MAINTENANCE OF INGERSOLL RAND AIR COMPRESSOR, MODEL IHE-5-NL-2
Pharma Editor
November 18, 2016
Engineering
1,210 Views
- OBJECTIVE
- To lay down a procedure for Maintenance of Air compressor
- SCOPE
- This SOP is applicable to Air compressor.
- RESPONSIBILITY
- Technical Supervisor / Engineer
- ACCOUNTABILITY
- Sr.Executive / Manager
- PROCEDURE
- Daily Maintenance
- Check and ensure oil level 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 inlet should be within limits. (Pressure range from 1.5 to 2.8 kg/cm² & temperature range from 26º C – 35º C)
- Check and ensure lubrication oil pressures 1.1 to 2.8 kg/cm²
- Check and ensure discharge air pressure is in 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 Daily Check Sheet after completion of each activity. If it is not O.K put a cross (X) in Daily Check Sheet indicating the reason in remarks column.
- Immediately inform to the concern 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 there of.
- Weekly Maintenance
- Clean and reset the auxiliary valve with 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 Cora cloth.
- Check and ensure the air compressor load is below 60 Amps during unloading and below160 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 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 by EMERY paper.
- Open the motor terminal covers and tighten the terminals, replace terminal strip if terminals are broken.
- Clean the control panel with air blower and ensure no control wires should hang, tag the wires with cable tag if it is hanging.
- Put a Tick mark in Monthly Check Sheet.
- 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 not to exceed 0.002mm.
- Change 20micron filter, if pressure drop exceeds 20 PSI.
- Put a Tick mark in 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, replace the contactor kits if it is damaged.
- Air inlet filter element to be replaced if necessary.
- Put a Tick mark in 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 to exceed 0.0025 mm
- Check and ensure no vibration of driven pulley.
- Calibrate the safety valve. Temperature and pressure gauges.
- Check crankshaft thrust and replace if it is worn out.
- Check the working condition of soft starter; do the servicing if it not functioning.
- Check the working condition of contactor, replace if it is chattering.
- Put a Tick mark in Yearly Check Sheet.
- Forms and Records (Annexures)
- Not Applicable
- Distribution
- Master copy – Quality Assurance
- Controlled copies- Quality Assurance, Production, Quality Control
- History
| Date |
Revision Number |
Reason for Revision
|
| – |
00 |
New SOP
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