1. Content and purpose
This training manual is intended for compressed air system maintenance, including dryers, filters, and leak audits. This service is performed during regular maintenance of the compressed air system, checking the effectiveness of filters, detecting and eliminating leaks. Suitable for industrial installations using compressed air in aerodynamic, food, chemical and energy industries.
2. Safety
Turn off the power supply and connect the system to lockout and tagout (LOTO) before doing any work.
Wear personal protective equipment, including work gloves, goggles, protective jacket and hat.
Do not work with no air in the system to avoid hazardous conditions.
3. Necessary tools and materials
| Tool / material | Specification | Quantity |
|---|---|---|
| Torque screwdriver (moment 10-30 Nm) | With variable setting | 1 |
| Multimeter | Range 0-250 V, 0-20 A | 1 |
| Alligator tongs | With a size of 10-25 mm | 2 |
| A laser for measuring parallelism | Range 0-10 m | 1 |
| Air filters (standard) | 20-25 microns | 1 |
| Dryer filters (for a dryer with a light lamp) | Dry air filter | 1 |
| Stands for filters | Iron | 1 |
| Power supply for opening | 12 V | 1 |
4. Inspection before service
| Point | Verification | Acceptance / rejection criterion | Notes |
|---|---|---|---|
| 1 | Turning off the power supply | Shutdown must be performed and locking performed | Execution in accordance with LOTO |
| 2 | Air in the system | The presence of air during work is prohibited | Execution in accordance with LOTO |
| 3 | Filters | Filters must be secured and must not leak | Execution in accordance with LOTO |
| 4 | Dryer | The dryer must be disconnected and prepared for operation | Execution in accordance with LOTO |
5. Step by step procedure
-
Turn off the power supply and lock the system using LOTO.
Bug: Failure to block can result in injury.
-
Unclip the filters using alligator clips. Before unfastening, check that the system is switched off and compliant with LOTO.
Bug: Unpinning filters without disconnecting could lead to unsafe conditions.
-
Delete the old filters and replace them with the new ones. Install the filters in the previously prepared stands.
Bug: Improperly setting filters can lead to loss of performance.
-
Fix the filters using a torque wrench with a torque of 10-30 Nm.
Error: Using the wrong torque can cause unscrewing or damage.
-
Test the system for leaks using a multimeter or leak detector. The system must be free of air.
Error: Failure to perform the check may result in malfunction.
-
Perform a leak audit using a laser to measure parallelism and compare with regulatory values.
Error: Using the wrong tools can lead to wrong results.
-
Perform a function test using a booster to open and check for air in the system.
Error: Failure to run the test may result in malfunction.
-
Return the system to working mode after all work is completed.
Error: performing work without verification may lead to incorrect operation.
6. Inspection after service
| Test | Expected result | Actual result | Pass/Fail |
|---|---|---|---|
| 1 | Air in the system | Presence of air | Pas |
| 2 | Filters | Filters must be fixed | Pas |
| 3 | Dryer | The dryer must be turned on | Pas |
| 4 | Leaks | No leaks | Pas |
7. Troubleshooting
| Symptom | A possible reason | Correction |
|---|---|---|
| Incorrect operation of the dryer | Contamination of filters | Replace the filters |
| Air leakage | Air in the system | Perform blocking and verification |
| Low pressure | Filters do not match | Replace the filters |
| High pressure | Incorrect dryer setting | Perform the setting |
8. Recommended maintenance schedule
| The task | Frequency | Estimated duration | Skill level |
|---|---|---|---|
| Replacement of filters | Once every 6 months | 1 hour | Average |
| Dryer service | Once every 12 months | 2 hours | Tall |
| Leakage audit | Once every 6 months | 1 hour | Average |
| Function test | Once every 12 months | 2 hours | Tall |
9. Links to spare parts
| Description of the spare part | Typical specification | UNITEC-D category |
|---|---|---|
| Air filter | 20-25 microns | Category 4200 |
| Dryer filter | Dry air filter | Category 4201 |
| Stand for filters | Iron | Category 4202 |
Spare parts for this service can be found on the official UNITEC-D website.
10. Links
- DSTU 3018-95: Technical conditions for industrial compressed air systems - EN 12021: Compressed air systems – Requirements for production and use - ISO 8068: Compressed air systems – Maintenance and operation - UkrSEPRO: Protective equipment when performing work on electrical equipment
List of equipment
- Torque screwdriver (moment 10-30 Nm)
- Multimeter
- Alligator tongs
- A laser for measuring parallelism
- Air filters
- Dryer filters
- Stands for filters
- Power supply for opening
