Extending the Life Cycle
EXTENTING THE LIFE OF YOUR SYSTEM
Rotary Screw Air End
- Check for mechanical seal leakage.
- Check for inlet valve wear.
- Check for excessive bearing “play.”
- It is recommended to rebuild between 35,000 and 100,000 hours depending on each manufacturer.
- Grease motor bearings with grease recommended by the manufacturer. 0 Replace bearing on a conservative schedule.
- Check amp draw to prevent motor overload.
- Compressor room ventilation.
- Limit high ambient temperatures.
Direct Drive Train
- Make sure the system is perfectly aligned.
- Check frame & mounting blocks for “settling.” This may cause misalignment & coupling damage.
Drive Train Gears
- Check spray bar for excessive contaminants & plugged orifices.
- Check for wear and backlash.
- Ensure proper lubrication.
Drive Train Coupling (Flex)
- Inspect for wearing and cracking.
Drive Train V-Belts
- Check belt tension.
- Check wear on v-belt/pulley.
- Use only manufacturer recommended grade.
- Drain existing lubricants before refilling.
- Draw routine oil samples to determine maximum lubricant life. 0 Use synthetic lubricants for maximum service life.
- Minimize contaminants in surrounding environment, as they will damage machinery over time.
- Check pressure differential; if necessary, “counter flow” compressed air through filters to clean them.
- Check for worn/damaged seals.
- Check for structural integrity.
- Replace filters per manufacturer’s recommendations. Filters can only be cleaned a limited number of times.
- Ensure that all filters meet the appropriate performance criteria as specified by OEM, including micron rating, contamination capacity, & pressure drop.
Lubricant Filter & Lubricant Separator
- Change when max pressure differential is reached or at each lubricant change, whichever occurs first.
- Check for visible contamination.
- Clean regularly.
- Keep clean and dry.
Refrigerated Dryer Maintenance Condenser Unit
- Periodically clean fins with compressed air or bristle brush to ensure enough refrigerant is transformed into a liquid state.
- Do not bend or damage fins of heat exchanger during cleaning.
- Check separator and drain function regularly by monitoring discharge amounts.
- Service or rebuild at least once per year.
- Check pressure switch setting if condenser fan is not running during full load operation.
Most modern heat exchangers are self-cleaning & do not require any pre-filtration or cleaning, however, a few things should be considered.
- Ensure ambient air does not contain traces of ammonia or acidic substances, as water and ammonia can create an acid that destroys copper/aluminum heat exchangers.
Desiccant Dryer Filtration
- Verify adequate pre-filtration, as it is essential to protect desiccant from oil and bulk water.
- Check pressure drop across filters.
- Change filter cartridge when pressure drop exceeds 8 to 10 psid.
- Check drains for proper operation; rebuild them at least once a year.
- Sample desiccant, & examine for proper size and discoloration which indicate oil contamination.
- Replace desiccant every 2 to 3 years.
- Check diaphragms & seals of valves.
- Replace at least once per year.
- Check valves for wear.
- Check gauge reading on pressure vessels during “purge” cycle. Lower than normal pressure can indicate excessiveleaks. Higher than normal pressure can indicate a clogged muffler or stuck valve.
- Check desiccant dryers outlet dewpoint to verify proper degree and current state of desiccant bed.Replace desiccant bed if elevated dew point is found.
- Periodically check for dewpoint if dryer is not equipped with a dewpoint monitor.
- Make sure mechanical “cam” timer or PLC operates correctly. Purge Mufflers
- Check for excessive desiccant dust.
- Check purge line for obstruction and excess pressure drop.
Heater and Temperature Controls
- Check operation and temp settings of thermostat to avoid heater element burn out, typically between 350 – 450°F.
- Check safety temp switch for proper operation.
- Service blower per manufacturer’s recommended guideline.
- Grease or replace motor bearings as required or per manufacturer’s recommended guideline.
- Clean or replace blower air inlet filter as required or per manufacturer’s recommended guideline.
- Check clearance of fan blades or impeller.
- Membrane Dryers
- Check manufacturer’s requirements for pre-filtration & drain traps.
- Replace element at manufactures recommended differential pressure setting.
Aftercooler, Drains, and Filters Air-cooled Aftercoolers
- Clean heat exchanger fins with compressed air or bristle brush.
- Caution should be taken to avoid damaging or bending fins.
- Check for proper water pressure, and inlet/outlet temp.
- Check heat exchanger on water and air side for fouling. Mineral deposits on water side will negatively influence heat transfer.
- Clean or flush with special cleaning solvent if necessary.
Moisture Separator with Drain
- Check separator filter element for pressure drop.
- Ensure that the filter is installed in the proper flow direction.
- Check particulate & liquid inlet loading versus rated performance.
- Check pressure drop regularly or use an electronic filter monitor.
- Check drain function periodically or as recommended by manufacturer.
- Check for any liquid water, as it renders the carbon ineffective.
- Carefully open drain valve and check for smell.
- Change cartridge when smell is detected.
Note: With cartridge style filters, change after 1,000 & on “tower” style filters after 10,000 operating hours. (whichever occurs first) Carbon “Tower” style filters need a fine filter installed to remove carbon dust.
- Check for clogged strainer installed ahead of drain. Note: High quality drain does not require a strainer.
- Periodically clean off excessively large contaminants which did not pass through the drain.
- Annually rebuild drains. Note: Drains can cycle up to 250,000 times a year.
- Ensure drain is installed correctly, as vent lines are often necessary to provide reliable operations.
- Never feed more than one condensate line into drain.
Condensate Management System
- Ensure that condensate is properly treated before being discharged into municipal sewer systems. Failure to do so could result in severe fines.
- Check manufacturer’s documentation for maintenance schedule.