What to replace air compressor maintenance

As a key equipment in industrial production, regular maintenance of air compressors is the core link to ensure stable operation and extend service life. According to industry specifications and equipment characteristics, the following components and consumables need to be replaced during the maintenance process:

1. Maintenance of the core filtration system

1. air cleaner
   As the first barrier to compressed air, the filter element needs to be replaced every 2,000 – 3,000 hours. In dusty environments, it is recommended to conduct cleaning inspections every 1000 hours and use dry air below 0.2MPa to purge from the inside out. When the pressure difference of the filter element reaches 0.08MPa or is deformed or perforated, it must be replaced immediately to avoid impurities entering and causing wear on the main machine.

2. oil filter
   It needs to be replaced after the first 500 hours of operation, and replaced every 2000 hours or when the pressure difference exceeds 0.15MPa. Blockage of the oil filter will cause insufficient lubricating oil flow and cause the main engine to be shut down for high temperature protection. Under high temperature conditions (ambient temperature>40℃), it is recommended to shorten the replacement cycle to 1500 hours.

3. oil-gas separator
   When the oil content of compressed air exceeds 3ppm or the pressure difference reaches 0.1MPa, it needs to be replaced. The component is made of multiple layers of glass fiber to effectively separate oil and gas mixtures. When blocked, it will cause a surge in oil content in the exhaust gas, causing carbon deposition in the pipeline and pollution of gas-using equipment.

2. Lubrication system update

1. special lubricate oil
   All of them need to be replaced after 500 hours of first operation, and replaced every 4000 hours or during annual maintenance. In environments containing corrosive gases (such as coastal areas) or working conditions with an average load rate of>80%, it is recommended to shorten the replacement cycle to 3000 hours. Deposits in the oil system need to be cleaned up simultaneously during replacement.

2. Oil circuit seals
   Replace every 2 years or when oil leakage occurs. Including O-rings, oil seals and other components, aging will lead to lubricating oil leakage and pressure attenuation.

3. Maintenance of transmission components

1. belt drive system
   Check the belt tension every 2000 hours of operation and use a belt tension meter to measure it. When the elongation of the belt exceeds 3% or cracks appear, it needs to be replaced in groups. It is prohibited to mix old and new belts. Direct drive equipment needs to check the wear of coupling elastomer every 4 years.

2. bearing assembly
   The main engine bearings are replaced every 20000 hours of operation or when abnormal vibration occurs (vibration speed>7.1mm/s). When adopting the hot charging process, the heating temperature needs to be controlled not to exceed 120℃ to avoid annealing of the bearing steel.

4. Verification of safety accessories

1. safety valve
   Send it for calibration every year, and the opening pressure is set to 1.05-1.1 times the rated pressure. Private adjustment is prohibited. After calibration, lead sealing is required and opening pressure is recorded.

2. pressure gauge
   Verify every six months, and the accuracy level shall not be less than 1.6. Replace the pointer when the pointer trembles and the return error is greater than 1%.

V. Auxiliary system maintenance

1. cooling system
   Clean the surface area of the cooler quarterly and use a soft brush to clean it in the direction of the heat sink. Water-cooled models need to clean the cooling water pipes every year to control the hardness of the circulating water to be less than 200ppm to avoid fouling affecting heat exchange efficiency.

2. electrical components
   Check the wear of contactor contacts quarterly and replace them when the contact thickness is less than 1 mm. The frequency converter needs to be tested for capacitance every 3 years and replaced when the capacity attenuation is greater than 20%.

6. Response to special working conditions
In an environment with humidity>80%RH, a pre-cold dryer needs to be installed to control the compressed air pressure dew point at 2-7 ° C to reduce the generation of condensed water. For intermittent gas use scenarios, it is recommended to configure a zero-gas-consumption drainer to avoid backflow of water in the gas storage tank.

By strictly implementing the above maintenance specifications, the operating efficiency of the air compressor can be maintained at more than 90%, the failure rate can be reduced by 65%, and the service life can be extended to 1.5 times the design value. It is recommended to establish equipment health files to record the running time and maintenance records of key components to provide data support for preventive maintenance.