significant impact on energy consumption via lower compression efficiency, air leakage, or pressure variability. It can also lead to high operating temperatures, poor moisture control, and excessive contamination.
Most problems are minor and can be corrected by simple adjustments, cleaning, part replacement, or the elimination of adverse conditions. This maintenance is very similar to the car maintenance mentioned above, replace filters, fluids, checking cooling systems, check belts and identify any leaks and address.
All equipment in the compressed air system should be maintained in accordance with the manufacturers specifications. Manufacturers provide inspection, maintenance, and service schedules that should be followed strictly. In many cases, it makes sense from efficiency and economic stand-points to maintain equipment more frequently than the intervals recommended by the manufactures, which are primarily designed to protect equipment.
One way to tell if your system is being maintained well and is operating properly is to periodically baseline the system by tracking power, pressure, flow (EXAIR Digital Flowmeter), and temperature. If power use at a given pressure and flow rate goes up, the systems efficiency is degrading.
Types Of Maintenance
Maintaining a compressed air system requires caring for the equipment, paying attention to changes and trends, and responding promptly to maintain operating reliability and efficiency. Types of maintenance include;
- Poor Maintenance – Sadly, some plants still operate on the philosophy, “If it isn’t broke, don’t fix it.” Due to the lack of routine preventative maintenance, this practice may result in complete replacement of an expensive air compressor as well as unscheduled and costly production interruptions.
- Preventive Maintenance – This type of maintenance can be done by plant personnel or by an outside service provider. Usually, it includes regularly scheduled monitoring of operating conditions. Replacement of air and lubricant filters, lubricant sampling and replacement, minor repairs and adjustments, and an overview of compressor and accessory equipment operation.
- Predictive Maintenance – Predictive maintenance involves monitoring compressor conditions and trends , including operating parameters such as power use, pressure drops, operating temperatures, and vibration levels. The Right combination of preventive and predictive maintenance generally will minimize repair and maintenance costs.
- Proactive Maintenance – If a defect is detected, proactive maintenance involves looking for the cause and determining how to prevent a recurrence.
Unfortunately, even the best maintenance procedures cannot eliminate the possibility of an unexpected breakdown. Provisions should be made for standby equipment to allow maintenance with out interrupting production.
If you would like to discuss improving your compressed air efficiency or any of EXAIR’s engineered solutions, I would enjoy hearing from you…give me a call.
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Images Courtesy of Tampere Hacklab