MAINTENANCE OF INGERSOLL RAND AIR COMPRESSOR, MODEL IHE-5-NL-2

  • 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.
  • 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 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
    DateRevision Number
    Reason for Revision

     

    00New SOP

     

 

 

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