A detailed Ammonia Compressor WEEKLY preventive maintenance checklists
1. Safety Precautions
2. Visual Inspection
3. Fluid Levels and Quality
- Locate the oil reservoir.
- Use a dipstick or sight glass to check the oil level.
- Add the appropriate oil type if below the recommended level.
- Ensure the oil is free from debris during topping off.
- Observe the oil color; it should be clear and translucent.
- Check for any visible particles or sludge.
- Smell the oil for any burnt odor.
- If contamination is present, plan for an oil change.
- Locate the coolant reservoir.
- Check the coolant level against the marked indicators.
- Inspect hoses and connections for any signs of leakage.
- Repair leaks if detected and refill coolant as necessary.
- Locate the drain valve on the oil separator.
- Place a suitable container underneath the drain.
- Open the valve and allow any accumulated water or contaminants to drain.
- Close the valve securely after draining.
- Locate the hydraulic fluid reservoir.
- Use a dipstick to check the fluid level.
- If low, add the appropriate hydraulic fluid.
- Ensure no spillage occurs during filling.
- Seal the reservoir cap securely after inspection.
- Visually inspect all hoses and connections.
- Look for fluid puddles or damp areas.
- Check for any cracks or wear on hoses.
- Tighten any loose connections as needed.
- Report any leaks requiring further repairs.
- Obtain a sample of the coolant.
- Use pH test strips or a meter.
- Compare results to manufacturer specifications.
- Adjust coolant as necessary to maintain pH.
- Document the pH level in maintenance records.
- Locate the oil filter on the compressor.
- Inspect the filter for dirt or blockages.
- If dirty, replace with a new oil filter.
- Ensure proper tightening of the new filter.
- Dispose of the old filter according to regulations.
- Check the oil's viscosity using a viscosity meter.
- Compare results with the manufacturer's specifications.
- If viscosity is low, consider oil replacement.
- Ensure oil is at the proper temperature during testing.
- Record viscosity measurements for reference.
- Visual inspection of coolant for discoloration.
- Check for rust or scaling on surfaces.
- Use a flashlight for better visibility.
- Sample coolant for laboratory analysis if necessary.
- Document findings and plan for necessary treatment.
- Check the oil temperature gauge.
- Ensure temperature aligns with operational specs.
- If temperature is too high, investigate causes.
- Allow the compressor to cool if needed.
- Log the oil temperature reading.
- Observe the flow indicators or gauges.
- Listen for unusual noises indicating blockage.
- Inspect return lines for obstructions.
- Check for consistent pressure throughout the system.
- Document circulation status in maintenance log.
- Use a standardized format for logging.
- Include date, time, and observations.
- Note any actions taken during inspection.
- Ensure clarity for future reference.
- Store the log in a secure and accessible location.
4. Mechanical Components
- Check for visible cracks or fraying.
- Ensure belts are aligned correctly.
- Measure tension using a tension gauge.
- Adjust tension if it is outside manufacturer specifications.
- Listen for unusual noises when operating.
- Check for excessive play or movement.
- Inspect for discoloration or pitting.
- Replace bearings showing significant wear.
- Use the specified grease type.
- Apply grease until it oozes from seals.
- Wipe away excess grease to prevent dirt accumulation.
- Check lubrication schedule in the manual.
- Refer to the torque specifications in the manual.
- Use a calibrated torque wrench for accuracy.
- Inspect for any missing or damaged fasteners.
- Re-torque if fasteners were previously loosened.
- Look for rust, cracks, or dents.
- Check for paint chipping or peeling.
- Inspect welds for integrity.
- Document and address any significant findings.
- Use a dial indicator to measure misalignment.
- Adjust mounts or shims as necessary.
- Verify alignment after adjustments.
- Review alignment specifications in the manual.
- Operate the compressor and listen for valve noise.
- Inspect seals and seating surfaces for damage.
- Check for leaks around the valves.
- Replace any faulty valves immediately.
- Look for wet spots or corrosion on pipes.
- Check joints and fittings for tightness.
- Use a leak detection solution if necessary.
- Repair or replace damaged piping or connections.
- Inspect isolators for cracks or tears.
- Check for proper installation and alignment.
- Ensure that they are securely mounted.
- Replace any isolators showing wear.
- Listen for grinding, squealing, or rattling sounds.
- Document the time and conditions of noises.
- Investigate sources of noise immediately.
- Consult manual for troubleshooting guidance.
- Check for oil build-up or sludge.
- Inspect seals and fittings for leaks.
- Clean or replace the separator as per guidelines.
- Ensure proper function after service.
- Look for cracks, tears, or hardening.
- Check for leaks around seals and gaskets.
- Replace any that are compromised.
- Use manufacturer-approved replacements.
- Inspect cooling fins for blockages.
- Check coolant levels and quality.
- Test system operation under load.
- Clean components as needed to maintain efficiency.
- Look for scoring or discoloration.
- Check for play in connecting rods.
- Listen for unusual noises during operation.
- Consult manual for wear limits and replacement recommendations.
5. Electrical System
6. Operational Checks
- Check pressure gauges and temperature indicators.
- Compare readings with manufacturer specifications.
- Document any deviations from standard conditions.
- Investigate potential causes for any discrepancies.
- Initiate the start sequence and observe operation.
- Verify that the compressor reaches normal operating conditions.
- Stop the compressor and ensure it turns off completely.
- Repeat the process to confirm reliability.
- Test alarm indicators for audible and visual alerts.
- Simulate fault conditions to ensure shutdown activates.
- Check reset functions after alarms are triggered.
- Document results and address any issues found.
- Maintain a log of unusual readings and behaviors.
- Include time stamps and conditions during occurrences.
- Categorize anomalies by type and severity.
- Plan follow-up inspections or investigations as needed.
- Attach the vibration analysis tool to designated points.
- Record vibration levels during operation.
- Compare results against acceptable thresholds.
- Investigate any excessive vibration readings.
- Listen carefully for any irregular sounds.
- Identify specific noise sources, if possible.
- Document findings and schedule further inspection if needed.
- Consult technical manuals for noise description.
- Check oil pressure gauges regularly during operation.
- Measure oil temperature using appropriate gauges.
- Compare readings with manufacturer specifications.
- Report any inconsistencies for review.
- Record discharge and suction pressure readings.
- Compare with normal operating ranges.
- Document any significant deviations.
- Investigate potential causes if values are inconsistent.
- Perform manual tests on safety relief valves.
- Ensure they open and close at specified pressures.
- Inspect for any signs of wear or leakage.
- Document valve performance for maintenance records.
- Check coolant levels and flow rates.
- Inspect cooling fins for blockages or damage.
- Measure temperature differentials across the system.
- Document findings and any maintenance actions taken.
- Use an ammeter to measure current draw.
- Compare current draw with rated specifications.
- Document any discrepancies for evaluation.
- Investigate potential causes of abnormal current draw.
- Inspect all piping and connections visually.
- Use leak detection methods (e.g., soap solution) where applicable.
- Document any leaks and schedule repairs immediately.
- Monitor areas previously identified as problematic.
- Inspect each gauge and meter for clarity and functionality.
- Calibrate or replace any faulty instruments.
- Document any instruments that require attention.
- Ensure all readings are logged correctly during checks.
- Monitor the compressor's operational cycles closely.
- Document any extended run times or irregular patterns.
- Investigate causes for irregular operation.
- Report any findings for further analysis.
Use in Manifestly