Recurring inspections and maintenance intervals for air compressors
Maintenance intervals:
In principle, all systems should be subjected to a functional check/maintenance once a year, regardless of the operating hours. The spare parts or wear parts to be used or renewed are strongly dependent on the following parameters:
- Gas used - e.g. air, inert gases (N2, H), CNG etc.
- Ambient temperature
- Environmental conditions e.g. dust, salt water,
- Installation conditions (cooling air)
- Standstill times (downtimes)
- Compressor oil used
- Regular condensate drainage
Otherwise every 500, 1000, 1500, 2000 operating hours etc.
This applies to wear parts such as valves, seals, condensate drain automatic, sinter filter etc.
Oil change intervals:
Mineral/partially synthetic oil every 1000 operating hours or annually
Fully synthetic oil every 2000 operating hours or every 2 years
Safety valves:
Intermediate pressure safety valves must be replaced - if defective - cannot be repaired. Low pressure safety valves are available with TÜV adjustment or factory adjustment in exchange or as a new spare part. There is no adjustment possibility for the customer. All Si-valves must have an undamaged seal. Test of the safety valves at each commissioning by mechanical lifting device.
(passage / function test)
Monthly start-up of the set pressure.
Currently no statutory inspection intervals.
Hoses:
The current statutory inspection requirement is:
Every 6 months external visual inspection for integrity and pressure test with single operating pressure. The gas to be compressed must be used as the medium.
General compressor recommendation:
In addition to the statutory 6-monthly inspection, a 1-year hydraulic pressure test should be carried out with 1.5 times the nominal pressure of the hose used.
Hoses should be replaced after 10 years at the latest.
Every pressure test must be documented in writing.
Pressure vessels:
They are generally subject to the new "Pressure Vessel Guidelines" (see there) In particular, this includes all final separators or fine aftercleaners. Pressure vessels / filters are subjected to dynamic stress. Depending on the mode of operation, the service life of the vessels is limited. Depending on the filling pressure 200 or 300 bar, the operating instructions indicate the number of permissible load cycles. When half of the number of load cycles is reached, a visual tank inspection by an expert is recommended. After reaching the max. number of load cycles, the filter housing / separator must be replaced with a new one.
Recommendation:
After 15 years at the latest, all cyclically loaded containers - and in particular those mentioned above - should be replaced for safety reasons!
Operating authorisation or regulations
In general, there is an obligation to present / register with the TÜV or
Trade Supervisory Office if air is supplied to third parties and the system has a delivery volume > 130 l/min.
In the case of a fixed installation, this must also be reported to the above-mentioned authorities. Persons who are at least 18 years old and can prove that they have the necessary expertise (see TRG's in our operating instructions) are authorised to fill.