Air compressor maintenance needs to be replaced

Technical Specifications for Air Compressor Maintenance–Guidelines for Replacement of Consumables

The stable operation of air compressors relies on standardized maintenance, of which the replacement of consumables is the core link. In order to clarify maintenance standards and extend the service life of equipment, the consumables and operating specifications that need to be replaced during air compressor maintenance are as follows:

1. Daily inspection and consumables replacement cycle

1. air filter

• replacement cycle: Every 500 hours of operation or 3 months (whichever comes first).
• function description: Filter particulate matter (≥5μm) in the inhaled air to prevent impurities from entering the compression chamber and causing rotor/scroll wear.
• operation specifications: When replacing, clean the air filter housing simultaneously to prevent residual dust from entering the air path.

2. oil filter

• replacement cycle: Every 1000 hours of operation or 6 months.
• function description: Intercept metal debris and oxidation products in lubricating oil to protect bearings and gears.
• precautions: After replacement, check the tightness of the oil circuit to prevent leakage leading to insufficient oil pressure.

2. Quarterly maintenance and consumables replacement

1. lubricating oil

• replacement cycle: Oil-injected air compressors run every 2000 hours or 12 months; oil-free air compressors do not need to be replaced.
• Oil selection：
  • Screw machine: Use ISO VG68 -100 synthetic oil, flash point ≥220℃, oxidation stability ≥3000 hours;
  • Scroll machine: Select PAO base oil, viscosity index ≥120, anti-foaming property ≤50ml/10 min.
• operation specifications: Before draining oil, it is necessary to run the equipment for 10 minutes to increase the oil temperature to above 60℃ to ensure that the old oil is drained.

2. oil-gas separator

• replacement cycle: Every 4000 hours of operation or 24 months.
• function description: Separate the oil content in the compressed air to ensure that the oil content in the exhaust gas is ≤3ppm.
• Selection requirements: It needs to match the air compressor’s displacement, and is forcibly replaced when the pressure difference exceeds 0.1MPa.

3. Annual maintenance and consumables replacement

1. minimum pressure valve

• replacement cycle: Every 8000 hours of operation or 48 months.
• function description: Maintain oil circuit circulation pressure to prevent compressed air from flowing backwards.
• testing standards: The opening pressure needs to be stable at 0.4-0.5MPa, and the leakage volume is ≤1L/min.

2. temperature sensor

• replacement cycle: Every 10000 hours of operation or 60 months.
• function description: Monitor exhaust temperature and oil temperature, and protect equipment during over-temperature alarm.
• calibration requirements: Use a standard thermometer for verification every year, and replace it when the error exceeds ±2℃.

4. Maintenance requirements under special working conditions

1. High dust environment

• Filter element upgrade: Increase the accuracy of the air filter element to ≤1μm and shorten the replacement cycle to 250 hours.
• Add pre-filter: Install a cyclone separator in front of the air filter to intercept large particles of dust.

2. high temperature environment

• Lubricating oil upgrade: Select high-temperature resistant synthetic oil (such as polyether) with flash point ≥240℃.
• cooling system maintenance: Clean cooler fins quarterly to ensure heat exchange efficiency ≥90%.

3. humid environment

• Anti-emulsification of oil: Select lubricating oils with anti-emulsification ≤3 to prevent water emulsification and clogging of oil paths.
• Drainage device inspection: Drain condensate from the air storage tank every day and verify the sensitivity of the automatic drain valve quarterly.

5. Consumables selection and procurement specifications

1. genuine guarantee: Equipment manufacturer’s supporting consumables shall be preferred, and third-party substitutes shall pass compatibility test (such as size, flow rate, pressure and other parameters matching).
2. storage requirements: Consumables such as filter elements and seals need to be stored in a dry and light-protected environment, and the validity period shall not exceed 24 months.
3. scrapping standard: Consumables that are deformed, damaged or exceed their validity period are strictly prohibited from being used and must be disposed of according to the hazardous waste treatment process.

6. Supplementary Provisions

This specification applies to the daily maintenance and overhaul management of air compressors. When special gas compression or extreme working conditions are involved, a special maintenance plan needs to be formulated based on equipment operating data and manufacturer’s recommendations.

By standardizing the consumable replacement process and selection standards, companies can ensure long-term stable operation of air compressors, reduce failure rates and risks of unplanned downtime, and improve the economic benefits of the entire life cycle of the equipment.