Top 12 Compressed Air Safety Guidelines

Top 12 Compressed Air Safety Guidelines

1. Never apply compressed air to the skin or direct it at a person. Even air at a pressure of 15 psig can cause serious injury. Never use a compressed air hose to clean dirt or dust from your clothing or body.

2. When using compressed air for cleaning purposes, ensure pressure does not exceed 30 psig (per OSHA regulations). Always use goggles or a face shield over approved safety glasses for this application.

3. Wear ear protection. Exposure to excessive noise can damage hearing. Noise reducing mufflers can be fitted to machines to lessen the noise health hazard.

4. Never crimp, couple, or uncouple pressurized hose. Shut off valves and bleed down pressure before making any hose connections.

5. Use heavy duty clamps and fittings made especially for compressed air hose.
Use only the correct type and size of hose end fittings and connections.

6. Never use frayed, damaged or deteriorated hoses. Always store hoses properly and away from heat sources or direct sunlight. A hose failure can cause serious injury. Hose Reels can decrease your chances of injury, as well as help hoses last longer.

7. When blowing compressed air through a hose or air line, ensure that the open end is held securely. A free end can whip and can cause injury. Open the supply air valve carefully and ensure that any ejected particles will be restrained. A blocked hose can become a dangerous “compressed air gun.”

8. Make sure all hoses exceeding 1/2 inch ID have a safety device at the source of supply or branch line to reduce the pressure in case of hose failure (per OSHA regulations).

9. Do not use air directly from a compressor for breathing purposes unless the system has been specifically designed for such purpose and suitable breathing air filters and regulators are in place.

10. Isolating valves should be of the self venting type and designed to be locking in the "off" position so that air pressure cannot be applied accidentally while the machine is being worked on.

11. Never alter or install an A.S.M.E. safety relief valve that has a higher PSIG rating than the pressure vessel rating to which it is installed.

12. Only pressure vessels built to a national or international standard should be used for air receivers.

Download a FREE color Safety Poster - click here
Print it out and post it near your compressors.

Provided for your safety by
McGuire Air Compressors, Inc.
1-888-229-9999
compressors@mcguire.biz
www.industrialaircompressors.biz

TOP TEN Compressed Air "Rules of Thumb"

Here are our TOP TEN Compressed Air "Rules of Thumb" that we've come up with throughout our 25+ years of experience. These are the things that our compressor customers seem to ask about most.

1. Air Compressor CFM delivery per Horse Power at 100 PSIG:
• For "home owner" type of air compressors---2 to 2.5 CFM per HP
• For Industrial Air-cooled 2-stage air compressors----3.5 CFM per HP
• For Small Vane & Screw air compressors (25 HP or less) 4 CFM per HP
• For large Piston, Screw & Centrifugal air compressors--4.5 to 5 CFM per HP

NOTE: THE MORE CFM PER HP - THE LESS ENERGY USED.

2. Air Receiver Size needed for these types of inlet control:
• Modulating Control------------ 0 to 1 gallon per CFM
• On-Line/Off-Line-------------- 3 to 4 gallons per CFM
• Stop-Start / Variable Speed--- 4 to 6 gallons per CFM

NOTE: THE MORE AIR STORAGE - THE LESS ENERGY USED


3. Amperage per Horse Power:
115 Volts-------1 phase--------10 amps per horse power
230 Volts-------1 phase-------- 5 amps per horse power
208 Volts-------3 phase-------- 3 amps per horse power
230 Volts-------3 phase-------- 2.5 amps per horse power
460 Volts-------3 phase-------- 1.25 amps per horse power
574 Volts-------3 phase-------- 1 amp per horse power

NOTE: THE MORE ENERGY EFFICIENT THE MOTOR - THE LESS ENERGY
IS USED.

4. Air Piping Size by CFM and Pressure Drop:
• Compressor Room Header--0.25 PSIG pressure drop per 100 feet of piping
• Main Line---------------0.5 PSIG pressure drop per 100 feet of piping
• Loop Line---------------1 PSIG pressure drop per 100 feet of piping
• Branch Line-------------2 PSIG pressure drop per 100 feet of piping

NOTE: THE LESS AIR PRESSURE DROP - THE LESS ENERGY USED.

5. Size Compressed Air Line Filters to be twice (2x) your compressor CFM flow rate.
• This will lower your pressure drop approximately 2-3 PSIG and save 1% on energy costs.
• Elements will last twice (2x) as long and save on maintenance costs.

6. Lowering Compressor Pressure settings 2 PSIG will result in a 1% energy savings.

7. Lowering Compressor Inlet Air Temperature 10° F will result in a 2% energy savings.

8. The average energy cost to operate an air compressor is approximately $0.10 per horse power per hour.

9. Compressed air system leaks totaling the size of a ¼" orifice, at 100 PSIG, running 24 hours a day will waste approximately $15,000 worth of electrical energy a year.

