AIR COMPRESSOR
OBJECTIVE: To lay down a procedure for the Maintenance of the Air compressor
SCOPE: This SOP applies to Air compressors.
RESPONSIBILITY: Technical Supervisor / Engineer
ACCOUNTABILITY: Sr.Executive / Manager
PROCEDURE
Daily Maintenance
Check and ensure the oil level is as per the mark given on the view glass.
Clean the outer surface of the Air compressor, motor, and all pipelines.
Check and ensure loading and unloading of the compressor w.r.t pressure Limit 7.5 kg/ sq cm loading 8 kg/sq cm unloading.
Open the drain valve to drain the condensed water.
Check and ensure cooling water pressure and temperature of the inlet are within limits. (Pressure range from 1.5 to 2.8 kg/cm² & temperature range from 26º C to 35º C)
Check and ensure lubrication oil pressures 1.1 to 2.8 kg/cm²
Check and ensure the discharge air pressure is between 7.5 to 8.0 kg/cm²
Check and ensure discharge air temperature should be between 110ºC to 180º
Check the condition of belts.
Put a Tick mark (Ö) in the Daily Check Sheet after completion of each activity. If it is not O.K. put a cross (X) in the Daily Check Sheet indicating the reason in the remarks column.
Immediately inform the concerned superior if it is not O.K (X) and take necessary corrective action as per the advice.
Any such deviations should be maintained in the Machine History Cord along with necessary corrective action and its compliance thereof.
Weekly Maintenance
Clean and reset the auxiliary valve with a Cora cloth.
Clean the bowl air filter element with Cora cloth and air.
Clean the air intake filter with compressed air and Cora cloth.
Clean the oil breather with a Cora cloth.
Check and ensure the air compressor load is below 60 Amps during unloading and below 160 Amps during loading.
Blow off oil from Low pressure and High-pressure side of the crankcase.
Check and ensure no air leakages in the system.
Put a Tick mark in the Weekly Check Sheet.
Monthly Maintenance
Check and tighten the motor Bed Bolts if it is loose.
Clean the contactor kits with carbon tetra chloride.
Clean the auxiliary valve inside with EMERY paper.
Open the motor terminal covers tighten the terminals, and replace the terminal strip if the terminals are broken.
Clean the control panel with an air blower and ensure no control wires hang, tag the wires with a cable tag if it is hanging.
Put a Tick mark in the Monthly Check Sheet.
Quarterly Maintenance
Do the alignment of the motor pulley and compressor pulley.
Regrease the motor Bearings.
Clean the inlet and discharge valves and replace if worn out or damaged.
Check and ensure connecting Rod Bearing side clearance is not to exceed 0.002mm.
Change 20 micron filter, if the pressure drop exceeds 20 PSI.
Put a Tick mark in the Quarterly Check Sheet.
Half Yearly Maintenance
Calibrate the pressures and Temperature gauges. Of Inlet and Outlet.
Calibrate the pressure switches.
Check and clean the contactors, and replace the contactor kits if it is damaged.
Air inlet filter element to be replaced if necessary.
Put a Tick mark in the Half Yearly Check Sheet.
Yearly Maintenance
Lubricate the pedestal bearings.
Check piston ring and rider band axial clearance not exceed 0.0254 mm.
Check and ensure the X-HD share clearance not exceed 0.0025 mm
Check and ensure no vibration of the driven pulley.
Calibrate the safety valve. Temperature and pressure gauges.
Check the crankshaft thrust and replace it if it is worn out.
Check the working condition of the soft starter; do the servicing if it not functioning.
Check the working condition of the contactor, replace if it is chattering.
Put a Tick mark in the Yearly Check Sheet.
Forms and Records (Annexures)
Not Applicable
Distribution
Master copy – Quality Assurance
Controlled copies- Quality Assurance, Production, Quality Control
