Preventive Maintenance

What it is

Air Compressor & Air Dryer

A planned, periodic maintenance program to keep your compressed-air system efficient, reliable, and safe, minimizing unplanned downtime and energy loss. Work is performed by certified engineers using OEM-grade parts and documented procedures.

Objectives

Maintain stable pressure & flow with lowest possible kWh/m³.
Prevent premature wear of critical components (airend, bearings, valves, drains).
Detect issues early (leaks, overheating, high ΔP, abnormal vibration).
Keep air quality within ISO 8573 class targets.

Recommended Schedule (guideline)

Daily/Weekly: visual checks, pressures/temps, drain operation, leaks.
Every 1,000–2,000 h: air filter, belt/coupling check, basic cleaning.
Every 2,000–4,000 h: oil & oil filter, general inspection, parameter log.
Every 4,000–8,000 h: separator element, deeper inspection, valve service.
Yearly: full system audit (energy, leaks, safety), dryer performance check.

Varies by model, ambient, and duty cycle.

Scope of Work – Screw Air Compressor PM

Incoming Inspection & Safety
- LOTO, safety brief, machine ID/serial verification.
- Visual check for leaks, abnormal noise/vibration, hot spots.
Operational Check & Data Logging
- Record load/unload hours, pressure band, discharge temperature, ambient temp, voltage/current balance.
- Check controller alarms/history.
Filtration & Lubrication
- Replace air intake filter (or clean if reusable) and inspect housing seals.
- Replace oil filter and compressor oil (per spec—synthetic/mineral, viscosity grade).
- Check for oil contamination or oxidation; sample for analysis if required.
Separator & Breather
- Measure ΔP across oil separator; replace when above limit or per interval.
- Inspect/clean crankcase breather (if applicable).
Valves & Cooling Circuit
- Inspect/clean: inlet valve, minimum pressure/check valve, thermostatic/bypass valve.
- Check cooler fins (aftercooler/oil cooler); clean coil and straighten fins as needed.
- Verify fan operation and airflow path.
Drive Train
- Belt tension & alignment (for belt drive) or coupling condition (direct/gear).
- Check motor bearings for noise/heat; measure vibration (if contracted).
Sensors & Protection
- Verify pressure/temperature sensors, safety switches, relief devices (per site policy).
- Inspect electrical connections, contactors, and control wiring for heat or looseness.
Receiver & Distribution (spot checks)
- Drain function (manual/automatic), gauge condition, safety valve tag/date.
- Quick leak survey on main headers and critical drops.
Housekeeping
- Clean interior/exterior, remove dust/oil mist, restore guards and labels.
Run Test & Handover

Start-up under load; verify setpoints, unload timing, ΔP, temperatures.
Record final readings and recommendations.

Deliverables (Compressor PM)

PM checklist & photos, ΔP logs (filter/separator), running parameters, oil change record.
Findings & recommendations (parts forecast, corrective actions, energy opportunities).
Sticker/tag with next service due.

Scope of Work – Refrigerated Air Dryer PM

Operational Verification
- Check dew point (or outlet temp), suction/discharge pressures, and compressor cycling.
- Inspect moisture indicator (if fitted) and sight glass condition.
Heat Exchanger & Condenser
- Clean condenser coil/fins; verify condenser fan operation.
- Inspect air path—remove dust or obstruction.
- Check refrigerant lines for frost, oil stains (possible leaks).
Drainage System
- Test automatic drains (timer/zero-loss type) on dryer and pre/post filters.
- Clean strainers and verify discharge to safe point.
Filtration Around Dryer
- Inspect/replace pre-filter (coalescing) and post-filter elements; record ΔP.
- Check housing O-rings/seals.
Electrical & Controls
- Inspect contactors/relays, tighten terminals, verify thermostat/controller settings.
- Check anti-freeze protection if applicable.
Cabinet & Housekeeping
- Clean panels, ensure good ventilation clearances, verify labels and safety notices.
Run Test & Documentation
- Confirm stable dew point at rated load; monitor pressure drop.
- Log readings and recommend corrective actions (e.g., leak repair, pre-filter upgrade).

Deliverables (Dryer PM)

PM checklist & photos, dew point and ΔP records, drain test results.
Consumables replacement log and improvement notes (e.g., airflow, room temp, filtration grade).

Optional Add-Ons

Leak detection & repair with savings estimate.
Energy audit (kWh/m³, load profiling, pressure optimization).
VSD retrofit and control band tuning.
ISO 8573 air quality testing (solid, oil, moisture).
Spare parts kit provisioning & consignment stock.
Emergency SLA: response ≤ 4–8 hours (Premium).

Lower energy cost through clean filters, correct setpoints, and sealed leaks.
Higher uptime with early detection and scheduled replacements.
Longer equipment life and stable product quality (dry, clean air).
Full traceability with documented reports and service tags.

Notes: Intervals depend on model and conditions (ambient dust, temperature, duty cycle). Work is performed under SOP/HSE with OEM-grade parts. For certified values and model-specific tasks, request our official maintenance plan/datasheet.

Benefits to Your Plant