1、 Daily maintenance (before/after each startup/shutdown, or once a day)

Basic inspection of the core filtering components and operating status of the equipment to avoid shutdown or secondary oil contamination caused by immediate failures.

Filter material status inspection

Check the coarse filter (pre filter): If there are a large number of impurities (such as particles and sludge) attached to the surface of the filter screen, or if the oil inlet pressure increases significantly during equipment operation (exceeding the rated pressure by 10% -20%), the filter screen (usually a metal mesh, can be cleaned 3-5 times before replacement) should be disassembled and cleaned immediately.

Check the fine filter (high-precision filter element, such as 5 μ m, 1 μ m level): observe whether the appearance of the filter element is swollen or damaged. If the cleanliness of the treated oil does not meet the standard (such as NAS level 8 or below), it needs to be replaced in a timely manner.

Vacuum system inspection

Check the oil level of the vacuum pump: whether it is between the oil mark "MIN-MAX". If the oil is cloudy, emulsified, or below the lower limit, it is necessary to supplement or replace the vacuum pump special oil (recommended to use 100 # vacuum pump oil).

Check the vacuum degree: After 5-10 minutes of starting up, the vacuum gauge reading should be stable between -0.095MPa and -0.098MPa. If the vacuum degree is insufficient, check whether the vacuum tank seal (such as rubber gasket) is aging and whether the vacuum pump blades are worn.

Electrical and piping inspection

Check whether the power cord and wiring terminals are loose or aging to avoid the risk of short circuit;

Check whether the inlet/outlet pipelines and valves are leaking, and whether the joints are tightened.

Cleaning and maintenance

Wipe off oil and dust on the surface of the equipment, clean the oil leakage tray under the body, and maintain good ventilation and heat dissipation.

2、 Regular maintenance (every 100-200 hours of operation, or every 2-4 weeks)

After the device has been running for a certain period of time, it is necessary to conduct in-depth inspection and replacement of consumable components and critical systems to ensure stable filtration efficiency.

Mandatory replacement of core filter material

Regardless of whether the appearance is intact, it is recommended to replace the fine filter element every 100-200 hours (if dealing with highly polluted oil, such as waste oil regeneration, it can be shortened to 50-100 hours);

If the equipment is equipped with a dehydration filter (such as a coalescence filter), its coalescence effect should be checked simultaneously. If the oil dehydration rate decreases (such as the water content of the treated oil still being greater than 50ppm), it should be replaced immediately.

Vacuum pump maintenance

Thoroughly replace the vacuum pump oil: After draining the old oil, wipe the residual impurities in the pump body with a clean cotton cloth, and then add new oil to the standard scale;

Check the exhaust valve plate of the vacuum pump: If the valve plate is aged or deformed, it needs to be replaced to ensure vacuum efficiency.

Heating system inspection

Check if there is scale on the surface of the heating tube (the burnt layer formed by high-temperature carbonization of the oil). If the scale is severe, use a special descaling agent to clean or replace the heating tube (scaling can cause a decrease in heating efficiency and increase energy consumption);

Calibrate temperature controller: Ensure that the actual heating temperature does not deviate from the set temperature by more than ± 5 ℃ (if set at 60 ℃, the actual temperature should be between 55-65 ℃).

Seal inspection

Replace the sealing gaskets of the vacuum tank and oil-gas separator (usually made of nitrile rubber material, oil resistant but prone to aging) to avoid vacuum leakage.

3、 Quarterly/semi annual maintenance (every 3-6 months, or accumulated over 1000 hours of operation)

Comprehensive maintenance of equipment structural components, transmission systems, and control systems to extend the overall service life of the equipment.

Mechanical component maintenance

Check the bearings and shaft seals of the gear pump/screw pump: If there is abnormal noise (such as "buzzing" or "clicking" sound) or oil leakage from the pump body during operation, the bearings and mechanical seals need to be replaced;

Lubricate transmission components: Apply lubricating grease (such as lithium based grease) to motor bearings, reducers, and other parts to reduce mechanical wear.

Control system calibration

Calibrate pressure sensors and vacuum sensors: ensure accurate readings (with an error not exceeding ± 2%);

Check the PLC controller and touch screen: test button response and program operation for normal operation, backup equipment operating parameters.

Overall cleaning and inspection

Cleaning the interior of vacuum tanks and oil storage tanks: removing impurities and sludge deposited at the bottom (after blowing with compressed air, wipe with a clean, lint free cloth);

Conduct no-load trial operation: Test whether the linkage between various systems of the equipment is normal, record parameters such as vacuum degree, heating temperature, flow rate, etc., and compare them with the factory standards.

4、 Special circumstances: signals that require immediate maintenance

If the equipment encounters the following problems, there is no need to wait for a fixed cycle, and it needs to be immediately shut down for maintenance:

Serious abnormal noise and abnormal heating of the vacuum pump (shell temperature exceeding 80 ℃);

Damaged filter material leads to obvious impurities in the oil;

Heating tube burned out (no heating effect, or circuit breaker tripped);

The vacuum degree continues to be below -0.08MPa, and there is still no improvement after replacing the seal;

The motor overload protection is frequently triggered.

5、 Maintenance precautions

Safety first: Before maintenance, the main power supply of the equipment must be cut off, the oil in the pipeline must be drained, and the heating tube must be cooled to room temperature before operation;

Filter material matching: When replacing the filter element, it is necessary to use original filter materials that match the equipment model to avoid a decrease in filtration efficiency or equipment damage caused by mismatched filter material accuracy;

Record and archive: Establish a maintenance ledger to record the time, content, replacement part model, and operating parameters of each maintenance, for easy traceability of equipment status.