AirUser 2008 96+4pp 24/7/08 11:31 Page 14
Maintenance
Prescribed maintenance
As industry continues to tackle significant cost pressures Chris Camsell, the UK
service manager at Boge Compressors discusses how regular maintenance can
help compressed air users reduce their all up costs
R
egular maintenance is the key to mineral lubricants will require more frequent service visits.
reducing life-time maintenance
costs. From the outset, if For existing compressor systems, cutting maintenance
maintenance cost is a criteria of costs by reducing maintenance frequency on
initial purchase of a compressor then the compressors may seem a plausible solution to reducing
client must look outside the box! For short term costs in light of increased energy and
example, an optimised and energy business costs. However, beware! Cutting regular
efficient compressed air system will prescribed maintenance out will lead to increased costs
require the least maintenance. in the long term.
• Compressors which are correctly specified for the The integrity and efficiency of a compressor will be
application will require less maintenance as they will jeopardised if a recommended service schedule is not
be performing optimally and efficiently – off load running followed, with unnecessary premature wear and tear to
costs can be eliminated, stop-starts therefore eliminated. parts as well as a reduction in the air quality as possible
outcomes.
• Opting for a quality engineered compressor will also
ensure minimal maintenance requirements. As an Poor air quality will lead to increased costs in other areas
example, the Boge S series screw compressor modular of the business. As an example, an inefficient
concept assures an uncluttered cabinet and a simplified compressor being used to power a paint spray system
service friendly layout. As a result, it needs fewer may create inconsistencies and blemishes in a paint job.
components, this saves on service and spare parts costs. As a result, additional materials and resource may be
required to touch up or re-paint the end product.
• Integrating a compressed air management system
ensures an energy efficient supply of compressed air. It Moreover, a compressor running inefficiently uses more
provides an on-going audit to track system changes in energy which will increase compressed air related
order to maintain optimum efficiency. electricity bills.
• Ensuring the integrity and quality of the actual One of the most common misconceptions we have
maintenance work required will also impact on the come across is that regular maintenance doesn’t matter.
related costs. Opting for trained and authorised This derives from the time that the piston compressor
manufacturer service technicians will affect the long was the only way of generating compressed air. The
term maintenance related costs. modern screw package is totally different. Properly
maintained they are reliable and efficient work-horses.
• A common cause of poor efficiency is the use of Without regular maintenance they quickly become
spurious spare parts. Not using the manufacturer’s unreliable. Initially with petty control issues – intake or
genuine parts, for example oil filters and separators can solenoid based perhaps. In the unluckiest situation it
drastically alter compressor specification and efficiency. In could cause premature airend failure – at that stage the
turn this will create additional maintenance requirements. real cost of poor maintenance is counted!
• The client should also consider the recommended In order to keep costs to a minimum, when planning a
operating hours of the compressor between service compressor maintenance programme it is
intervals. The frequency of maintenance required will recommended that the client considers; how many
also be affected by the quality and longevity of hours a day the compressor operates, what the
consumables proposed by the service provider (e.g. prevailing site conditions are, whether a mineral or
OEM parts versus spurious parts). synthetic lubricant is used and whether the compressor
is brand new or a used machine.
• The initial choice of lubricant will also impact on
lifetime maintenance costs. As an example, the service Opting for a prescribed maintenance plan for your
regimes of a lubricated screw compressor will vary compressed air system will certainly assist in reducing
depending on whether a mineral or synthetic lubricant is your business costs in the long term.
used. Lubricant choice affects the operating hours
recommended between service intervals. Those using
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