FEATURE COMPRESSED AIR
KEEPING THE PRESSURE ON T
Despite an outstanding reliability record compressors work much more efficiently with the correct maintenance, argues Andrew Westwood, Service Manager at BOGE Compressors
here are millions of air compressors installed worldwide and the vast
majority of them work day in, day out without complaint. That doesn’t mean they can be taken for granted, however. A poorly maintained compressor will consume more energy and produce less output than it should. Ultimately, such a machine is likely to
fail suddenly and could constitute a significant safety hazard. Fortunately, the consumables and wearing parts of modern compressors are all designed for straightforward replacement, making an effective maintenance programme simple to design and manage.
OIL AND AIR FILTERS Oil and air filters have tough jobs. They may need to be 99.99% effective at removing particles as small as 3μm, for example or reduce oil carry-over to 1-3 mg per m3, all without creating energy- consuming high differential pressures. The best filters do this with a
combination of the highest quality filtration materials and a sophisticated design such as the two-stage cyclone system used in BOGE air intake filters. Details such as these matter: while they
might look outwardly similar, cheaper non-genuine service parts are frequently made to inferior specifications, resulting in poorer performance, higher energy use and a shorter service life. In some well-documented cases such parts have failed catastrophically causing prolonged downtimes and serious damage to equipment. Even the best filters get blocked over time and regular replacement is essential to avoid compromising compressor efficiency. BOGE filters are designed and recommended to be replaced every 3,000 operating hours. In the best quality products user-friendly features such as tool free changes with spin-on housings help to speed up and simplify the maintenance process. An important but frequently overlooked aspect of compressor filtration is the external cabinet filter which keeps larger dust and dirt particles away from the
valves prevent back flow from the line into the compressor during standby or idle mode, reducing the current required to restart the compressor and preventing condensate from running back from the line and contaminating or corroding internal parts. Over time, repeated operation and heat stress can cause the spring in the MPV to lose its original tension, affecting its performance. Leading compressed air systems
manufacturers design wearing mechanical components to offer a high level of reliability under normal maintenance regimes. Typically, that means cleaning and inspection every 3,000 hours and replacement after 9,000 hours. To simplify inventories and reduce service time, manufacturers provide kits containing all the necessary parts to do these jobs.
COOLANTS AND LUBRICANTS
compressor motors, coolers and other key parts. Under normal use these filters should be checked for contamination on a weekly basis and replaced as often as necessary; in normal operating conditions this is usually monthly.
MECHANICAL PARTS Regular inspection, service and replacement of a number of mechanical parts are essential to compressor performance. For example, BOGE screw compressors use a multifunction suction intake regulator which controls the load and unload cycles of the compressor and works as a fast-acting non return valve to prevent oil or aerosols from flowing back to the suction filter during the unload sequence. Wear can prevent the intake from sealing properly, leading to unreliable compressor operation and damage to filters. Screw compressors use a minimum pressure non-return valve (MPV) on their internal compressed air circuit. These
“With sustainability and total cost of ownership high on the corporate agenda many companies are looking for ways to minimise energy
consumption and maximise performance of their assets 16 SEPTEMBER 2015 | FACTORY EQUIPMENT ”
Regular inspection, service and replacement of several mechanical parts are essential to compressor performance
Selection of the right lubricants and coolants is an underestimated aspect of compressor performance, especially once compressors have moved beyond their original warranty period. Synthetic lubricants offer several advantages over more traditional mineral oils. They improve compressor efficiency, leaving fewer carbon deposits on compressor components and maintain the right viscosity over a wider operating range. They last longer, being less prone to oxidisation or evaporation which means lower oil consumption, reduced carry- over of oil into compressed air and almost doubling the intervals between air-end overhauls. Similarly, BOGE coolants are custom engineered to deliver the right combination of cooling, sealing and lubrication characteristics to suit compressor applications. With sustainability and total cost of ownership both high on the corporate agenda many companies are looking for ways to minimise energy consumption and maximise the performance and service life of their assets. A well-designed compressor
maintenance regime using high quality parts and consumables is one of the simplest and most effective ways to simultaneously achieve those aims.
BOGE Compressors T: 01908 533253
www.boge.co.uk
/ FACTORYEQUIPMENT
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