To ensure the reliable and efficient operation of the compressed air system’s by Preventive Maintenance of Compressed Air System in regular time intervals, thereby minimizing downtime, optimizing energy usage, and extending equipment lifespan.
SOP for Preventive Maintenance of Compressed Air System
OBJECTIVE:
To lay down the procedure for Preventive Maintenance of Compressed Air System
SCOPE:
This procedure is applicable to Preventive Maintenance of Compressed Air System installed in the Utility Block of Engineering Department.
RESPONSIBILITY:
Technician/ Operator shall be responsible for proper execution of Preventive Maintenance of Compressed Air System as per SOP.
Engineering – Head shall be responsible for reviewing the SOP and for ensuring proper execution of Preventive Maintenance of Compressed Air System.
ACCOUNTABILITY:
Head of department- Engineering shall be accountable for SOP for the Preventive Maintenance of Compressed Air System.
DEFINITION:
Preventive Maintenance of Compressed Air System refers to a systematic and planned approach aimed at maintaining the reliability, efficiency, and optimal performance of a facility’s compressed air infrastructure. It involves conducting routine inspections, servicing, and adjustments to various components within the compressed air system, including compressors, dryers, filters, piping, and associated equipment.
PROCEDUREfor Preventive Maintenance of Compressed Air System
Preventive maintenance shall be executed as per the SOP No.: SOP/EN/XXYYY – Execution of Preventive Maintenance.
Ensure that the spare parts are available at the time of preventive maintenance.
Mechanical Preventive Maintenance of Compressed Air System
Air suction and discharge valve
Check for any abnormal noise from the piston cylinder.
Open the body flange of the piston cylinder, check the valve assembly, valve seat gasket, unloading piston, piston o rings valve holder o rings.
Replace the valve service kit for first stage after every year or 3500 hours.
Replace the valve service kit for second stage after every year or 3500 hours..
If found damage then call the service person from M/s. Chicago Pneumatics for the maintenance operation.
The frequency of checking the air suction and discharge valve of after every quarterly or 1500 hours.
Cylinder and cylinder heads
Check for the cylinder bore for wear and ovality.
Clean the cylinder jackets to remove the scale.
Clean and remove the scale from cylinder heads.
If found any abnormality then call the service person from M/s. Chicago Pneumatics for the maintenance of the same.
Check the bolts and nuts if required tighten the same; the replacement frequency as and when required.
The frequency of checking the cylinder heads and cylinder is after every six months
Piston and piston rods, packing ring
Open the cylinder heads and cylinder
Check for the pistons, piston rod and piston rings for bumping clearance, check for wear and ovality.
Check piston nut for loosening.
Check end gap.
If required to replace the piston, Piston and piston ring then call the service person from M/s. Chicago Pneumatics.
Checking of piston rods and packing rings shall be done after every six month.
Replace the piston ring for first stage after every year or 3500 hours.
Replace the piston ring for second stage after every year or 3500 hours
Change the oil wiper ring with the piston ring kit. If required
Lubricator oil tank, oil lines and Coolant
Check the level of oil in oil tank; if found low level top up the same by every monthly.
Check the level of coolant in radiator every month ,if found low level top up the same .Make Acdelco-A19246046
The recommended oil brands are as follows.
Manufacturer
Ambient temp +0 to +15 deg C
Ambient Temperature +15 deg C to +48 deg C
Indian oil corporation for crank case
Servo Press 150
Servo press 220
Indian oil corporation for cylinders
Servo press C 150
Servo press C 220
Hindustan Petroleum
Enklo 150
Enklo 220
Bharat Petroleum
Bharat Hydrol 150
Bharat Hydrol 220
Castrol Oil
Castrol Hyspin AWS 150
Castrol Hyspin AWS 220
Preventive Maintenance of Compressed Air System
Heat exchanger
If found leaking of pipe between cylinder and heat exchanger; tighten the pipe connection.
If heat exchanger does not cool effectively, then call the service person of M/s. Chicago Pneumatics for the maintenance of heat exchanger.
Checking frequency shall be Quarterly.
Suction filter
Clean the suction filter by monthly.
Motor and belt alignments
Check the belt tension if required adjusts the belt tension.
Check the motor alignment if required make the proper alignment and ensure the same.
Check the guard are in place and secured fastened.
Checking frequency shall be Monthly.
Maintenance of solenoid valvein Preventive Maintenance of Compressed Air System
Check and clean the air filters connected to the solenoid valve, if found any abnormality rectify the same
Checking Frequency of solenoid valve is every month.
Checking of the safety valve
Increase the air safety valve above the set point, the safety valve should pop up and air will come out.
If air is not come out then check the set point. Recheck the operation of safety valve if found okay, then put it in the system or otherwise replace the same.
The checking of safety valve should be done once in after six mont
Replacement of Filters
Replacement of the filters shall be done as per SOP/EN/XXXYYY.
Checking of spare parts
Check the stock of spare parts as listed below
Checking frequency shall be after every three months.
Sr. No.
Spare Part Descriptions
Quantity (Nos.)
1
Oil Wiper Ring
2
Packing Ring
3
Auto Drain Strainer
4
Air Suction Filter
5
Oil Filter
6
V Belt
7
Solenoid Valve
8
Disch. Valve service kit-HP
9
suction valve service kit-HP
10
Valve cover “O” Ring
11
Piston Ring Replacement Kit – HP Side
12
Piston Ring Replacement Kit – HP Side
13
V – seal
14
Rider Ring HP
15
Tension Nut
Preventive Maintenance of Compressed Air System – Electrical
Checking of Terminals and Wiring
Ensure that the power supply to the machine is switched off.
Visually check all the power and control wiring for its tightness if found loose rectify the same.
Checking shall be done monthly.
Checking of Safety Interlocks
Check all the pressure switches for proper functioning, .if found abnormality rectify the same.
Checking shall be done quarterly.
Checking of motor
Check all connection tightness, if found loose tighten it.
Check the phase continuity and winding continuity of motor with the help of tong tester.
Physically check the motor terminal box and terminal connections.
A good earthing shall show less than 2 Volts between the Neutral Wire of the Incoming Power supply and Panel Body.
Checking shall be done after every six month.
Checking of Contactors
Check the functioning of contactor if found any abnormality, rectify the same.
Check the earthing of the panel body.
Check the overheating of conductor it found, rectify the same.
Checking of contactors shall be done quarterly.
Post Preventive Maintenance of Compressed Air System – Check List
Whenever any modifications and major works are carried out to the equipment, the same shall be mentioned in the equipment history card as per the respective SOP.
Connect the equipment main power supply and start the equipment.
Ensure that the equipment is running smoothly, without any abnormality.
If any abnormality is observed in the above, same will be attended in co-ordination with User department Head.
Record the preventive maintenance record in Format No. SOP/EN/XXXYYY
ABBREVIATIONS:
CRF No. : Change Request Form number
QA : Quality Assurance
SOP : Standard operating procedure
REFERENCES:
Operational & Maintenance Manual of Air Compressor and major activity will be carried out by authorized vendor or manufacturer.
DISTRIBUTION LIST:
SOP shall be distributed to following departments Quality Assurance, Engineering as per user request.
ANNEXURES:
Preventive Maintenance Checklist and record format for Air Compressor: SOP/EN/XXXYYY
