Maintenance Tech Tip – Shutting Down to Get Started

Maintenance is an essential part of keeping things running. Last month, we shared a maintenance tech tip that detailed the ways keeping air intakes clean helps keep your air compressor running clean and easy. Today, we’re going to review some essential compressed air system maintenance basics, including a crucial step that anyone and everyone should always take into consideration: stopping operations before you get started.

There are certain precautions that are no-brainers when it comes to maintenance or repairs. If you’re tinkering with an electrical circuit, you always shut down the corresponding breaker and check the outlet, wire, or cable with a voltage tester or meter to ensure there’s no current present (or alternate power source). Climbing up even a couple rungs on a ladder? Double and triple check the footing to make sure it won’t tip or slip. Working under the hood of a vehicle? Make sure there’s no loose-hanging clothing, jewelry or hair that could get snagged in any fast-moving engine parts.

The same holds true when undertaking any level of air compressor maintenance. Like all electro-mechanical equipment, industrial compressed air systems require periodic maintenance to operate at peak efficiency and minimize unscheduled downtime; proper maintenance is essential to compressed air system efficiency and reliability. 

The following procedures should be followed when stopping the compressor for maintenance or service:

1. Per S.H.A. regulation 1910.147: The Control of Hazardous Energy Source (Lockout/Tagout), disconnect and lockout the main power source. Display a sign in clear view at the main power switch stating that the compressor is being serviced. Never assume a compressor is safe to work on just because it is not operating. It could restart at any time.

2. Isolate the compressor from the compressed air supply (or supplies) by closing a manual shut-off valve downstream (and upstream, if applicable in booster service) from the compressor. Display a sign in clear view at the shut-off valve stating that the compressor is being serviced. Be certain that a pressure relief valve is installed upstream of any isolation valve.

3. Lock a pressure relief valve open within the pressurized system to allow the system to be completely depressurized; never remove a plug to relieve the pressure.

4. Shut off the water-cooling supply (water-cooled compressors).

5. Open all manual drain valves within the area to be serviced.

6. Wait for the unit to cool before beginning service. Temperatures of 125°F can burn skin; some surface temperatures exceed 350°F when the compressor is operating, and they’re likely still just as hot soon after it’s shut down.

7. Always refer and give preference to the manufacturer’s manuals over these typical maintenance procedures.

Compressed air system maintenance is similar to that performed on cars; filters and fluids are replaced, cooling water is inspected, belts are adjusted, and leaks are identified and repaired. Inadequate maintenance can have a significant impact on energy consumption via lower compression efficiency, air leakage or pressure variability. It can also lead to high operating temperatures, poor moisture control and excessive contamination. Most problems are minor and can be corrected by simple adjustments, cleaning, part replacement or the elimination of adverse conditions.

As always, all equipment in the compressed air system should be maintained in accordance with manufacturers’ specifications. Maintenance is a significant responsibility, and working in and around powerful machines and electrical currents can be dangerous; any work by you or anyone responsible for the maintenance and performance of your air compressor or your compressed air system should only be conducted by a trained professional; if you’re not, leave it to a representative of the manufacturer. Manufacturers provide inspection, maintenance and service schedules that should be followed strictly. In many cases, it makes sense from efficiency and economic standpoints to maintain equipment more frequently than the intervals recommended by manufacturers, which are primarily designed to protect equipment.

Protecting your capital investment takes time and dedicated resources – two things that are often in short supply. If you or your facility can benefit from a team of maintenance professionals whose primary responsibility is keeping your compressed air system running clean and pure, contact Atlas Copco for more information on the ways our customer support plans and parts servicing programs can keep your processes and applications operating in superior condition.