Maintenance: Putting plans in place

Regarded as industry’s fourth utility, compressed air is vital for many manufacturing processes – which means regular servicing and maintenance is essential. A poorly maintained compressor won’t perform properly or efficiently, affecting production and increasing running costs and carbon emissions. Not only that, but neglecting to maintain a compressor can result in serious safety hazards, including, in very extreme cases, fires or explosions. 

Implementing a compressor service schedule and maintenance regime should be very straightforward, with official guidance available for factory and plant managers to follow. Compressor manufacturers will supply specific service intervals for their machines, and, alongside this, a compressor should have a Written Scheme of Examination, which outlines the regular inspections required. The latter is a legal requirement under the Pressure Systems Safety Regulations 2000, and there is a potential fine of up to £20,000 for not complying.

The document will contain a wide range of information, including the parts of the system that need to be examined, the nature of the examination required, the preparatory work needed and the maximum interval allowed between examinations.  

It’s important to have a maintenance plan in place for the entire compressed air system, not just the compressor. This should include checking the pipework for rust, corrosion and, importantly, leaks. In many systems, more than 30% of air generated is wasted through leaks – but they are simple and cost-effective to identify and rectify. Leak detection surveys should ideally be carried out on an annual basis, and always before a new compressor is installed.

Additional checks should be carried out on compressor oil levels as well as any intake filters and coolers to ensure they remain free of blockages and to avoid overheating. The original manufacturer’s genuine parts and oil should be used; if not performance and reliability could be affected.

When a new compressor is being purchased, it’s worth considering the level of maintenance involved, and the impact this will have on lifecycle costs. As an example, if a Mattei rotary vane compressor is looked after in accordance with our instructions (which require compliance to standard servicing, rather than onerous maintenance regimes), the operating life of its air end can easily extend to more than 100,000 hours without wear – in fact, some of Mattei’s vane machines have lasted more than 200,000 hours in arduous, dusty operating conditions with the original air end. 

Many compressor manufacturers and suppliers offer service and maintenance contracts, and can help with producing a Written Scheme of Examination. Unfortunately, however, there are currently no formal accreditation schemes for engineers working with compressed air systems. The British Compressed Air Society (BCAS) offers a range of courses, including a Working Safely with Compressed Air course, and a Written Schemes workshop and Competent Examiner course for those involved in providing written schemes, but they are voluntary.  

In the absence of formal accreditation, we recommend using a maintenance company that is a member of BCAS. Membership is voluntary and is by peer review, and joining demonstrates professionalism and competence, as well as a commitment to health and safety and best practice. Members have to adhere to BCAS’ codes of conduct, and can choose to proactively participate in the Air Rated register, which promotes the credibility and professionalism of BCAS members as identified via customer feedback.

Compressors need to be properly maintained to protect their performance and efficiency and minimise safety hazards. A Written Scheme of Examination should be adhered to, alongside the compressor manufacturer’s service schedule. Any company maintaining a compressed air system needs to be reputable and professional, and membership of voluntary schemes such as BCAS can help to demonstrate they have the necessary competencies.