Inspections: A vital component in compressed air maintenance strategy

In this article, BCAS provides an overview of the key maintenance considerations outlined in the guide, specifically around compressed air inspections.

Inspection is a key component of a broader compressed air maintenance strategy and helps ensure that equipment continues to operate efficiently, reliably, and safely. Regular inspections enable early detection of issues before they escalate into significant failures, which could result in expensive repairs, system downtime, or safety hazards.

It is important to note that inspection routines are not a one-size-fits-all activity; rather, they must be tailored to the type of equipment, the application environment, and the manufacturer's specifications.

Typical inspection activities

There are several routine checks that should be built into a comprehensive maintenance programme. While simple to carry out, they play an important role in maintaining air quality and compressed air system performance.

While daily checks are typical for high-use systems or mission-critical applications, weekly or monthly checks may suffice for lower-risk components. The manufacturer’s operation manual is the primary reference for establishing appropriate frequencies, but site-specific risk assessments should also influence the inspection plan.

Many modern compressed air system components, such as compressor or downstream equipment, feature built-in status indicators or screens that provide real-time operational data. Regular checks can alert users to potential faults and allow remedial action to be taken.

Effective lubrication is critical to the operation of many compressors and users should inspect oil levels regularly to ensure they are within the manufacturer’s specified range. Low oil can result in overheating, increased wear, or seizure of moving parts, while overfilling may lead to foaming or oil carryover.

For applications that require high quality, dry air, such as the food and beverage, pharmaceutical and electronics industries, checking the dewpoint readings on dryers is crucial. A rise in dewpoint can indicate a potential issue, such as saturation of desiccant materials, which would need to be rectified quickly.

Condensate must also be removed from the system constantly to prevent corrosion, water hammer, or contamination of tools and products, requiring regularly checks of separators, filters, and receiver tanks.

Finally, condensate drains should be inspected regularly, as blocked drains can lead to water buildup in the system, affecting performance and increasing maintenance costs.

Keeping accurate records

As well as building routine compressed air system inspection into the plant’s maintenance regimes, it is also recommended to maintain detailed records of these inspection activities. These should be retained in an easily accessible format and reviewed regularly by competent personnel.

Logging the parameters observed, any faults detected, the remedial action taken, as well as the site personnel involved will help with trend analysis, building an accurate picture of equipment performance over time.

Historical data can guide future service planning and prioritise equipment repair or upgrade based on evidence rather than guesswork.

Written logs also provide an audit trail to assist compliance with both regulatory and manufacturer requirements.

Training for competence

Finally, operators should remember that all inspection tasks require a certain level of training and awareness. Although they may not be as technically complex as full compressed air maintenance procedures, they may still involve certain safety risks will require a degree of technical knowledge.

Individuals assigned to inspection duties should therefore be trained fully in the correct procedures for each type of inspection as well as the safety practices related to electrical and pneumatic hazards.

To purchase a copy of the compressed air installation best practice guide (BPG 101-6) please visit the BCAS shop

The British Compressed Air Society

Tel: +44 (0) 207 935 2464

Email: [email protected]

Web: www.bcas.org.uk