sop for Preventive Maintenance of Air Compressor

1.0 Objective
To lay down a procedure Preventive Maintenance of Air Compressor.
2.0 Scope
This Standard Operating Procedure is applicable for Preventive Maintenance of Air Compressor to be followed at formulation plants
3.0 Responsibility
3.1 Engineering Officer / Executive shall be responsible for the execution of this procedure.
3.2 Engineering Manager shall be responsible for the implementation of this SOP.
3.3 Head QA/designee shall be responsible for the compliance of this SOP.
4.0 Abbreviations and Definitions
SOP : Standard Operating Procedure
No : Number
QA : Quality assurance
Qty : Quantity
ER : Engineering
5.0 Procedure
5.1 General Conditions
5.1.1 Refer the master plan of preventive maintenance concern department.
5.1.2 Equipment shall be available for preventive maintenance.
5.1.3 Clean oil / grease stains & remove unwanted material, spares after completion of work.
5.2 Precautions
5.2.1 Use necessary safety wears, while doing the work.
5.2.2 Ensure covers & guards are properly fixed.
5.3 Procedure for Preventive Maintenance Of Air Compressor.
5.3.1 Ensure that electrical supply is in off position in main panel and display “Under Maintenance” Board on the panel board.
5.3.2 Switch OFF the drive unit and inform all the concerned.
5.3.3 Operator or above has to ensure and verify the check points for the preventive maintenance as shown in the Annexure-1, 2&3.
5.3.4 After the completion of preventive maintenance, check the machine for smooth operation.

5.3.5 Remove “Machine under Maintenance” Board on the panel board after completion of the Maintenance.
5.3.6 The operator / technician who perform the job will enter his name / sign in “Done By” Column and responsible Engineer / Officer will put sign in “Checked by” column. Department Head will review the record every month.
5.3.7 Quarterly Maintenance will include the jobs of monthly maintenance, Half Yearly Maintenance will include the jobs of Monthly and Quarterly Maintenance and Yearly maintenance will include the jobs of Monthly, Quarterly and half yearly maintenance.
5.3.8 Quarterly Preventive Maintenance is to be carried out as per the following check points.
5.3.8.1 Check and tight all exposed nuts and bolts of the unit.
5.3.8.2 Check and tight all foundation bolts of the motor and compressor.
5.3.8.3 Check the Lubricating oil level, if required top up the oil.
5.3.8.4 Clean the suction air filters.
5.3.8.5 Check the tightness of all the terminals in electrical device in machine.
5.3.8.6 Clean and Inspect compressor suction and discharge valves for and leakages.
5.3.8.7 Clean and inspect compressor suction and discharge valve gaskets surfaces and air passages.
5.3.8.8 Check the V-belt condition and its tension.
5.3.8.9 Check pulley locking bolts of motor & compressor.
5.3.8.10 Check the proper earthling.
5.3.9 Half Yearly Preventive Maintenance is to be carried out as per the following check points.
5.3.9.1 Check valve un-loaders.
5.3.9.2 Check the motor bearings for any abnormal noise. If required lubricate with oil and grease (or) if required replace the bearings.
5.3.9.3 Replace the Lube oil filter.
5.3.9.4 Clean and flush the oil reservoir, and replace the oil with fresh oil.
5.3.9.5 Replace the suction air filters
5.3.9.6 Check all drive motor high-tension terminal connections, if required tighten the same.
5.3.9.7 Check the controllers for proper working, if not rectify the problem as per the situation.
5.3.10 Yearly Preventive Maintenance is to be carried out as per the following check points.
5.3.10.1 Check oil wiper and pressure packing.
5.3.10.2 Inspect the coolant system for scale and sludge. If required de scale cylinder water Jackets.

5.3.10.3 Check all electrical connections (compressor control panel, all pump motors, fan motor) for any loose connections, burned contacts, signs of Overheated wires etc.

sop for Preventive Maintenance of Air Compressor

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