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    Ga Training 3 (BBarnes)

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    TAHRI BELGACEM
    The document provides guidance on standards for starting up and maintaining a compressor service. It details various checks and inspections to perform during startup, daily operation, and periodic maintenance at intervals of 2000, 4000, 8000 hours or 1-2 years. These include checking connections, oil levels, indicators, leaks and performing more thorough component inspections.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    Ga Training 3 (BBarnes)

    Uploaded by

    TAHRI BELGACEM
    46 views10 pages
    The document provides guidance on standards for starting up and maintaining a compressor service. It details various checks and inspections to perform during startup, daily operation, and periodic maintenance at intervals of 2000, 4000, 8000 hours or 1-2 years. These include checking connections, oil levels, indicators, leaks and performing more thorough component inspections.

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    © © All Rights Reserved

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    The document provides guidance on standards for starting up and maintaining a compressor service. It details various checks and inspections to perform during startup, daily operation, and periodic maintenance at intervals of 2000, 4000, 8000 hours or 1-2 years. These include checking connections, oil levels, indicators, leaks and performing more thorough component inspections.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    46 views10 pages

    Ga Training 3 (BBarnes)

    Uploaded by

    TAHRI BELGACEM
    The document provides guidance on standards for starting up and maintaining a compressor service. It details various checks and inspections to perform during startup, daily operation, and periodic maintenance at intervals of 2000, 4000, 8000 hours or 1-2 years. These include checking connections, oil levels, indicators, leaks and performing more thorough component inspections.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 10

    G Compressor Service

    Standards
    Startup
    • Review compressor instruction manual
    • Remove shipping bolts and brackets as indicated in instruction book
    • Check electrical connections and grounding
    • Check external starter to control panel interface (customer supplied starter)
    • Check control panel transformer connections and jumper configuration
    • Check and verify motor overload relay and fan circuit breaker settings
    • Check all control panel electrical connections for tightness
    • Check setting and operation of shutdown switches (electro-pneumatic)
    • Ensure all safety shields are installed
    • Check oil drain plugs for leaks and tightness
    • Check oil level in receiver tank and top off if necessary (Do not mix oils)
    • Pour compressor oil into inlet of element (Do not mix oils)
    • Turn element by hand to displace oil
    • Verify proper condensate drain line installation (open drains)
    • Close aftercooler manual condensate drain valve
    • Check cooling water connections (solenoid, strainer, inlet, outlet)
    Startup (continued)
    • Check air system piping (receiver, condensate collection)
    • Check room for proper ventilation (see Product Data)
    • Turn on power to compressor
    • Jog the unit and verify correct drive motor and cooling fan motor rotation
    • Start unit and run unloaded for several minutes
    • Stop unit and recheck oil level
    • Repair air, oil, or water leaks as required
    • Restart and load compressor
    • Adjust pressure switch per customer’s requirements (electro-pneumatic)
    • Set load and unload pressures on Elektronikon
    • Adjust cooling water flow rates
    • Measure and record all temperature, pressure, and SPM readings
    • Instruct customer on proper operation of unit
    • Instruct customer on preventative maintenance (Daily, 2,000 hr, etc..)
    Daily Checks
    • Daily log book
    – 1310 9050 77 - GA/GR
    • Check gauge readings (electro-pneumatic)
    • Check Elektronikon readings
    • Check water circuit temperatures
    • Check compressor oil level
    • Check service indicators
    • Check condensate drain operation
    • Blow down manual condensate drain valve
    2,000 Hour Inspection
    • Check inlet filter element
    • Check control panel lamp operation (electro-pneumatic)
    • Check instrumentation (electro-pneumatic)
    • Check aftercooler condensate drain operation
    • Blow down manual condensate drain valve
    • Check operation of regulation system
    • Check programmed settings of Elektronikon
    • Check operation of Elektronikon LED’s
    • Check oil level and top off with specified oil as required (Do not mix oils)
    2,000 Hour Inspection
    (continued)
    • Replace drive belts: GA5-10
    • Inspect drive belts and retension: GA11-22
    • Inspect drive coupling rubber element: GA30-315
    • Check cooler performance
    • Draw oil sample for oil analysis
    • Change Oil if using mineral oil
    • Replace oil filter(s)
    • Repair air, oil, or water leaks as required
    • Adjust cooling water flow rates
    • Measure and record all temperature, pressure, and SPM readings
    4,000 Hour or Yearly Service
    All 2,000 hour inspection items plus:
    • Change compressor oil (Roto-Inject fluid)
    • Clean scavenge line orifice
    • Clean air cooled coolers externally
    • Disassemble and inspect condensate drain
    • Check all electrical connections for tightness
    8,000 Hour or 2 Year Service
    All 4,000 hour service items plus:
    • Check all flexible hoses for deterioration
    • Test safety shutdown switch operation (electro-pneumatic)
    • Change compressor oil (HD Roto Fluid)
    • Check all bolt connections for tightness
    • Replace oil separator element
    • Replace drive coupling rubber insert (24,000 hours)
    • Disassemble, inspect and rebuild inlet valve
    • Disassemble, inspect and rebuild vent valve assembly
    • Disassemble, inspect and rebuild discharge check valve
    • Disassemble, inspect and rebuild oil stop valve
    • Disassemble, inspect and rebuild minimum pressure valve
    • Grease motor bearings. follow manufacturer recommendations
    Element replacement
    All 8,000 hour service items plus:
    • Rebuild compressor gearbox (new seals and
    bearings)
    • Replace drive coupling rubber element
    • Clean air cooled coolers externally
    • Clean water cooled coolers internally
    • Replace compressor element with rebearinged
    element (pre-charge element with compressor
    oil before starting)
    Additional notes:
    Follow lubricant manufacturers instructions
    regarding oil change intervals and adjust the
    expected oil lifetime for abnormal operating
    conditions.

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