PREVENTIVE MAINTENANCE - WORK ORDER

Asset Number : Equipment No:

Asset Category MPGS Compressed-air plant Location:

:
PPM Frequency WEEKLY Service provider:
:
Schedule Date: Work Order No:

Target Start Date: Target Comp. Date:

Ensure the stipulated safety procedures are followed while carrying out the PM activities
CAUTION:

A. Safety Precautions Prior to PM procedure:

1.

2.

3.

Checklists YES NO REMARK

Confirm that ERM isolating valve is open and the ERM is able to supply air to the
1.  
pipeline system.
Before isolation of compressors takes place:
2.
(i) Check running of cooling fans where fitted.
(ii) Record input and output temperatures of oil/after-cooler where
fitted.
(iii) Check safety valves/pressure gauges for condition and leaks (note
gauge readings).
(iv) Examine all drainage traps and their respective manual bypass  
valves (where fitted), and check for correct operation and
opening: replace or repair if necessary.
(v) Check the condition of all flexible components and associated
electrical bonding.
(vi) Check the receiver(s) for general external condition.
(vii) Check the dryer columns for damage/rust.
(viii) Check all visible electrical components for damage/overheating
Isolate one of the compressors and check the following. (Note that a “plant fault” alarm
3.
will probably be given at this stage. The other compressor(s) should be selected as “duty”
plant).
(i) Holding down and fixing bolts – replace/adjust as necessary.
(ii) Anti-vibration mountings bolts – replace/adjust as necessary.
(iii) Air intakes, filters and silencers – replace/clean as necessary.  
(iv) Motor alignment – adjust as necessary.
(v) Drive coupling or pulleys and belts – adjust/replace as necessary.
(vi) Inter/after-cooler coils/fans – clean/replace as necessary.
(vii) Oil levels and oil filter – top up/change as necessary.
(viii) Motor windings and bearings – clean/replace as necessary.
Repeat (3) for the other compressor(s), making sure that you have changed over the
4.  
“duty selector” switch and isolated the compressor you are to work on.
5. Switch on both/all compressors in “auto” mode. Plant operation can now be tested, either  
with
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without the use of the ERM. If the ERM is to be used, it will be necessary to close the
 primary plant-isolating valve (slowly) to ensure that the ERM comes on line and is able to
supply the hospital.
6. Open the receiver drain valve(s) slowly and record the cut-in pressure and unloaded and
loaded running currents of the duty pump(s). (On a three-pump system, the second pump  
will cut in a few seconds after the first.)
7. Isolate the duty pump(s) and confirm that a “plant fault” alarm is initiated.  

Continue draining the receiver(s) and record the cut-in pressure and loaded running  
8.
currents of the stand-by pump(s).
NOTE If plant is fitted with a back-up pressure switch, the operation and set pressures of
the switch can be checked now. Continue to drain receiver: check that the back-up
pressure switch operates and record its pressure settings
Close the receiver drain valve(s) and record the cut-out pressure of the stand-by  
9.
pump(s).
Switch on the duty pump(s) isolator and put the stand-by pump(s) on manual control.  
10.

11. Record the cut-out pressure of the duty pump(s) and switch the stand-by pump(s) back to  
automatic control.
Change over the “duty selector” switch and repeat (5) to (11).  
12.

As a final test of operation, open the receiver drain valve(s) again and confirm that the  
13.
duty pump cuts in.
Close the receiver drain valves and record the hours run for each pump.  
14.

The operation of the “low line pressure” switch can now be tested. The ease of this
15.  
process will depend on its location in the system and the provision (or lack of) of a
convenient leak/test point.
Note 1 It may be necessary to isolate the outlet line from the dryers/regulators in
order to simulate pressure loss. If this is the case, affected valves must be reinstated
to their original operating positions.
Note 2 Dryer operation can now be tested. A large variety of dryers exists, including
heated, heatless and compressor-cycled (usually in conjunction with the compressor
unloading devices). Some dryer columns are fitted with pressure sensors, which will
signal a plant fault alarm if the column has not repressurised after regeneration. It
may not be possible to cycle the dryers quickly, although some dryer units offer a
“high speed” mode, which will perform this function.
Note 3 Some parts of the following procedure may not be relevant, therefore, to a
particular model of plant; the manufacturer’s instructions must be followed.
Note 4 Take care to isolate and bleed down all filters before dismantling.
16
Check filter element differential pressure gauges and/or age/running hours of filter,
and replace as necessary.
Confirm that any filter auto-drains are operating correctly

Record drying and reactivating pressures and confirm operation of cycling and
repressurisation controls where possible.
NOTE Some systems have a “plant fault” alarm initiated by failure of a column to
build up pressure after regeneration. This can be tested at this stage.
Test operation of the dryer change-over/control unit, both by manual selection
(where appropriate) and by removing and shorting the dew-point sensor connecting
cable. Confirm that a “plant emergency” alarm is initiated on this latter action.
NOTE Some units have multiple sensor connections. Those with sensors attached to
dryer columns, in addition to a line dewpoint sensor, may indicate a “plant fault”
alarm when the former are shorted and a “plant emergency” when the latter is
shorted.
Open
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stand-
by
regulator’s input isolating valve slowly, while keeping its output valve closed. Listen
 for leaks.

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 PREVENTIVE MAINTENANCE - WORK ORDER
Asset Number : Equipment No:

Asset Category : MPGS Automatic manifold Location:

PPM Frequency : Daily Service provider:

Schedule Date: Work Order No:

Target Start Date: Target Comp. Date:

D. Quantitative/Inspection Checklist (Identify the parameters to be measured and record all data in space provided
below, please attach additional sheets if required.):

Parameter:

Set Limits:

Data:

Materials Used:

Materials Quantity

Labor Details:
Technician Name Job Description Labor Hours Signature

Remarks Follow Up’s

Completed By: Sign: Date:

Reviewed by: Sign: Date:

Approved by: Sign: Date: