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Health and Safety Executive
Compressed air safety
This is a free-to-download, web-friendly version of HSG39 (Second edition, published 1998). This version has been adapted for online use from HSE’s current printed version.
Youcanbuythebookatwww.hsebooks.co.ukandmostgoodbookshops.
ISBN 978 0 7176 1531 5 Price £7.50
Thisbookaimstopromotethesafeuseofcompressedairanddescribesthemanywaysinwhichcompressedaircanbedangerousaswellashowtominimisetheriskofsuchdangersoccurring.
Itisaimedatdesigners,manufacturers,installers,usersandothersconcernedwithorresponsibleforhealthandsafetyatwork.
HSE Books
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Health and Safety Executive
© Crown copyright 1998
Firstpublished1990
ISBN9780717615315
Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans(electronic,mechanical,photocopying,recordingorotherwise)withoutthepriorwrittenpermissionofthecopyrightowner.
Applicationsforreproductionshouldbemadeinwritingto:TheOfficeofPublicSectorInformation,InformationPolicyTeam,Kew,Richmond,SurreyTW94DUore-mail:[email protected]
ThisguidanceisissuedbytheHealthandSafetyExecutive.Followingtheguidanceisnotcompulsoryandyouarefreetotakeotheraction.Butifyoudofollowtheguidanceyouwillnormallybedoingenoughtocomplywiththelaw.Healthandsafetyinspectorsseektosecurecompliancewiththelawandmayrefertothisguidanceasillustratinggoodpractice.
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ContentsINTRODUCTION 5
COMPRESSOR PLANT 6Groups of compressors 6Hazards 6General information and advice 6Precautions 7Safetyvalves 7Pressureindication 7Thermalprotection 7 Coolantprotection 8 Lubricantprotection 8 Explosionprotection 8Airinlet/outletmonitoring 8 Otherinstrumentation 8Airinlet/outletcontrol 9
AIR RECEIVERS 11Statutory requirements 11Hazards 12General information and advice 12Precautions 12
COOLERS 13Hazards 13General information and advice 13Precautions 13
AIR DRYERS 14Hazards 14General information and advice 14Refrigerant 14Dessicant 14Precautions 14
INSTALLATION OF COMPRESSORS 16Precautions 16Smallcompressors 16Mediumandlargecompressors 16Noise 16
MAIN LINE SYSTEMS 18Hazards 18General information and advice 18Precautions 18Pipe-runs 18Filters,traps,separatorsandlubricators 21Pressureregulators 22
PORTABLE PNEUMATIC EQUIPMENT 23Statutory requirements 23Hazards 23General information and advice 23Precautions 24Flexiblehoses 24
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Blowguns 24Portabletools 25
PNEUMATIC POWERED MACHINERY 26Hazards 26General information and advice 26Precautions 26
ACTUATORS 28Hazards 28General information and advice 28Precautions 28
INTERLOCKING METHODS AND CIRCUIT DESIGN 31General information and advice 31Interlocking systems 31Singlecontrolsysteminterlocking 31Dual control system interlocking 32Power interlocking 40Circuit design 41Pistonarrest 41Pistonarrestandhold 41Overridinglockedposition 41Predeterminedposition 41
INSPECTION AND MAINTENANCE 42Statutory requirements 42Hazards 42General information and advice 42Maintenance of compressors and ancillary plant 42Supervisionandprocedures 42Daily 43Checks mainly directed to reciprocating compressors 43Weekly 43600hours 43Six-monthly 432000hrsorannually 44Precautions 44Maintenance of air powered equipment 44Supervisionandprocedures 44Daily 44Weekly 45Monthly 45Threemonthly 45Sixmonthly 45Precautions 45
TRAINING 46Statutory requirements 46Hazards 46Precautions 46Further information 46British standards 47Health & Safety Executive publications 48Legal requirements 49
FURTHER INFORMATION 50
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Introduction1 Thisguidancebookletaimstopromotethesafeuseofcompressedair
bygivingadvicetodesigners,manufacturers,installers,usersandothersconcernedwithorresponsibleforhealthandsafetyatwork.Itwasoriginallyproducedin1990duringarapidlychangingsituationinEuropearisingfromthepreparationforthesinglemarketandwasfurtherrevisedunderthe‘ReviewofRegulationsandGuidance’undertakenbytheHealthandSafetyExecutive(HSE)in1996.
2 Therearemanywaysinwhichcompressedaircanbedangerous,forexample:
(a) itcanenterbodyorificessuchasthemouth,earsandanus,causing severeandoftenfatalinjuries;
(b) athighpressureitcanpenetratetheskin; (c) particlesoroilcarriedinanairjetcandamagetheeyes; (d) oil-cokedepositsinasystemcanspontaneouslyigniteandcausean
explosion; (e) vesselscontainingcompressedair,evenatcomparativelylowpressure,
canexplodeviolentlyoncetheirintegrityislost;and (f) dirtyor‘wet’aircanleadtocorrosionandblockedvalveswhichmay
makethesystemunsafe.
3 Thisbookletexplainshowtominimisethelikelihoodofsuchproblems,butitdoesnotgivespecificadviceonairseparationplant,thepneumatictransportationofmaterialsthroughpipelinesorthesupplyofrespirableair.Referenceinthisguidancebooklettoaparticularstandarddoesnotprecludeusinganequallyeffectivealternativestandard.
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Compressor plant Groups of compressors
4 Forthepurposesofthisbookletcompressorsaredividedintothreegroups:small,mediumandlarge.
5 Asmallcompressordeliversupto40litrespersecondoffreeairand/orhasapowerinputofnomorethan15kW.Suchcompressorsmaybemobileorfixedandmaybesuppliedaspackagedunits.Atypicalonewouldcompriseareciprocatingcompressordrivenbyanelectricmotorontopoforalongsideanairreceiver.
6 Amediumcompressordeliversbetween40and300litrespersecondoffreeairand/orhasapowerinputofbetween15and100kW.
7 Alargecompressordeliversmorethan300litrespersecondoffreeairand/orhasapowerinputofmorethan100kW.
8 Manymediumandlargecompressorsaresuppliedaspackagedunits.Atypicalonewouldcompriseacompressor,airintakefilter,motorandaircooler,allonacommonbedframewithfactory-connectedpipingandfactory-installedelectricalcontrolsandwiring.Itcouldbeenclosedinasheetmetalhousingtreatedwithsoundproofingmaterialtoreducenoiselevels.
9 Usingapackagedunithasanumberofadvantages;itsimplifiesfoundationwork,reducesinstallationtimeandprovidesaproperlyengineeredandadequatelyguardedassemblyofcomponentsinacompactspace.However,theuserisstillresponsibleforsitingthesystemsothatincomingairisasdryandfreefromcontaminantsassiteconditionsallow.Boththeairenteringthecompressorplantandthedeliveredairmustbeasdry,cleanandcoolaspossible.Adviceonsitingisgiveninparagraphs60to67.
Hazards
10 Themajorhazardassociatedwithcompressorsisoverpressurisation,whichmayarisefrom:
(a) ablockedoutletorsomeotherrestrictiontoflow; (b) failureofautomaticcontrolscombinedwithlowairconsumption; (c) compressormalfunction,egoverspeeding; (d) anexternalfirenearthepressuresystem;and (e) overheatingandthebuild-upofcarbonaceousdeposits,bothofwhich
canleadtofiresorexplosions.Althoughtheyarerare,firesand explosionscanalsooccurasaresultofoiloroilvapourbeingignitedin thepressuresystem.
11 Dirtyor‘wet’aircancauseasystemtofailegbycausingfineparticlesofdebristoagglomerate,blockingsafetyrelatedvalves.
General information and advice
12 Standardsforthesafedesign,construction,installationandoperationofmanytypesofstationarycompressoraresetoutinBS6244Code of practice
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for stationary air compressors.Itspecifiesrequirementstohelpminimisecompressoraccidentsanddefinesgeneralsafetypractices.BSEN1012Parts1&2coverCompressors and vacuum pump safety requirements.
NOTE: It is important that records are amended following modifications to plant and pipework.
Precautions
13 Transmissionmachineryeg‘V’belts,pulleysandotherdangerousparts,shouldbeguardedtopreventaccess,seeBS5304Code of Practice for Safety of machinery.
Safety valves14 Onallmediumorlargemulti-stagepositivedisplacementcompressorsa
safetyvalveshouldbefittedbetweeneachstageand,whereappropriate,intheinteroraftercoolercircuit.
15 Whereanisolatingvalveisinstalledinthedischargepipeworkbetweenthecompressorandreceiver,thepipeworkonthecompressorsideofthevalveshouldbeprotectedbyasuitablesafetyvalvethatcomplieswithBS6759,Part2Specification for safety valves for compressed air or inert gasesandisinstalledtoBS6244,clause21,unlessthesystemhasbeendesignedtowithstandthemaximumpressurethatcanbegenerated.(Thisvalveisinadditiontotheairreceiversafetyvalve.)Onsmallfixedandsmallandmediumtransportablecompressorunits,wheretheoutletofthecompressorisdirectlyconnectedwithoutshut-offornon-returnvalvestoanairreceivertowhichnoothersourceofpressureisattached,onesafetyvalveontheairreceiverissufficient.
Pressure indication16 Anaccuratelycalibratedairpressuregaugewithareadilyvisibleappropriate
scale-readingshouldbeprovidedaftereachstageofcompression.However,onsmalltwo-stagecompressorsthisisnotrequiredafterthefirststageofcompression,butasuitabletappingtoenableatestdevicetobefittedshouldbeprovided.GaugesshouldbeconstructedtocomplywithBSEN837-1Part1-Bourdon tube pressure gauges- Dimensions, metrology, requirements and testing andinstalledtocomplywithBSEN837-1Part2 Selection and installation recommendations for pressure gauges.
17 Onmediumandlargereciprocatingcompressorswithforcedfeedlubricationsystemsitisimportantthatagaugeisprovidedintheappropriatepositiontoindicateoilpressure.
Thermal protection18 Tominimisetheriskofoverheating,largecompressorsshouldbeprovided
withasuitablethermalprotectivedeviceasnearaspracticabletothelaststagedischargevalveor,wherethereismorethanonevalve,atacommonpointofdischargewhichwouldautomaticallyshutdownthecompressorwhenapredeterminedtemperatureisexceeded.Note - where automatic compressor shut-down may adversely affect the safety of pressure-dependent systems, additional high temperature warning devices may be required so that action can be taken prior to automatic shut-down.
19 Onlargetwo-stagecompressorsathermalprotectivedeviceshouldalsobeprovidedasnearaspossibletothefirst-stagedischargevalve.Largecompressorswiththreeormorestageswouldrequireaseparatedeviceforeachstage.
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20 Formediumandlargeair-cooledcompressorsprotectivedevicesshouldbeprovidedtomonitorgeneralcompressoroverheatingwhichmaybecausedbycooling-fanfailureorthefoulingofcoolingsurfaces.
21 Oil-floodedrotarycompressorsshouldhaveanautomaticshut-downdevicetopreventthetemperatureofthecompressedairfromexceedingasafelimit.
Coolant protection22 Ifthecompressoriswatercooled,athermostatshouldbeprovidedtothe
coolingwateroutletorwaterreturntotheradiatorheadertanktoshutdownthecompressorwhenthewatertemperatureexceedsthemanufacturer’srecommendedmaximum.Wherethethermostatdevicedoesnotgive‘nowater’or‘noflow’protection,awaterflowdetectiondeviceshouldalsobeprovided.Sufficientgoodqualitycoolingwaterisrequiredtocoolallpartsofthesystemandinhibitblockagesandcorrosion.Thesupplymayrequireprotectionagainstfreezinginlowtemperatures.
Lubricant protection 23 Onmediumandlargecompressorsapressure-sensingdeviceshouldbe
providedtoshutdownthecompressorandactivatevisibleandaudiblealarmsifthelubricatingoilpressuredropsbelowthemanufacturer’srecommendedminimum.Gravity-feedlubricationsystemsshouldbefittedwithalevelsensingdevice.Athermalsensingdeviceshouldbefittedtosetoffanalarmandshutdownthecompressoriftheoilinthecrankcase,sumporscavengesystemsexceedsthetemperaturespecifiedbythelubricantmanufacturer.Therecanbesafetyadvantagestousingsyntheticester-basedoilsforlubricatingcompressors.
Explosion protection24 Ifcomponentsrunhot,oroilcokedepositsspontaneouslyignite,theremay
beanexplosion.BS6244describesthechemistryofsuchconditionsandexplainshowoilcokedepositscanbeprevented.Toreducetheexplosionriskonmediumandlargecompressors,afusibleplugcanbefittedontheundersideofthepipebetweenthecompressorandthereceiverascloseasispracticabletothecompressor.Whenorderingsuchaplug,userswillneedtoprovidethefollowinginformationforthemanufacturer:
(a) maximumdesignworkingpressure; (b) makerandgrade,orclosedflashpointoftheoilusedforcylinder
lubrication; (c) maximumdesignoutlettemperatureofair;and (d) boreofoutletpipefromcompressor.
25 Fusibleplugsaregenerallyavailableforpressureupto340bar(5000psi).Asanadditionalprecautionregularinspectionsofthecompressorshouldbecarriedout(seeparagraphs142to170).
Air inlet/outlet monitoring26 Awatermanometerorotherpressure-indicatingdeviceshouldbefittedto
eachinletairfilteronlargecompressors.Thedevicemeasuresthepressuredropacrossthefilter,indicatinghowcleanitis.Itisrecommended,whereitisreasonablypracticabletodoso,thatsuchdevicesbefittedtosmallandmediumcompressors.
Other instrumentation27 Onmediumandlargecompressorsconsiderationshouldbegiventofitting
temperaturereadingorrecordinginstrumentstoindicate:
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(a) airtemperatureat: (i) theinlettothecompressor; (ii) theoutletfromthefirststageofcompression,neartothedischarge
valve; (iii) theinlettothelaststageofcompression; (iv) theoutletfromthelaststageofcompression,neartothedischarge
valve;and (v) theoutletfromtheaftercooler (b) oiltemperatureat: (i) thecrankcase;or (ii) withforcedfeedandscavengelubricationsystem,thepointwhere
theoilleavesthecrankcase; (c) watertemperatureat: (i) theinlettoeachcoolingcircuit(exceptonradiator-cooledsets);and (ii) theoutletfromeachcoolingcircuit.
Itisimportantthattheuserandmanufacturerdiscusswhethersuchinstrumentsareneeded.
Air inlet/outlet control28 Theinletvalvecaneitherbedesignedsothatitcannotbeusedinapartially
openposition,orbefittedwithvisibleandaudiblewarningsthatindicatewhetherthevalveisfullyopenorclosedduringplantoperation.Thevalveoperationisnormallyautomaticexceptwhenrequiredforstartingupthecompressor.Oil-floodedrotarycompressorshavebuilt-inself-regulatinginletthrottles.Constantspeedcompressorsshouldbeprovidedwithsuitablecontrolgearsothattheamountofairdeliveredcanbecontrolledtosuitdemand.
29 Figure1showsanillustrationofalargecompressorinstallationandthepositionsatwhichsafeguardsarerequiredorrecommended.Itisunlikelythatanyinstallationwillrequireallthesafeguardsindicated.Thefinalrequirementwilldependonrelevantstatutoryrequirements,thedegreeofsupervisiontheinstallationwillreceiveandthelocalenvironment.
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Figure 1 Illustrationofalargecompressorinstallationshowingthepositionatwhichsafeguardsare
requiredorrecommended
Thermal protective device to monitor air-cooled
compressor general overheating
Stopvalve
Receiveridentification
Cooling water feed
Compressor Aftercooler
Intercooler
Lowpressurecylinder
Highpressurecylinder
Air inletfilter
Totalclosure
unloader
Cooling water discharge
Receiver
Manhole
AR1SWP
Oil pressure protective device Manometer
Thermometer Safety valves or relief valves Non return valves Drain
GHI
L
JK
ABCDEF
Fusible plug Thermal protective device Water flow protective device Oil level protective device Oil pressure gauge Air pressure gauge
It is unlikely that any installation will require all the safeguards indicated. However, a combination of these should be fitted, taking into account the statutory requirements and the degree of supervision the installation will receive.
Instruments will normally be mounted on a common panel
NOTEKEY
Water or air flowI
I J F
II L
B F I
I
J K J F I
A
I L
F
J
A
I
L
I
B C I
IBDEGI
IBI
H
B
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Air receivers Statutory requirements
30 Bothmanufacturersandusersshouldbefamiliarwiththestatutoryrequirementsapplyingtocompressedairsystemsandairreceivers.TheseareprincipallycontainedinthePressureSystemsandTransportableGasContainersRegulations1989.AdditionalrecommendationsaregivenintheApprovedCodeofPracticeSafety of pressure systems.
31 Inpremiseswheretheairreceiversmustbecleanedandexaminedatregularintervalsandforairreceiverswithavalueofpressuretimesvolumegreaterthan250barlitres,thenatureandfrequencyoftheexaminationmustbecontainedinawrittenschemeofexamination.Thewrittenschemeofexaminationdrawnuporcertifiedbyacompetentpersonwillnormallyspecifyaperiodbetweenexaminationsof24to48months.
32 Whenconnectedtoanaircompressingplantareceivershouldeitherbeconstructedtowithstandthecompressor’smaximumpressuresafely,orbefittedwithasafetyvalveandapressure-reducingvalvetopreventthereceiver’ssafeworkingpressurefrombeingexceeded.Whenprovidingasafetyvalveandpressuregaugeforasetofairreceiversthatareinterconnectedandcollectivelysuppliedthroughasinglepipe,theymaybetreatedasonereceiver,providedthat:
(a)anyreducingvalveorothersuitableapplianceisprovidedinthesingle supplypipe;and
(b)thereisnomeansofisolatinganyinterconnectingpipework.
33 ThereceivershouldbefittedwithasuitablesafetyvalvecomplyingwithBS6759,Part2orsimilarequivalentstandardandadjustedsothatairisallowedtoescapeassoonasthesafeworkingpressurehasbeenexceeded.Itisessentialthatthevalveiscapableofdischargingmoreairthanthesystemcansupplytothereceiver.
34 ThereceivershouldbefittedwithacorrectpressuregaugecomplyingwithBS1780orsimilarequivalentstandardandwhichindicatespressureinbar,lbf/sqin,orothersuitableunits.
35 Thereshouldbeasuitableappliance,eithermanualorautomatic,fordrainingthereceiver.Itisrecommendedthatmanualdrainvalvesshouldbefullboreandstraightthrough,tominimiseanybuild-upofdebriswhichcouldpreventtightshutoff.Automaticdrainvalvesshouldhaveadequatecapacityforliquiddischarge,bedesignedtominimisedebrisbuild-upandhaveamanualoverridetocheckperformance.Astrainerpositionedimmediatelyupstreamofthevalvewillhelppreventdebrisbuild-up.Protectionagainstfreezingofvalveswillberequiredininlowtemperatureconditions.
36 Areceivershouldhaveasuitablemanhole,handholeorothermeans(asdeterminedbytherelevantstandards,forexampleBSEN286-1Specification for simple unfired pressure vessels designed to contain air or nitrogenandBS5169Specification for fusion welded steel air receivers)toenabletheinteriortobethoroughlycleanedandinspected.
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37 Areceivershouldbeclearlymarked,inaconspicuousposition,withitssafeworkingpressureandotherrelevantinformationrequiredbythePressureSystemsandTransportableGasContainersRegulations1989.Thedetailsshouldbeclearlyvisibleonthevesseloraplateattachedtoit.
38 Areceivershouldbereadilydistinguishable.Thiscanbeachievedbypaintingonidentificationmarkingsorbyaffixingamanufacturer’splate,givingthenameofthemanufacturer,serialnumberetc.
Hazards
39 Themainhazardisthatthevesselmayexplodebecauseitssafeworkingpressurehasbeenexceededorbecauseitsabilitytowithstandpressurehasbeenreducedthroughcorrosionfatigueorinternalcokefiresforexample.
General information and advice
40 AllnewairreceiversshouldconformtoBSEN286-1orBS5169,whereapplicable,ortoastandardprovidingequalintegrity.
Precautions
41 Todeterminetherequiredcapacity,thecompressoroutputanddemandpatternneedtobetakenintoaccount.Asaguide,thiswillbebetweensixandtentimesthefreeairoutputofthecompressoratnormalpressure(litres/second).Manyuserstrytosaveoninitialcostandmakethemistakeofbuyingareceiverthatistoosmall.
42 Thedrainvalve,safetyvalve,examinationholesandmanholesneedtobeaccessible.
43 Thescaleofanygaugesneedstobeclearlyvisible.
44 OnlargecompressorsystemstheairreceivershouldbefittedwithafusibleplugconformingtoBS1123,Part1.Ifafirebreaksoutnearby,theplugwillhelptopreventanexplosionbyguardingagainst:
(a) theairtemperaturerisingtothecompressorlubricatingoilflashpoint;or (b)anexplosionoccurringbelowthedesignedworkingpressurebecauseof
lostintegrityowingtoheat.
45 Welded-onbracketsareoftenusedtomountcompressor-motorcombinationsontoairreceivers.Wherethisisthecase,weldingshouldbetothespecificationandapprovaloftheairreceivermanufacturer.Itshouldnotbecarriedoutindiscriminatelybecausetheweldermayunwittinglyweakenthereceiver.Mountingbracketsshouldbedesignedandfittedinaccordancewiththeapplicableairreceiverstandard.Itisgoodpracticetoweldmountingbracketsontointermediatereinforcingplatesratherthandirectlytotheairreceiver.
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Coolers Hazards
46 Manyaftercoolersarepressurevesselsandtheassociatedhazardsaresimilartothoseofairreceivers(seeparagraph39).
General information and advice
47 Coolingplaysanimportantpartinthesupplyofgoodqualitycompressedair.Intercoolersandaftercoolerslowerthetemperatureofthecompressedair.Thesecoolersareusuallywateroratmosphericaircooled.Withverysmallaircompressorsthefunctionoftheaftercooler(ietheloweringofthedewpointofthecompressedair)isperformedbytheairreceiver.Forothercasesaseparateaftercoolerwillnormallybenecessary.
Precautions
48 Air-cooledcoolersusuallyrelyonagoodcirculationofexternalairovertheheatexchangersurfacetoensureeffectivetransferofheat.Thereshouldbeadequatespaceavailablearoundtheseheatexchangerstoalloweffectivecleaningofallsurfaces.Thecoolingairinletsandoutletsshouldnotbeobstructedbylooseequipment,materialsetcorbyanysubsequentlyerectedbuilding.Wherepossibletheairinletshouldbesitedonthenorthsideofthebuilding.
49 Itisrecommended,particularlyatmediumandlargecompressors,thataftercoolersarefittedtothedischargesideimmediatelyafterthecompressor.Thesearefrequentlyprovidedwithseparatorstoremoveoilandmoisturefromtheair.
50 Acondensateseparatorwithanautomaticdrainvalveshouldbeprovidedatasuitabledrainagepointatthecooler’scompressedairoutlet.Protectionagainstfreezingofthevalvewillberequiredinlowtemperatureconditions.
51 Whereafluidisusedasthecoolingmedium,acoolantdrainvalveshouldbefittedandthecoolingcircuitprotectedagainstcorrosion.Thereshouldbesomewayofmeasuringtheinletandoutlettemperaturesofthecompressedairandofthecoolant.
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Air dryers Hazards
52 Thehazardsassociatedwiththeshellsoflargedryersdesignedonthetube-in-shellprinciplearesimilartothoseofanairreceiver(forinformationonhazardsseeparagraph39).Asecondaryhazard,shouldanairdryernotfunctionproperly,isthatmoisture-ladenaircancauseasafetysystemtofail.
General information and advice
53 Airdryersaresometimesdesirablewherepiperunshavetoberoutedoutsidebuildingsorwherethecompressedairisusedoutsidebuildingsegforoperatingvalves.Whereexceptionallydryairisneeded,egforpurgingdoubleglazingunits,airdryersareessential.Therearetwomaintypes:refrigerantanddesiccant.FurtherclassificationcanbefoundinBS6754Specifications and testing of compressed air dryers.
Refrigerant54 Refrigerantairdryerscanusuallyreducethedewpointofthecompressed
airto2°C.Thispreventscondensationfromforminginthedistributionpipeswheretheambienttemperatureexceeds2°C.Thismaybesuitableevenwhereshortrunsofpipeareroutedintheopenair,providedtheyareproperlyinsulated.
Dessicant55 Desiccantdryerscanreducethepressuredewpointofthecompressedairto
verylowlevels,exceptionally,aslowas-100°Cbutnormally,between-20°Cand-40°C.Thereductioninthepressuredewpointofcompressedairshouldbecloselyrelatedtotherequirementsoftheplantorequipmentinstalled.Adesiccantdryernormallyconsistsoftwochambersthatbothcontaindesiccant-oneonstream,theotherbeingregenerated.Anautomaticinletvalvedirectsairfromthecompressortoeachchamberinturn,thusensuringaconstantsupplyofdryair.
56 Positioningoftheairdryerwilldependonthecustomer’sparticularrequirements,butwillbeeitherimmediatelybetweentheaftercoolerandreceiver(wherefitted)orimmediatelyafterthereceiver.Wheretheneedforexceptionallydryairrepresentsonlyasmallpercentageofthetotalcompressedairused,adryermaybelocatedimmediatelyupstreamoftheparticularplantwherethedryairisneeded.
Precautions
57 ThechambersofairdryersarepressurevesselsandshouldconformwithBS5500Specifications for unfired fusion- welded pressure vesselsortoastandardprovidingequalintegrity.Ifmeansareprovidedforisolatingthedryer(anditisgoodpracticetoprovidemeansofisolationforallequipment),eitherthechambersshouldbeconstructedtowithstandthemaximumpressurethatcanbegeneratedbythecompressororasuitablepressurereducingvalveandasafetyvalveshouldbefittedtopreventthesafeworkingpressureofthechambersfrombeingexceeded.
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58 Wherethereisnomeansofisolatingthedryerfromasuitablesafetyvalve,egonthereceiver,andwherenon-returnvalvesarefittedtothedryeroutlet(toprotectitfromstoredenergyinthesystem),nosafetyvalvesareneeded.
59 Somedryersregeneratethedesiccantsimplybypassingaproportionofthedrierairthroughit.Othersuseheatercoilsembeddedinthedesiccant.Thislattertypeshouldbeequippedwithathermalprotectivedevicethatcandetectanytemperatureriseabovethethermostatsetting.Excessivetemperaturerisesduetothermostatfailureshavebeenknowntoleadtooilmistexplosions.
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Installation of compressors60 Smallcompressorinstallationsmayeasilybeoverlooked,especiallyifsited
inaseparateenclosureoutsidetheworkingarea,andconsequentlymaynotreceivepropermaintenance(seeparagraph146-158).Thedesignoflargeinstallationswillneedtoincorporateadequateaccessandsuitableliftingequipmenttofacilitatemaintenance.Ifnormallightingislikelytobeinadequate,locallightingshouldbeprovidedsothattheworkingareaisadequatelylit.Considerationshouldalsobegiventocompressorspecificationsiftheyaretobeinstalledinpossiblehazardousareas,e.g.ingaragepitswhereaflammableatmospheremaybepresent.
Precautions
Small compressors61 Wherepossiblethecompressorunitshouldbemountedatgroundleveland/
orinanareabigenoughtoallowforinspectionandmaintenance.
62 Anyplatformusedforaccessorasaplaceofworkshouldbebigenoughforapersontostandsafelyonit,andhaveguardrailsandtoeboards.
63 Theunitshouldnotbemountedonaplantstructurewherethereisexcessivevibration.
64 Smallunitsusedtosupplyworkshopsandsimilarinstallationsshouldbesitedwheretheyareaccessibleandphysicallyprotectedagainstdamagefrommaterial,toolsandequipment.Wheretheriskofdamageishightheyshould,wherepossible,beinstalledinseparateroomsadjacenttothemainbuilding(seeparagraphs60and67).
Medium and large compressors65 Whereusersareresponsibleforon-sitesystemdesignandinstallationthey
shouldfollowthemanufacturer’sinstructionscarefully.Mediumandlargecompressorsshouldbelocatedinaposition(usuallypermanent)bestsuitedforthepurposeandwithaccessforeaseofmaintenance.Thismeansthatthecompressor,includingitsprimemover,airreceiver,cooleretc.shouldbe:
(a) nearthecentreoftheloadtominimisepiperuns; (b) housedinabuildingthatisinsulatedorheatedtokeeptheambient
temperatureabovefreezing; (c) providedwithadequateventilatingairtopreventoverheating,andsited
sothattheintakeofmoistureisminimised;and (d) sitedawayfromdustyatmospheresandprovidedwithadequatefacilities
fordrainingofcondensate.
66 Thereshouldbesomemeansofcontrollingairbornedustandcontaminantsinthevicinityofthecompressor.Theairintakeshouldbeprovidedwithanefficientfilter.
Noise
67 Compressornoiseisoneofthemostcommonnoiseproblemsassociatedwiththeworkplaceandispotentiallydamaging.ReferenceshouldbemadetothePreventionofDamagetoHearingfromNoiseatWorkRegulations,
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enactedon1January1990,andtheassociatedguides1and2and3to8.Wherenoisefromcompressorsislikelytocauseexposuretohazardouslevelsofnoise,thisshouldbeincludedinthenoiseassessment(requiredundertheNoiseatWorkRegulations1989)andtheassessmentshouldindicatethedegreeofnoisereductionrequiredtoreducetheexposuretosafelevels.Compressorsshouldbesuppliedwithnoiseemissioninformation.Ifthisisnotthecase,purchasersshouldrequestthisinformationwhichcanbeusedintheassessment.Noisecontrolmeasures,ifrequired,includethefollowing:
(a) sitingthecompressorawayfromworkareas; (b) providingthecompressorwithanacousticenclosure(theneedfor
accessandremovalformaintenancewillneedtobeaddressed); (c) providinganti-vibrationmountings; (d) thefittingoforimprovingtheperformanceofsilencers; (e) accesstoenclosuresprovidedforcompressorsshouldonlybe
permittedtopersonswearingsuitableandeffectiveearprotection.
68 HSE Guidance note PM 56givesinformationandadviceaboutnozzledesigntoreducenoise.
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Main line systems69 Thissectiondealswiththesystemofpipes,valvesandfittingsfromthe
sourceofthesupplytothepointofapplicationorcontrol.
Hazards
70 Inadequatelysizedanddesignedsystemscanleadtotheoperatingunitsbeingstarvedofair,causingmachinemalfunction.Repeatedmalfunctionsmaytemptoperatorstoadoptunsafepracticestoovercomeanyproblems.Badlydesignedpiperunsandlackofisolationvalvesmayexposemaintenancestafftounnecessaryrisks.Somegradesofplasticpipeworkarenotrecommendedforuseincompressedairinstallationsanddesignersareadvisedtoconsultmanufacturerswhenselectingmaterials.
71 Incorrectmaintenanceofnon-metallicbowlsusedonfilters,traps,separatorsandlubricatorscanleadtoexplosions.Itisimportanttoensurethatalllubricantsusedtoreplenishlubricatorsarecompatiblewiththelubricatorbowlandtheequipmenttobelubricated.AttentionisdrawntoBS6005Specification for moulded transparent polycarbonate bowls used in compressed air filters and lubricators,regardinginstallation,useandmaintenanceofunitsfittedwithpolycarbonatebowls.
General information and advice
72 Compressedairsystemsinvariablygrow.Itisimportanttotakeintoaccountanyforeseeableexpansionofthesystem,andgenerousallowanceshouldbemadeonthesizeofpipingprovided.Thecostofinstallinga50mmdiameterpipeislittlemorethana25mmone,anydifferencebeinginthecostofmaterial.However,flowcapacityofa50mmpipeisfourtimesthatofa25mmoneandusingthelargersizeensuresbetterperformanceandfacilitatesfutureadditionstothesystematlittleextracost.Asageneralguidethepipesizewouldbesuchthatthepressuredropbetweenthereceiverandthemostremotetakeoffpointswouldnotexceed5%oftherequiredsupplypressurewithamaximumof0.3bar(4psi).Thepipesizeforinitialmainrunsinanysystemwouldnotnormallybelessthantheoutputportofthecompressor.
73 Therearetwomaintypesofcompressedairsystem;singlelineandringmain.Figures2and3showtypicallayouts,withpositionsindicatedforvariousvalves,drains,filters,airlinelubricatorsandpressuregauges.
74 Usersshouldkeepaschematicdrawingoftheairsystemshowingpiperuns,intendeddirectionofairflow,andthepositionsoffittingssuchasvalves,drains,etc.Thedrawingsshouldbeamendedwhenmodificationsoradditionsaremadetothesystem.AnygraphicsymbolsusedshouldcomplywithBSISO1219Fluid power systems and components. Graphic symbols and circuit diagrams.
Precautions
Pipe-runs 75 Therouteofthepiperunandthepositionofvalvesandoperatingpoints
shouldbesafeandconvenientforthosewhowilluseandmaintainthesystem.
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76 Thepiperouteitselfshouldnotpresentahazardorobstructaccessandshouldberoutedawayfromanyareaswhereitmaybevulnerabletomechanicaldamage.
77 Thereshouldbeadequateandsufficientaccessways,workingplatformsandclearancespaceprovidedtoenablethecompressedairsystemtobeoperatedandmaintainedwithoutexposinganyonetounnecessaryrisk.
78 Piperunsshouldhaveaslightfallinthedirectionofairflow,anddrainagevalvesshouldbefittedatthelowestpoint,insuchawaythatmoistureandaircanbedischargedsafely.Adrainvalveshouldbefittedatthebottomofverticalpiperuns.Sectionsofpipeandvalvesthatmayhavewaterinthemandmaybeexposedtofrostshouldbesuitablyinsulated.Note: receiver drains generally have a heavier duty than normal pipe run drains-see paragraph 35.
79 Piperunsshouldbesecuredbybracketsorothersupportsinstalledatappropriateintervalstosupportthepipesystemsuchthateachremovablesectionisself-supportingandtheremainingpipeisstableafterremoval.Toallowforexpansion,particularlyatthecompressor/receiverdischargeoronstraightrunsexposedtosunlightorheatfromtheprocess,suitableandadequateexpansiondevicesshouldbefitted;egbellows,loopbends,flexiblepipes.BS3974:Parts1-3Specification for pipe supportsgivesdetailsofsuitablemethods.
Figure 2 Singlelinesystem-typicallayout
Symbols DescriptionShut-off valve
Manual drain (water trap)
Automatic draining valve
Lubricator
Pipe fall in direction of air flowFilter, pressure regulatorpressure gauge, lubricator
Filter with manual control
Control valve
Pressure gauge
Air cylinder(spring return)
KEY
Chuteoperation
Maintenance area
Airgrinder
Compressorinstallation
Airpoint
Todrain
Todrain
To drain
Airvent
Bin gateoperation
DO NOT CROSS-CONNECT AIRLINESIN A SINGLE LINE SYSTEM
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Figure 3 Ringmainsystem-typicallayout
80 Pipingandassociatedfittingsconnectedbetweenthecompressorandairreceivershouldbeeasytoclean.Ifcarbondepositsbuildupinsuchpipeworktheremaybeanexplosion(seeparagraph24).
81 Alloutletpointsshould,wherepracticable,betakenfromthetopofthepiperun,andastopvalveorself-ventingballvalve(wherenecessarycompletewithhandle)shouldbeprovidedadjacenttotheconnectionpoint.Theconnectionpointatanyoutletshouldbearrangedhorizontallyorfacedownwards;upwardfacingconnectionpointsinvariablyfillwithdirtandpromptthebadpracticeofblowingoutbeforeuse.Outletpointsshouldbeprovidedatconvenientplacesforallroutineactivitieswhichrequirecompressedair.Theyshouldbepositionedsothathosesattachedtothemwillnotcrossorobstructthenormalaccesstotheworkplace,andcanbeconnectedwithouttheneedforclimbing.
82 Piperunsshouldbeidentifiedbypaintingthepipelightblue(BScolourreference20.E.51)inaccordancewithBS1710.Whereapplicabletheriskofcouplinguptothewrongcompressedgassupplycanbefurtherreducedbytheuseofnon-interchangeableconnections(seealsoparagraph100).
83 Stopvalvesshouldbeprovidedandpositionedsothatthecompletepipeworksystemcanbeisolatedfromthecompressedairsupply.Allbranchlinesofsubsectionsofthesystemshouldalsohavestopvalvesfittedtoallowseparateisolation.Whereappropriateeachvalveshouldhaveafacilitytobelockedintheclosedposition.
Symbols DescriptionShut-off valve
Manual drain (water trap)
Automatic draining valve
Lubricator
Pipe fall in direction of air flowFilter, pressure regulatorpressure gauge, lubricator
Filter with manual control
Control valve
Pressure gauge
Air cylinder (spring return)
KEY
B
A
Controlpoint
Todrain
Airpump
Airpoint
Chuteoperation
Maintenance area
Airgrinder
Compressorinstallation
Compressorinstallation
Bin gate
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84 Forringmainsorsystemswithdualsupply,stopvalvesmustbeprovidedwhichenableeachindividualairsupplytobeisolatedfromthepipeworksystem.Thisarrangementofstopvalveswillallowsafeoperatingprocedurestobeadoptedduringmaintenanceofthesystemandancillaryequipment.
85 Whereaircannotbeventedfromthesystemoranypartofthesystemthroughthenormaloutlets,valvesshouldbefittedforthispurpose.Thevalvesspecifiedshouldbesuitablefortheapplication.Inmostcasesthree-portvalvesorself-ventingballvalvesarethemostsuitabletypeforisolatingandventing;thesevalvesshouldbearrangedsothatwhenthesupplyisshutoff,thedownstreampartoftheairsystemisventedthroughtheexhaustportofthevalveandprovisionmadetolockthevalveinthisposition.
86 Wherevalvesaregrouped,orwherethepurposeorlocationofthevalveisnotobvious,anoticeshouldbeprovidedindicatingthepositionand/orpurposeofthevalve.
87 Leveroperatedstopvalvescanbeinadvertentlymovedtotheopenposition.Duringmaintenancetheyshouldbeeitherlockedintheclosedpositionortheleverhandleshouldberemoved.
Filters, traps, separators and lubricators88 Filtrationandlubricationtoastandardofcleanlinessappropriatetoend
usagearenecessary.Airlinelubricatorsshouldbeprovidedforoperationswhichinvolveairtools,aircylindersoraircontrolvalves;theyshouldbepositionedafterthestopvalveandafteranyfilterorseparator.Inbothcasesitisessentialthatfiltersandlubricatorsarepositionedafterandadjacenttoastopvalvetoallowsafeserviceandmaintenance.Theyshouldnotbefittedintoringmainswherethedirectionofairflowisnotcontrolledbutintothebranchlinesleadingfromthem.Highstandardsoffiltrationwillberequiredforinstrumentcontrolorintheelectronicsindustry.Ultra-highefficiencyfiltrationwillberequiredinhospitalsandthepharmaceutical,foodstuffspreparationandbrewingindustries,andappropriatefilters,trapsorseparatorsshouldbefitted.Whereextremelycleanorsterileairisrequiredspecialistequipmentsuppliersshouldbeconsulted.Precautionsshouldbetakenagainsttheingressofdirtandothercontaminantsfromthesurroundingareathroughcarefulsitingofthecompressor.Theuseofexhaustportfiltersshouldbeconsidered.
89 Inmostcasesthesecomponentswillhaveeithermetallicortransparentplasticbowls(usuallypolycarbonateorpolyamide),whichhavegoodimpactstrength.Thepropertiesofthematerialsmayhoweverbeadverselyaffectedbysolvents,alcohols,cleaningsolutionsorsyntheticlubricantsandmaintenanceinaccordancewithmanufacturers’recommendationsisessential.(NBUsefulguidanceforpolycarbonatebowlsisprovidedinBS6005Specification for moulded transparent polycarbonate bowls used in compressed air filters and lubricators.)Itisthereforeessentialthatcleaningofpolycarbonatebowlsiscarriedoutwithcleanrags,andthatmateriallikelytobecontaminatedwithdilutedsolubleoilsshouldbeavoided.Wherepossible,filters,separatorsandlubricatorsshouldbepositionedsothattheriskofaccidentaldamagetoanynon-metallicbowlsisminimised.Evensubsequentminorknocksmayleadtodamagedbowlsexploding.Itisgoodpracticetoshieldallnon-metallicbowlsandmanufacturersshouldensurethatsuch
bowlscanbeshielded.Specificrequirementsforfilters,traps,separatorsandlubricatorsarediscussedinparagraphs104,105and109.
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Pressure regulators90 Whereitisnecessarytoprotectequipmentfromoverpressurisation,
pressureregulatorsshouldbeprovidedandsettomaintainaconstantsafedownstreampressure.Anairpressuregaugeshouldbeprovidedontheoutletside.Dependingonthelevelofriskcreatedbyoverpressurisationalladjustablecontrolsshouldhavesomeformoftamper-resistantprotection.Wheretheriskislow,asimplesnapactionlockshouldsuffice.Astheriskincreases,greatersecurityagainstunauthorisedadjustmentisneeded.Considerationshouldbegiventousingmodelsincorporatingpositiveinternalstopsorpositivemeansoflocking.Forveryhighrisks,non-adjustablemodelsmaybethebestanswer;alternativelytheadjustableitemsmaybesitedinlockableenclosureswiththekeykeptbyaresponsibleperson.
91 Apressurereliefvalve(safetyvalve)orothersuitableoverpressureprotectivedeviceshouldbefittedandsettorelieveifthesafeworkingpressureoftheequipmentorvesselisexceeded.Thereliefvalveshouldbepositionedsothatifthevalvedischarges,therisktopersonnelisminimised.
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Portable pneumatic equipment Statutory requirements
92 ThePressureSystemsandTransportableGasContainersRegulations1989andtheProvisionandUseofWorkEquipmentRegulations1992setoutthedutiesofusersandownersofportablepneumaticequipment.
93 ThePersonalProtectiveEquipmentatWorkRegulations1992setoutwhateyeprotectionisneededforcertainprocessesusingcompressedair.
94 UndertheManagementofHealthandSafetyRegulations1992andtheHealthandSafetyatWorkAct1974employershavearesponsibilitytotraintheirstaff.Furtheradviceontrainingisgiveninparagraphs171to173.
Hazards
95 Bothblowgunsandhandheldtoolsareusuallyconnectedtoalengthofflexiblehosewhichduringthecourseofitslifewillbesubjecttomechanicaldamageandconsiderableflexing.Thisdamageand/orflexingparticularlyatconnectionpointscancausethehosetorupture.Thiscanleadtosuddendischargesofcompressedairandmaycauseunsupportedlengthsofhoseto‘whip’and‘snake’dangerously.
96 Thepracticeofusingblowgunsforremovingswarf,powderedmaterialsetcfromcomponentsandfrommachineryiswidespreadthroughoutindustry.Thereareanumberofhazardsconnectedwiththeuseofblowgunsincluding:
(a) eye injuries-atairlinepressurestheaircausesswarforotherparticles tomoveathighvelocitycreatingaserioushazardtotheeyesofthe operatororanyonenearby;
(b) other injuries-injurieshavebeencausedbydischarginggunswiththe nozzleheldclosetotheskin.Veryseriousinjuries,sometimesfatal,have occurredwhenthenozzleofthegunhasbeenpointedtowardsthe anus,evenatsomedistancefromit.Manyoftheinjuriesoccurwhen clothingisdusteddownandbecauseofthiscompressedairshould neverbeusedforcleaningclothing;insteadvacuumcleanerswithbrush typeheadsarerecommended.Othersaretheresultofhorseplay(see alsoparagraphs172and173);
(c) dust explosions-therehasbeenatleastoneseriousexplosionofadust cloudwhenablowgunwasusedtoremoveflammabledust;
(d) toxic hazards-theuseofcompressedairforcleaningtoxicmaterialcan resultinthedispersalofthematerialintotheair;
(e) noise-blowgunsfrequentlyproducehighnoiselevels.
General information and advice
97 Byfollowingtheadviceintheprevioussectionsaclean,dryairsupplyshouldbesafelygeneratedanddistributedtoalloutletpoints.Thetypeofequipmenttobeconnectedtotheoutletpointwilldeterminewhatextraprecautions,ifany,willberequired.Themostcommonrangeofdeviceswillbeairorblowguns,portabletoolsorpneumaticpoweredmachinery.Eachhasitsownparticularrequirements.
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Precautions Flexible hoses98 Whenselectingaflexiblehose,usersshouldtakeintoaccountthesite
conditions,includingtemperatures,oilsandpressurestowhichitwillbesubjected.Wherelubricatingoilispresentinpipelines,agradeofhoseresistanttothatparticularoilmustbeused.Asyntheticbasedgradeofhoseshouldbeusedformineraloilsandanaturalbasedgradeforvegetableoil.Wherefireandexplosionrisksmaybepresent,theuseoffire-resistantanti-static(FRAS)hosesshouldbeconsidered.Themanufacturer’sadviceshouldalwaysbefollowed.
99 Heavy,mediumandlightgradesofhoseareavailable.Wherehosesareusedforsemi-permanentdistributionofcompressedair,forexampleinquarries,constructionsites,shipyards,farmyards,garageforecourtsetc,heavygradesshouldbeused.Mediumandlightgradesareusedforgeneralpurposessuchasfixedpneumaticmachineryandpneumaticcylinders,smallpowertoolsandportableequipment.Hosesusedwithhand-heldpowertoolsshouldbelightandflexible(butsuitablefortheduty).
100 Tubesandhosesusedtoconnectcylinderstotheircontrolvalvesareavailableinavarietyofcolourstomakefaultfindingandmaintenanceeasier(seeparagraph143).Theyshouldbeneatlyrunandadequatelysecured.Ifthefailureofaflexiblehosewouldbehazardousitshouldbefurtherrestrainedorshielded.
101 Couplingaportabletooltotheoutletpointisusuallyachievedbyuseofaquick-actingconnector.Theconnectorshouldbedesignedsothatwhendisconnecteditautomaticallysealstheairpressureontheupstreamsideandslowlyventstheairpressureonthedownstreamside.Forallhosesabove10mmbore,morethan10mlongorsubjecttoapressureexceeding7bar,theconnectorshouldhaveaself-ventingsocketwhichreleasesthedownstreampressurebeforedisconnectionispossible.Alternatively,aplugwithacontrolledventingactionshouldbeused.Thesesafetyfeaturespreventinadvertenttooloperationanduncontrolledwhippingofthehosewhenitsinletendisuncoupledfromthesocket.Anotherwayofreducing‘whipping’or‘snaking’istofitemergencyshut-offvalves,hoserupturevalvesorairfusesascloseaspracticabletotheconnector.Thevalveswillcloseorreduceflowtoaverylowlevelintheeventofexcessiveair-flowconditionscausedbyafailureofthehose(seealsoparagraph83aboutfittingofisolationvalves).Thesamerequirementcouldbenecessarywhenusingplastictubing.
102 Similarrequirementsforquick-actingconnectorsapplytomostpercussiveandvibratingairtools,whichmaybefixedorhandheld.Ifaquick-actingcouplingsocketisfittedatthehoseendadjacenttothetool,theplugshouldnotbescreweddirectlyintotheinletportbutshouldbefittedontoashortisolationhose(0.5to1.5mlong),thusisolatingtheplugandsocketfromthetoolvibrations.
103 Wherehosesareusedtosuspendtools,theloadstrengthofhoseandcouplingsshouldbeatleastfivetimesthesuspendedload.
Blow guns104 Blowgunsconsistingsimplyofareducedorificeindirectlinewiththesupply
hosecanbeextremelydangerous,unlesspreceededbyapre-settamper-proofpressureregulatorsetatareducedpressurefromthenormal80psiairlinesupply.Modelsareavailablecommerciallywhichincorporateanaircurtaindesignedtoprovideaprotectiveshroudaroundthenozzle.Although
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notcompletelysafe,thesedesignssignificantlyreducetheriskofeyeinjuryandthedangersfromcloseskincontact.Ifdesignedcorrectlysuchnozzlescanoftenhelptopreventtheoperatorfrombeingsubjectedtoexcessivenoise.Becauseairisventeddirectlyintotheatmosphere,cleandryairisessentialandlubricatorsshouldnotbeused.Blowgunscanexhaustsignificantquantitiesofairandplaceextraloadingonthecompressorsystem.Inviewofthisandtheattendantriskarisingfromuseofblowguns,theiruseshouldbeconsideredcarefullywithaviewtousingalternativemeansforcleaningdownmachineryorcomponents.
Portable tools105 Pressureregulatorsshouldbeusedtoreducethepressuretotheoptimum
valueforthesafeandefficientuseoftheequipment.Thisvalueshouldbeclearlymarkedonthetool.Filtersandlubricatorsshouldbefittedinthesupplypipeasshownat‘A’inFigure3.Topreventover-speeding,toolswithairmotorsshouldincorporateagovernororthrottle.Thereshouldbeavailableaneasilyaccessiblemeansofisolatingtheairsupplyfromthetool.EuropeanStandardprEN792Hand-held non electric power tools-Safetycoversdesignofdrills,grinders,nibblers,polishersetc.Itispoorpracticetopullportabletoolsusingthehoseoruseitasameansofaccessbyclimbingontosuspendedhose.Olddamagedhoseshouldnotbeusedtomakeupfreshhoseassemblies.
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Pneumatic powered machinery Hazards
106 ThehazardsnormallyassociatedwithpoweredmachineryareequallyapplicabletopneumaticpoweredmachineryandsuitablesafeguardsarenecessaryasdescribedinBSEN982Safety requirements for fluid power systems and their components-PneumaticsandBS5304CodeofPractice Safety of machinery.
107 Unlikeliquidfluidpowermedia,compressedairiselastic(compressible),andbecauseofthis,additionalhazardscanarisefromstoredenergyandactuatorsunderload(seeparagraphs138to141).Thishazardrequiresparticularconsiderationwhenthemachineryisfittedwithinterlockingguards.Interlockingsystemsarecoveredinparagraphs129to137ofthisbooklet.
General information and advice
108 Wherepneumaticallypoweredmachineryisconnectedtotheoutletpointthisshouldbebymeansofconventionalconnectors,egcompressionorpush-in,push-onconnectorswithashut-offvalve.PlastictubingmadefromPVCornyloniswidelyused,inparticularforpipinguppneumaticallyoperatedmachinesemployingpneumaticcylindersandvalves.Compressionorpush-in,push-on,connectorsofvarioustypescanbeusedwiththetubingwhichissuitableforconnectingtovibratingandmovingpartsbyformingloopswhichabsorbthevibrationormovement,but,asforflexiblehoses(Para98)itisalwaysnecessarytoconsidersiteconditionswhenapplyingplastictubing.ThespecificationfornylontubingisgiveninBS5409,Part1.Note: To prevent errors during installation and maintenance, all component parts should be clearly identified. The identification should correspond to the data on the circuit diagram.
109 Themachineshouldhaveitsownfilter,pressureregulator,pressuregaugeandlubricatorset,asshownatPartBofFigure3.Withthisarrangement,optimumconditionsfortheoperationoftheparticularmachinecanbesetwithoutaffectinganyotherequipmentconnectedtothesupply.Ifthefilter,pressureregulator,pressuregaugeandlubricatorsetareproperlymaintained(seeparagraphs160to170),wearonsealsinactuatorsandvalveswillbelimitedandthemachineryshouldperformcorrectlyandefficiently.Thelikelihoodofmalfunctions,whichcouldleadtounintendedoperation,willalsobereduced.
Precautions
110 Toalargeextentthedesignfeaturesneededwilldependonhowthemachinewillbeused.However,paragraphs111to141outlinesomebasicrequirementsformachineandcircuitdesign.
111 Allcomponentsusedinthemachinedesign,includingconnectinghoses,shouldbeabletowithstandsafelythemaximumpossibleairmainpressure.Themaximumsafeworkingpressureofthemachineshouldbeclearly,prominentlyandpermanentlymarkedonthemachine.
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112 Allcomponentsshouldbeprotectedagainstover-pressurisationbytheprovisionofpressurereliefvalvesunlessthecomponentscanwithstandthecompressor’smaximumpressureandwillnotbesubjectedtounacceptablepressurebuildupduetohighexternalloads.
113 Themachineshouldbedesignedandconstructedsothatanycomponentswhichrequireadjustmentorregularmaintenanceareeasilyandsafelyaccessible.
114 Supplyorcontrolsystemfailureshouldnotcauseahazard.Toensurethatsuchapossibilityisminimised,theeffectsofgravity,impactorvibrationshouldbeconsidered.Forthisreason,valvescontrollingactuatorsshouldbemountedwiththemainspoolhorizontal.Inaddition,anyactuatorsthathavetoadoptaspecificpositionforsafetyifthesupplyorcontrolsystemfails
shouldbecontrolledbyavalvewhichisspringbiased(mono-stable)tothesafeposition.
115 Ifthemachineistobeprovidedwithanemergencycontrolitshould,withoutdelay,stoporsetmovingpartstowhicheverpositionprovidesmaximumsafety.Theemergencycontrolshouldbeofthemushroomheadtype,colouredred,prominentlylocatedandreadilyaccessibletotheoperator.Whereanoperatorhastoworkfrommorethanonepositionitmaybenecessarytoprovideadditionalemergencycontrols.Operationoftheemergencycontrolshouldnotofitselfcreateahazard.
116 Whereairisdischargedtotheatmosphereduringthenormalcourseofoperationofthemachine,andthiscausesworkerstobeexposedtohighlevelsofnoise,somemethodofreducingtheworker’sexposureshouldbeconsidered.Componentsshouldbelocated,orshielded,sothatoperatorsarenotsubjectedtoairblastfromexhaustports.Ifsilencersarefitted,theseshouldbedesignedtocreateminimumbackpressureandshouldbecompatiblewithwaterandanylubricantsused.Alternativelyanexhausthosecanbefittedsothattheairisdischargedwellawayfromworkers,forexampleunderafactoryroof(seeHSEGuidanceNotePM56Noise from pneumatic systems).
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Actuators Hazards
117 Wherelinearactuatorsareused,specialattentionshouldbegiventostrokelength,loadingandthemethodsofmountingthecylindertoavoidbucklingofthepistonrodandexcessivesideloadingwhichcouldleadtopistonrodbearingandsealwear.Whereshearforcesonfixingscrewsarelikelytobeexcessive,thecylindermountingshouldalsobekeyedordowelledinposition.Alternatively,fittedboltsmaybeused.
118 Repeatedshockloadsoncylinderendcapscaneventuallycauseeitherthe
cylinderorthepistonrodassemblytofail,whichcouldleadtoseriousinjury.Mostcylindermanufacturerscansupplycylinderswithbuilt-incushioningdesignedtoreducespeedatstrokeextremities,thusbringingthemachinecomponenttoashocklessstop.Equallyhazardousisthepotentialforpistonandrodtoseparate.Cylindermanufacturersshouldensurethatpistonsarepositivelylockedtothepistonrod.
General information and advice
119 Thefunctionoftheactuatordeterminestheprecautionsnecessaryforasafedesign.Ifthepurposeistoimpartmotiontoaloadwhichisotherwisesupported,theproblemwillbedifferentfromthoseforanactuatordesignedtoliftorloweraload.Cylindersdesignedtoclampposeyetanotherproblem.
Precautions
120 Foranyactuatorsimpartingmotion,smoothactionispreferableandcushioningisdesirable.Ifthecylindersaredouble-actingtheremaybeoccasions,egatstart-uporfollowinganemergency,whenthecylinderispre-exhausted,causingtheactuatortoacceleraterapidlywhenairisfirstintroducedtothecylinder.Wherethisislikelytocauseahazardasoftstartarrangementshouldbeintroducedinthesupplylinetothemachine.Thiswill
initiallyrestricttheflowrateuntilacertainpredeterminedpressurehasbeenreached.
121 Linearactuatorswithmagneticpistonsandintegralmountedreedswitchesorproximityswitchesforsignallingcontrolvalvesarenowpopular.Thisislargelyduetothecomparativecheapnessofusingelectricormicro-electroniccontroltogetherwithcostandspacesavingsfromnotneedingtoinstallindependentmechanicallyactuatedtrips.Safeguardingpneumaticallypoweredmachineswherethecontrolcircuitiselectricalrequiresextracautiontoensurethattheriskofinjuryisminimisedifeithertheelectricorpneumaticpowersupplyfails.Reedswitchesmaymalfunctioninareassubjectedtohighvibrationlevelsorelectromagneticfields.
122 Actuatorsdesignedforliftingorsupportingloadsmaycollapsedangerouslyifthesupplyfails.Themachineshouldhavespring-appliedmechanicalscotchestosupporttheloadwhenevermovementisnotrequired.Incertaininstancesmechanicalscotchesmaybeimpracticable.Asasafetybackupanormallyclosed,airtoopen,springreturnvalveinthecylindersupplylinecouldbeused.
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123 Supplyfailuretoclampingcylinderscanleadtoahazardbyreleasingthecomponentprematurely.Thiscanbeovercomebyusingsingleactingcylinderswherethereturnspringappliestheclampingforce(seeparagraph127),ortheuseoftwocontrolvalveswilltemporarilykeepthecylinderpressurised(seefigures4and5).Butcareshouldbetakeninusingthisdesignasevenasmallleakcouldaffecttheintegrityofthesystem.
Figure 4 Singlecontrolsysteminterlockingwithpistonarrestandhold(guardopen)
Note:Figures 4 - 19 illustrate principles only, and they are not intended to provide all the
information needed to construct a safe working system.
124 Machinesincorporatingseveralactuatorsmayrequirethemtobesetinacertainpositionbeforethemachineisfirstused,andsubsequently,aftertheemergencycontrolorinterlockingguardshavebeenoperated.Re-positioningmaybepossiblewithoutre-establishingthepneumaticsupply,butthesecaseswillbeintheminority.Inallothercasesre-positioningisbestachievedbyprovidingmanualoverridecontrols.Suchcontrolsshouldbeofthetwohandtypeiedesignedsothatthetwocontrolsareplaced,separatedandprotectedtopreventspanningwithonehandonly,beingoperatedwithonehandandanotherpartofthebody,orbeingreadilybridged.Itshouldnotbepossibletosettheactuatorsinmotionunlessthetwocontrolsareoperatedwithinapproximately0.5secondsofeachother.Movementoftheactuatorsshouldbearrested,orwhereappropriatereturned,immediatelyoneorbothcontrolsarereleased.BSEN574Two Hand Control Devicescoversfunctionalaspectsandprinciplesfordesignofthistypeofcontrol.
Cylinder
Stopvalve
Guard
(a) Interlockingvalves(b) Control
valves
(c) Power control valve(Air operated)
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Figure 5 Singlecontrolsysteminterlockingwithpistonarrestandhold(guardclosed)
Cylinder
Stopvalve
Guard
(a) Interlockingvalves(b) Control
valves
(c) Power control valve(Air operated)
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Interlocking methods and circuit design General information and advice
125 Themethodusedforinterlockingshouldbecommensuratewiththerisk.Thehighertheriskthehighertheintegrityoftheinterlockingsystemshouldbe.
126 PrinciplesfordesignandselectionofinterlockingdevicesassociatedwithguardsaregiveninEN1088andBS5304.GeneralprinciplesforapplicationaregiveninBSEN983Safety of Machinery-Safety requirements for fluid power systems and their components-Pneumatics.
127 Onpneumaticmachinery,becausethepowermediumiscompressibleandnormallyexhaustedtoatmosphere,thesafetycircuitdesignisnotstraightforwardasforotherpowermedia.However,thebasicaimsforinterlockingremainthesameand,wherepossible,thepowersupplyshouldbeinterruptedbytheguardoperatedinterlockingdeviceandanyresidualsystempressureexhaustedtoatmosphere.Inthisconditionanycylinderswillbepre-exhaustedandalternativearrangementsinthesystemdesignwillbenecessarywhereanycylindersarerequiredtobeunderconstantload(seeparagraph122).Inaddition,particularprecautionsmaybenecessarywhenreinstatingthesupplytopre-exhaustedcylindersifrapidaccelerationisundesirable.Toavoidtheneedtomaintainsupplypressuretocylindersrequiredtobeunderconstantload,suchasthoseoperatingclampsorsupports,alternativefeaturesshouldbeconsidered,suchassingle-actingcylinders,orspringappliedmechanicalscotches.Cylindersfittedwithrodlocks,thelockingactionofwhichistriggeredbylossofairsupply,mayalsobeusedtopreventuncontrolledmovement.
128 Signalairlinesshouldbekepttoaminimumlengthtofacilitaterapidexhaustpressuredecay.Wherethisisnotpracticableandpilotsignalsexhaustingtotheatmosphereretainsufficientpressurelevelstooperatemaincontrolvalves(evenafteraguardhasbeenopened),additionalinterlockingdevicesshouldbeprovidedwhichpreventopeningoftheguarduntilitissafetodoso.When3-positionvalvesareusedinsafetycircuits,wherepracticablethecentrepositionshouldprovideasupply-sealed-onlycondition(outletsvented)becauseanall-ports-sealedcentrepositioncanresultinstoredenergyintheactuator,leadingtounintendedmovementifpipingisdisconnected.
Interlocking systems
Single control system interlocking129 Thebasicelementsofsinglecontrolsysteminterlocking(seeFigures4and5)
are:
(a) aninterlockingvalveorpositionswitchoperatedbytheguard; (b) interposedcontrolvalves,electromechanicalrelaysand/orsolid-state
switchingdevices,ifany;and (c) anairoperated,solenoidoperatedorsolenoidactuatedairoperated
valve,controllingpowertothedrive.
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130 Anyoftheseelements,orthepipingorwiringinterconnectingthem,canfailandcausedanger,sotheyshouldbechosentoprovidethemaximumdegreeofreliability.Thegreaterthenumberofdevicesincorporatedinthesystem,theloweritsinherentreliability,sointerposingdevicesshouldbeavoidedifpossible.
Dual control system interlocking
131 Thebasicelementsaresimilartothoseemployedinsinglecontrolsysteminterlocking.Wherethepossibilityofcommonmodefailureneedstobeminimiseddifferentcontrolpowermediashouldbeusedandkeptseparateexceptfornecessaryinterconnectionsforcrossmonitoring(whereprovided),andconnectiontothesupply.
132 Suchsystemscanbeentirelypneumatic(seeFigures15and16),orhybridforexampleonesystem,pneumaticandonesystem,electric(seeFigures17and18).Thislatterarrangementmaybeparticularlyappropriatewherecylinderswithmagneticpistonsandintegralreedswitchesorproximityswitchesareused.Inbothsystemstheoutputofthepowercontrollingdevicesshouldbeconnectedsothateithercanstophazardousmovementofthemachinery,irrespectiveoftheconditionoftheother.Wherethecircuitissuchthatasinglefailureisnotself-revealingegtheactuatorcontinuestooperate,theintegrityofthedualcontrolsystemcanbeimprovedbycrossmonitoring(shownalsoinFigures17and18).
Figure 6 Singlecontrolsysteminterlockingwithpistonarrest(guardopen)
Cylinder
Guard
(a) Interlockingvalves
(b) Controlvalves
(c) Power control valve(Air operated)
Note:Manual reprositioning of the cylinder is possible with this type of control valve.
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Figure 7 Singlecontrolsysteminterlockingwithpistonarrestandhold(guardclosed)
Figure 8 Useofanequalisingvalve-controlinterlocking(guardopen)
Cylinder
Guard
(a) Interlockingvalves
(c) Power control valve(Air operated)
(b) Equalisingvalve
Cylinder
Guard
(a) Interlockingvalves
(b) Controlvalves
(c) Power control valve(Air operated)
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Figure 9 Useofanequalisingvalve-controlinterlocking(guardclosed)
Figure 10 Useofanequalisingvalve-powerlocking(guardopen)
Cylinder
Guard
(a) Interlockingvalves
(c) Power control valve(Air operated)
(b) Equalisingvalve
Cylinder
Equalising valve(with power interlocking)
Guard
Control valve(Air operated)
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Figure 11 Useofanequalisingvalve-powerlocking(guardclosed)
Figure 12 Useofareservoir-powerinterlocking(guardopen)
Cylinder
Equalising valve(with power interlocking)
Control valve(air operated)
Guard
Cylinder Guard
Reservoir
Power control valve(Solenoid operated)
Interposedcontrolvalves Power
interlockingvalves
NoteCylinder returnsto instrokeposition wheneverguard is open
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Figure 13 Useofareservoir-powerinterlocking(guardclosed)
Cylinder Guard
Reservoir
Power control valve(Solenoid operated)
Interposedcontrolvalves Power
interlockingvalves
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Figure 14 Controlsysteminterlockingfromcomplexsequence
A B
D
C
Guard
TocloseSpring
return
To portsmarked
Sequence
Closed guardA+B+C+ D+
A-C- D-B-Open guard
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Figure 15 Dualcontrolsysteminterlockingwithoutcross-monitoring,bothchannelspneumatic
(guardopen)
Figure 16 Dualcontrolsysteminterlockingwithoutcross-monitoring,bothchannelspneumatic
(guardclosed)
Guard openCylinder
(a) Interlockingvalves
(c) Power control valve (Air operated)
(b) Interposed control valves
Guard closedCylinder
(a) Interlockingvalves
(c) Power control valve (Air operated)
(b) Interposed control valves
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Figure 17 Dualcontrolinterlocking,onecontrolchannelpneumaticandoneelectric,withelectriccross
monitoring(guardopen)
Figure 18 Dualcontrolinterlocking,onecontrolchannelpneumaticandoneelectric,withelectriccross
monitoring(guardclosed)
Cylinder Guard open
Interlockingswitch
(electric)Interlocking
valve(Pneumatic)
Monitor
Controlvalves
A B
Powercontrol
valve
2nd channelinterposed powercontrol valve
Sol AMonitor C
Cylinder Guard closed
Interlockingswitch
(electric)Interlocking
valve(Pneumatic)
Monitors
Controlvalves
A B
Powercontrol
valve
2nd channelinterposed powercontrol valve
Sol AMonitor C
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Figure 19 Guardoperatedpowerinterlockingwithscotchtopreventdrillfallingundergravity.Alsofitted
withguardlocktopreventinadvertentopening
Power interlocking133 Powerinterlockingisachievedbydirectmechanicalactionofavalveinthe
mainairsupplyinserieswiththeactuator.Themechanicalactionmaybedirectfromguardmovement(seeFigures10and11)viaalinkage,byacaptivekeyoratrappedkey.
134 Interlockingbymeansofairisolationandexhaustmaycausedifficultiesonmachinerywhichreliesontheairsupplytokeepheavyarticlessuspendedorcomponentsclampedinposition.Similarly,wherecomplexmachineryisdesignedtoperformaseriesoffunctionsinsequenceautomatically(seeFigure14),airisolationandexhaustinterlockingcouldleadtotheneedforpotentiallydangerous,extensivemanualre-settingofactuatorsandsequencingvalves.Forthesereasons,powersystemmethodsofinterlockingarenotnormallypracticableforcomplexairoperatedmachineryandhencecontrolsysteminterlockingofthepilotsignalshastobeused.
135 Wherepracticable,however,powersysteminterlockingofcomplexsystemsisbetterthansinglecontrolsysteminterlocking,providedthepowerinterlockingvalveandthearrangementsbetweentheguardandvalveareofsimilarorhigherintegritythanthecontrolsysteminterlocking.Inaddition,anymachinerypartswhicharesupportedbycompressedairandwhichwouldfallundergravitywhentheairisisolatedandexhaustedshouldbeautomaticallyscotchedwhiletheguardisopen.
136 SuchprecautionsareshowninFigure19,thelayoutofwhichisinlinewithBSISO1219-2recommendations.HazardsarisefromactuatorsAl,A2,A3andA5,whichneedsafeguarding.Also,A3operatesverticallyandwill
V3
V2
V1
Run
Singlecycle
ClampA1
B11 ClampA2
B22 B21
DrillA3
ScotchA4
B31
DrillA5
B52 B51
FeedA61
A62B62 B61
C6 C7C5C1 C2 C3
B72
B62B52 B11 B21 B31 B22
Guardlock A7
B72
Interlockingvalve
Guard
Toclose
To lock
A7
B61 B51
Single cycle sequence
Close guardScotch withdraws (A4 - )Operate V2Guard locks(A7+)A1+A2+A3+A5+A2 - A3 - A5.
Guard unlocks (A7 -)A61 & A62 -Machine stopsOpen guardScotch engages (A4+)
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fallundergravitywhenairsupply,throughtheguardoperatedinterlockingvalve,isexhausted.Thecircuithasthusbeenarrangedsothat,withtheguardopen,A3isscotchedusingasingleactingcylinder.Oncetheguardisclosedthescotchwithdrawsandtheguardislockedsothatthesequencecannotbebrokenbyinadvertentlyopeningtheguard.ThecompletesinglecyclesequenceisindicatedinFigure19,whereitcanbeseenthattheguardunlockstoallowmanualfeedingifnecessary.Continuouscyclingcanbeeffectedbyoperatingthevalvelabelled‘run’.If,duringuse,amalfunctionoccursrequiringtheguardtobeopened,thiscanonlybeachievedbyshuttingthestopvalveinthemainairsupplyline.
137 Alltheseproblemshighlighttheneedforthemachinedesignertoconsidercarefullytheoverallsystemdesigntoensurethattheinterlockingarrangementsareeffective.Althoughinmanycasesinterlockingthepilotsignalsratherthanthepowersupplymaybetheonlypracticalsolution(seeFigure14),thisshouldbealastresortonly.
Circuit design
Piston arrest138 Whereitisnecessaryjusttoarrestthemovementofapistonwhenaguard
isopen,thiscanbeachievedbyusingeithertwothree-port,two-positionvalves(seeFigures6and7)oranequalisingvalve(seeFigures8to11).Ifanequalisingvalveisusedthepistonmaynotstopimmediately,butitwillseekanequilibriumpositionwherebyforcesonbothsidesofthepistonareequal.ThecircuitinFigure6willallowmanualrepositioningofthepistonwithoutdisconnectingpipes(dependingonthefrictioninthesystem).Neitherofthesetechniquesissuitableforclampingorsupportingapplications.
Piston arrest and hold139 Where,forsafetyreasons,thepistonmustbearrestedandheldinposition,
twotwo-portcontrolvalvescanbeused(seeFigures4and5).Thepistonwillseekanequilibriumpositionbeforecomingtorest.However,ahazardcouldariseifconnectionstothecylinderarebrokentosubsequentlyoverridethelockedposition.Airexhaustingthroughthebrokenconnectioncouldallowairunderpressureontheoppositesideofthepistontoexpand,therebycausingmovementwhichcouldleadtoinjury.
Overriding locked position140 Wherethelockedconditionmustbeoverriddenwhiletheguardisopen,a
two-portstopvalvecanbeaddedtothecircuit(seeFigures4and5).Thiswouldnormallyhaveblockedportsbutbydepressingthestopvalvebothsidesofthecylinderareopenedtoatmosphere,enablingthepistontobemovedmanually.
Predetermined position141 Itmaybenecessarytoensurethatpistonsadoptapredeterminedsafe
positionintheeventofpowersupplyfailing.Againtheuseofsingleactingcylindersmaybepossiblebutanalternativeistouseareservoirandnonreturnvalvearrangement(seeFigures12and13).Itisimportantto
ensurethatwherereservoirsareusedtheyareofsufficientcapacitytoensurethatthepistondoesnotstallinanunsafeposition.
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Inspection and maintenance Statutory requirements
142 Therearespecificstatutoryrequirementsfortheexaminationandmaintenanceofpressuresystemsincludingairreceivers(seeparagraph30).Inadditiontothespecificrequirements,generalrequirementsaresetoutinSection2(2)(a)oftheHSWActandPUWER:employersmustprovideandmaintainplantandsystemsofworkthatare,sofarasisreasonablypracticable,safeandwithoutriskstohealth.Thefollowingadviceisaimedatassistingemployerstocarryoutthisduty.
Hazards
143 Faultfindingonpneumaticmachinerycanbehazardousifitisnotproperlyplanned.Themachinedesignshouldincorporatemeansofminimisingtheneedfortrialanderrormethodsoflocatingafault.Furtherassistancecanbegiventofaultfindingbyincorporatingdiagnostictechniqueswhichindicatetheareaofafault(seealsoparagraph100).
General information and advice
144 Theefficientsaferunningofacompressedairsystemreliesoncleanliness,filtration,coolingandlubrication.Thebestwayofachievingthesefourconditionsistooperatetheplantinaccordancewiththeoperator’smanualandtodrawupandfollowawrittenscheduleofmaintenanceworkwhichcanberevisedinthelightofexperience.Thisisaformofsafesystemofwork.Thewrittenscheduleshouldidentifyareasforattention,howoftenattentionshouldbegivenandtheresponsibilitiesofthosewhocarryoutandsupervisethework(seeparagraphs146and147).
145 Thefrequencyofinspectiondependsverylargelyonthecircumstancesandenvironmentinwhichtheplantisused.ThefrequencystatedinthisBookletshouldthereforebetakenasaguideonlyandadjustedtosuitparticularinstallationsinthelightofoperationalexperience.
Maintenance of compressors and ancillary plant
Supervision and procedures146 Smallcompressorunitsareeasilyoverlooked,especiallyifsitedinaseparate
enclosureoutsidetheworkingarea.Particularcareisneededtoseethatregularmaintenance,inspectionandtestingiscarriedout.Proceduresshouldbelaiddownandrecordskept.
147 Theusershouldnominatearesponsiblepersontosupervisetheproperoperationandmaintenanceofthecompressorplantinlinewiththemanufacturer’sinstructions.
148 Thispersonshouldregularlycheckthatallinstructionsregardingoperationandmaintenanceareproperlyfollowedandthatthecompressor,itsaccessoriesandsafetydevicesarekeptingoodworkingorder.Theresponsiblepersonshouldalsomakesurethatmaintenanceworkiscarriedoutonlybyadequatelytrainedstaff.
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149 Althoughtherearestatutoryrequirementscoveringsomeaspectsofmaintenance,thefollowingadditionalmaintenanceproceduresarerecommendedtominimisethelikelihoodofhazardsoccurring.
Daily150 Thecompressingplantshouldbekeptascleanandfreefromoildepositsas
possible.
151 Adailyroutinecheckshouldbecarriedoutonreciprocatingcompressors.Thecheckshould,whereapplicable,includethefollowing:
(a) thecoolingwatershouldbevisuallycheckedtomakesurethatitis circulatingproperlybyobservingtheflowoutletorflowindicator;
(b) theleveloftheoilinthecrankchambershouldbecheckedusinga dipstick,levelgaugeorotherdevice.Anyexcessiveusageoflubricating oilshouldbeinvestigated;
(c) theoilpressureshouldbechecked; (d) theoilfeedtothecylindersshouldbecheckedtomakesurethatit
isadequatebutnotexcessive.Oilconsumptionshouldberecorded, asexcessiveconsumptioncanoftenleadtoexplosionsdownstreamof thecompressor;
(e) theoutletairpressureandtemperatureshouldbechecked; (f) thecompressorperformanceshouldbecheckedegbylisteningforany
unusualnoisesduringrunning; (g) anydefectsfoundshouldberectifiedandarecordkept;and (h) attheendofeachdayanyaccumulationofoilandwatershouldbe
drainedfromtheairreceiver,theintercooler,theaftercoolerandmain supplypipes.
Checks mainly directed to reciprocating compressors
Weekly152 Eachweekthesafetyvalves(wheredesignallows)shouldbecheckedby
easingthembyhand.
600 hours153 Aftereach600hoursofrunning:
(a) thequalityofoilinthecrankcaseshouldbecheckedand,accordingto themanufacturer’srecommendations,replacedifnecessary;and
(b) theconditionoftheinletairfiltersshouldbecheckedandthoroughly cleanedorreplaced.Theintervalbetweensuccessivereplacements willbedeterminedbylocalcircumstancesbutis,toacertainextent, controlledbythecapacityofthefilterandthecleanlinessofthe atmosphereinthevicinity.Whereoilwettedviscousfiltersareused, spareunitsshouldbeprovidedandexcessoilshouldbedrained fromthefilterunitsforatleastfourtoeighthoursbeforetheunitsare replaced,exceptwherethemanufactureradvisesotherwise.
Six-monthly154 Whereoilcokedepositsareliabletooccur,theexplosionriskcanbereduced
bycarryingoutsix-monthlyinspectionsofthedeliveryportsandpipeworkandcleaningasrequired.Theperiodbetweeninspectionscanbemodifiedinthelightofexperiencegainedfromoperatingaparticularinstallation.
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2000 hrs or annually155 Aftereach2000hoursofrunningorannually(whicheveristhesooner): (a) inthecaseofoillubricatedcompressors,thedeliveryvalves,portsand
allthepipework,vesselsandfittingsbetweenthedeliveryportandthat pointinthesystem
atwhichtheairtemperaturecanbeconfidentlyexpectedtobebelow 80°C,shouldbeinspected.Anycarbonaceousdepositshouldbe effectivelyremoved;
(b) fusiblepelletsorcompleteplugsshouldbereplaced; (c) theconditionofprotectivedevicesshouldbecheckedandtestedto
determinethattheyoperatecorrectly; (d) theintercoolerandaftercoolersectionsshouldbecleaned; (e) theradiatorshouldbedrainedandwashedout; (f) theoutputcontrolgearshouldbecleanedandinspected;and (g) theairreceivershouldbethoroughlycleanedandexaminedinternally.
Precautions
156 Allmaintenancework,otherthanroutinecheckstofiltersdesignedforcleaningin-service,shouldbeundertakenonlywhenthecompressorhasbeenstopped,disconnectedandlockedofffromthepowersupplyandallinternalpressuredissipated.Otherprecautionsmayalsobenecessary:forexample,thecompressormayhavetobescotchedtopreventmovementofthemechanism.
157 Undernocircumstancesshouldflammableliquidsbyusedforcleaning.Appropriatesafetyprecautionsshouldbetakenagainstanytoxicvapoursliberatedduringusageofanycleaningordegreasingliquids.
158 Anopenflameshouldneverbeusedforinspectingtheinteriorofacompressor,pressurevesselorpipework.
Maintenance of air powered equipment
159 Dirtyand‘wet’airandworncomponentsareamongthemostcommoncausesofhazardsassociatedwithairpoweredequipment.
Supervision and procedures160 Theusershouldnominatearesponsiblepersontosupervisetheregular
inspectionandmaintenanceoftheequipment.Wheretheequipmentisextensive,someformofwrittensystemofplannedmaintenanceshouldbeusedandrecordsoftests,repairsandmodificationskept.
161 Inadditiontoanymaintenancerequiredbystatutoryrequirements,thefollowingmaintenanceproceduresarerecommended.
Daily162 Thesystemshouldbecheckedforleaksandrepairscarriedoutas
necessary.
163 Attheendofeachdayanyaccumulationofwatershouldbedrainedfromthedrainpoints.Thedrainvalvesshouldbeinspectedtomakesurethattheyarenotchokedwithsediment.
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Weekly164 Attheendofeachweek,airlinelubricatorsshouldbetoppedupas
necessarywiththecorrectgradeofoilandcheckedtoensurethattheyareprovidingadequatebutnotexcessivelubrication.Filtersshouldbecheckedandthosethatarecloggedorcausingunacceptableflowrestrictionsshouldbereplaced.
165 Similarly,onmachineswhichrequirepressureregulationbelowmainspressure,thepressureregulatorshouldbecheckedtomakesurethatithasnotbeentamperedwithandthatthecorrectpressureismaintained.
Monthly166 Allhoseswhicharesubjecttoflexingand/ormechanicaldamageshouldbe
inspectedforsignsofcrackingordeteriorationandreplacedasnecessary.Particularattentionshouldbepaidtoareasadjacenttocouplings.
Three monthly167 Everythreemonthsmachineswithinterlockingguardsshouldbechecked
tomakesurethatallinterlockingvalvesarefirmlysecuredandoperatedpositivelybytheircams.Checkthatwearinanylinkagesorvalveoperatingmechanismsisnotsoexcessivethatthevalveisindangerofmalfunctioning.
Six monthly168 Everysixmonthsallstopvalvesshouldbechecked.Checkthataccessto
thevalvehasbeenmaintained,thatthehandleisinposition,thatitwillshutofftheairsupplyandthatitwillopenfullyandoperatefreely.
Precautions
169 Beforeanypressurisedcomponentsaredismantledtheyshouldbeeffectivelyisolatedfromallpressuresourcesandcompletelyventedtoatmosphere.Precautionsshouldalsobetakentoguardagainstthepossibilityofinjurythroughsuddenreleaseoftrappedsprings.
170 Whencomponents,especiallyvalves,arefoundtobewornandservicekitsofsealsareusedtorebuildthem,careshouldbetakentocheckthoroughlythefunctionoftherebuiltvalvebeforeplacingitintheequipment.Forconvenience,manufacturersofservicekitsoftenincludeenoughsealstoservicearangeorfamilyofvalves,althoughnotallthesealsinthekitarerequiredforeachvalve.Incorrectsealreplacementcancompletelyalterthevalve’sfunctionandifreplacedintheequipmentcouldpresentaserioushazard.Manufacturersshouldsupplyclearinstructionsonhowtousesuchservicekitsproperlyandsupervisorsshouldensurethatthisinformationispassedontothepersoncarryingoutthemaintenance.
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Training Statutory requirements
171 Section2(2)(c)oftheHSWActandManagement Regulations and Regulations 8 & 9 of the Provision and Use of Work Equipment Regulations (PUWER)requireseveryemployertoprovidesuchinformation,instruction,trainingandsupervisionasisnecessarytoensure,sofarasisreasonablypracticable,thehealthandsafetyatworkoftheiremployees.Sections7and8oftheHSWActplaceresponsibilitiesonemployeestotakereasonablecaretoco-operatewithemployersandnottointerferewithormisuseanythingprovidedfortheirsafety.
Hazards
172 Allthosewho,inthecourseoftheirwork,needtousecompressedairmustbeproperlytrained.Manyaccidentswouldbeavoidedifadequatetrainingwasprovided.Itisprobablybecausecompressedairsuppliesaresocommonplace,beingfoundatmostgarageforecourts,forexample,thatemployersfalselybelievethattrainingintheiruseisunnecessary.
Precautions
173 Supervisorsandworkersincludingmaintenancepersonnelmustbegivenpropertraininginsafeworkingpractices.Thetrainingshouldstressthehazardsassociatedwithcompressedair(seeparagraph2)andshouldhighlightthefollowingpoints:
(a) compressedairshouldneverbeusedforcleaningclothing;vacuum cleanerswithbrushtypeheadsarepermissible.Forothercleaning operationsspecialnozzlesdesignedtoprovidelowpressure,high volumemaybeusedwithcare(seeparagraphs96band104);
(b) horseplaywithcompressedairisextremelydangerousandisstrictly forbidden.Employersshouldnotethatyoungpeopleinparticularmay requirespecialsupervisiontomakesurethattheybehaveproperly;
(c) whenusingcompressedairtoolstheexhaustingairshouldbedirected awayfromthebody;
(d) compressedairshouldneverbeusednearanakedflame; (e) anydefectsinequipmentshouldbereportedatonce;and (f) safetyandmonitoringdevicesshouldneverbemisusedorabused.
Further information
ThefollowingfivepublicationsareproducedbytheEuropeanCommitteeonManufacturersofCompressors,VacuumPumpsandPneumaticTools(PNEUROP):
Safety recommendations for the use and operation of portable air compressors London
Safety recommendations for the use and operation of stationary air compressors London
Pneumatic tools - safety in operationLondon
Compressedairsafety Page47of50
Health and Safety Executive
Safety recommendations for the use and operation of portable pneumatic tools London
Recommendations for the proper use of hand held and hand operated pneumatic toolsLondon1986
BritishCompressedAirSociety(BCAS)produces:Guide to the selection and the installation of compressed air servicesLondon,4theditionISBN090560802XandA guide to compressor noise reductionLondon,underrevision
EuropeanOilHydraulicandPneumaticsCommittee(CETOP)Hydraulic and pneumatic systems circuit diagramsLondon(PNEUROP,BCASandCETOPpublicationsareavailablefromtheBritishCompressedAirSociety,33/34DevonshireStreet,LONDONW1N1RF)
RoyalSocietyforthePreventionofAccidents(ROSPA)Beware compressed airBirmingham,(IS303)(availablefrom:ROSPA,CannonHouse,ThePriory,Queensway,BIRMINGHAMB46BF)
BritishAggregateConstructionMaterialsIndustryCompressed Air SafetyLondon(availablefrom:BritishAggregateConstructionMaterialsIndustry,25LowerBelgraveStreet,LONDONSW1OLS)
BritishCoalReciprocalaircompressors(surfaceandunderground)(NCBcodesandrulesseries)Doncaster(availablefrom:BritishCoal,HQMiningDepartment,TheLodge,SouthParade,DoncasterDN12DX)
British and European Standards
BS1041: Temperature measurementBS1041: Part2Expansion thermometers(insevenparts)BS1041 Section2.1:1992Guide to selection and use of liquid-in-glass
thermometersBS1041: Part3:1969Industrial resistance thermometryBS1041: Part4:1992ThermocouplesBS1041: Part5:1992Radiation pyrometersBS1041: Part7:1988Guide to selection and use of temperatureltime
indicatorsBS1123: Part1:1987Safety valves, gauges, gas and fusible plugs for
compressed air or inert installations: code of practice for installationsBS1710: 1991Specification for identification of pipelines and services BS1704: 1992Specification for solid stem general purpose thermometersBS1780: 1992Specification for bourdon tube pressure and vacuum gaugesBS2917-1 1993/ ISO 1219-1 Specification for graphic symbols used on
diagrams for fluid power systems and componentsBS3974: Specification for pipe supports(inthreeparts)BS3974: Part1:1974Pipe hangers, slider and roller type supportsBS3974: Part2:1978Pipe clamps, cages, cantilevers, and attachments to
beamsBS3974: Part3:1980Large bore, high temperature marine and other
applicationsBSEN286 Part1:1991Specification for simple unfired pressure vessels
designed to contain air or nitrogenBSEN292 Part1:1991Safety of machinery: Basic concepts, general principles
for design. Basic terminology, methodology Part2:Technical principles of specifications
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BSEN983 1996Safety of Machinery- Safety requirements for fluid power systems and their components-Pneumatics
BSEN1012-11997Compressors and vacuum pumps-Safety requirements Part 1 Compressors
BSEN1012-21997Compressors and vacuum pumps-Safety requirements Part 2 Vacuum pumps
BSEN837 Part1Bourdon tube pressure gauges-Dimensions, metrology,requirements and testing
Part2Selection and installation recommendations for pressure gauges
BSISO1219-1995Fluid power systems and components. Graphic Symbols and circuit diagrams
BS4575: 1987Part2:Code of practice for pneumatic equipment and systems 1988Part3:Fluid Power Transmission and Control SystemsBS4862: 1983Mounting dimensions of single rod double 10 bar pneumatic
cylindersBS4862: Part1:1983Specification for cylinders up to 25 ml boreBS5118: 1980Specification for general purpose rubber hoses for compressed
airBS5169: 1992Specification for fusion welded steel air receiversBS5304: 1988Code of practice. Safety of machineryBS5409: Specification for nylon tubing BS5409: Part1:1976Fully plasticized nylon tubing types 11&12 for use
primarily in pneumatic installationsBS5500: 1994Specification for unfired fusion welded pressure vesselsBS5791: Glossary of terms for compressors, pneumatic tools and machinesBS5791: Part11990GeneralBS5791: Part21990CompressorsBS5791: Part31990Pneumatic tools and machinesBS6005: 1997Specification for moulded transparent polycarbonate bowls used in compressed air filters and lubricatorsBS6066: 1986Specification for thermoplastics hoses for compressed airBS6244: 1982Code of practice for stationary air compressorsBS6754: 1986Specifications and testing of compressed air dryersBS6759: Safety valvesBS6759: Part1:1984Specification for safety valves for steam and hot waterBS6759: Part2:1984Specification for safety valves for compressed air or inert gasesBS7226: 1989Methods of test for performance of inlet air cleaning equipment for internal combustion engines and compressors
BritishStandardsareavailablefrom:BSISalesandCustomerServices389ChiswickHighRoadChiswickLondonW44ACTel01819967000Fax01819967001
Health & Safety Executive publications
Pneumatic nailing and stapling guns 1979,(Guidancenote,plantandmachinery/PM17),ISBN0118831925
Noise from pneumatic systems1985,(Guidancenote,plantandmachinery/PM56),ISBN0118835297
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Safety in pressure testing1992(Guidancenote,generalseries/GS4)ISBN0717608115
Safety of pressure systems. Pressure Systems and Transportable Gas Containers Regulations 1989 Approved Code of Practice COP371990ISBN011885514X
A guide to the Pressure Systems and Transportable Gas Containers Regulations 1989 ISBN0118855166
Legal requirements
SupplyofMachinery(Safety)Regulations1992(asamended1994)ISBNS0-11-025719-7&0-11-045063-9
ProvisionandUseofWorkEquipmentRegulations1992(asamended1997)
ManagementofHealthandSafetyatWorkRegulations1992
MinesandQuarriesAct1954,HMSO,ISBN0108503895
PersonalProtectiveEquipmentRegulations1992
HealthandSafetyatWorketcAct1974,chapter37,HMSO,ISBN0105437743
ElectricityatWorkRegulations1989
ThePressureSystemsandTransportableGasContainersRegulations1989(SI1989No2169),HMSO,ISBN0110981693
The future availability and accuracy of the references listed in this publication cannot be guaranteed.
Further informationForinformationabouthealthandsafetyringHSE’sInfolineTel:08453450055Fax:08454089566Textphone:08454089577e-mail:[email protected],CaerphillyBusinessPark,CaerphillyCF833GG.
HSEpricedandfreepublicationscanbeviewedonlineororderedfromwww.hse.gov.ukorcontactHSEBooks,POBox1999,Sudbury,SuffolkCO102WATel:01787881165Fax:01787313995.HSEpricedpublicationsarealsoavailablefrombookshops.
BritishStandardscanbeobtainedinPDForhardcopyformatsfromtheBSIonlineshop:www.bsigroup.com/ShoporbycontactingBSICustomerServicesforhardcopiesonlyTel:02089969001e-mail:[email protected].
TheStationeryOfficepublicationsareavailablefromTheStationeryOffice,POBox29,NorwichNR31GNTel:08706005522Fax:08706005533e-mail:[email protected]:www.tso.co.uk(Theyarealsoavailablefrombookshops.)StatutoryInstrumentscanbeviewedfreeofchargeatwww.opsi.gov.uk.
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