10. Using Synthetic Compressor Lubricants can save you up to 9% of the energy cost of operating your compressor.


>>>>Click here to learn more about basic air compressor maintenance>>>>

Warm weather increases harmful compressed air moisture

Ask a Question:
There is more moisture in my compressed air in the warm weather. Can this water or moisture be damaging my compressed air system?

Answer:

Absolutely! Water corrodes pipes, valves, machinery controls. None of this is good. When controls malfunction, production can stop or product can be impaired and all this costs you time and money.
In summer’s warmer temperatures moisture and condensation occurs more frequently.

Why? The reason is warm air can hold more moisture than cooler air. Therefore when the temperatures rise in the heat of spring and summer, then the amount of moisture in the air around you and your compressed air also rises. In more humid regions of the country, compressed air systems can be challenged by this moisture increase.

Many processes need to remove moisture from their compressed air. One such example is spray painting. Condensed water droplets in a painting process can ruin the end result. Other examples are pharmaceutical production and medical applications that need clean, dry compressed air.

Ask a Question:

How does water or moisture get into my compressed air?


Answer:

Through your Compressor inlet.

Water vapor (humidity-moisture) enters the air system through the air compressor inlet air filter.
The air compressor sucks in approximately 7 cubic feet of atmospheric air at 0 psig, and that volume of air is compressed into 1 cubic feet of air at 100 psig.

The water vapor (humidity-moisture) that was in the seven (7) cubic feet of atmospheric air is now compressed into ONE (1) cubic feet of compressed air.


There are 3 forms of water in compressed air:

1. Liquid water
2. Aerosol (mist)
3. Vapor (gas)

Water in Aerosol or Vapor form is more difficult to remove and requires the use of a Compressed Air Dryer.
Refrigerated Air Dryers can be the solution to water and moisture in your Compressed Air System

HOW A REFRIGERATED AIR DRYER WORKS

The refrigerated air dryer cools the incoming compressed air first in an air-to-air heat exchanger where the outgoing cool dry air pre-cools the hot incoming air and condenses some moisture out.

Then the incoming air enters an air-to-refrigerant heat exchanger where the air is cooled to 38º F by the liquid refrigerant. This process causes the moisture to condense into liquid water and it is drained away.

The out going air then enters the air-to-air heat exchanger and is warmed up to keep the outside of pipes from sweating.

The refrigeration compressor pumps hot hi-pressure gas refrigerant (Freon) into the condenser which transfers the heat from the refrigerant gas to the ambient air as the gas condenses into a liquid.

The liquid refrigerant (Freon) is then metered to a cold low pressure where it enters the air-to-refrigerant heat exchanger and the heat from the hot compressed air is adsorbed into the cold refrigerant (Freon). The refrigeration compressor then sucks low pressure hot gas refrigerant (Freon) into the refrigeration compressor and the cycle starts over again.



Tommy McGuire
Owner of McGuire Air Compressors, Inc.
“Real People with Real Air Compressor Experience”

1-888-229-9999

Email: compressors@mcguire.biz

Learn more about Refrigerated Air Dryers

How to prevent moisture from damaging your compressed air system

Ask a Question:
Can moisture damage my compressed air system?

ANSWER:
Liquid water in a compressed air stream increases the cost of operation. It contributes to unnecessary product rejects and countless hours of unscheduled maintenance. Air tool lubricant gets washed away creating unnecessary wear. Highly acidic, this condensed water eats away at air motors and valves and, contaminates finished goods.
Invest in the correct drying technology for your application and the compressed air lines stay dry. Dry air will also pay your big dividends for years to come.

Ask a Question:
How does damaging moisture get in your compressed air system?

ANSWER:
At an ambient temperature of 75°F and 75% relative humidity, a typical 100 HP (500 scfm) air compressor inhales 90 gallons of water vapor every 24 hours. Discharging air at 100°F and 100 psig, a well maintained aftercooler may remove about 57 gallons. That leaves 33 gallons inside your air system.

At the CAGI ADF 100 design standard of 38°F, a refrigerated dryer removes an additional 29 gallons. The remaining 4 gallons safely pass through the system as water vapor. Because there is usually a rise in air temperature during compression, condensation often does not occur within your compressor itself.

Condensation in your compressed air system usually happens as compressed air cools when passing through the discharge piping. This condensed water must be drawn out of your line by a separator and a trap. While approximately two-thirds of the water vapor is converted to liquid from the system in an effective aftercooler, there is still a lot of water vapor remaining in the compressed air which is "saturated" at the exit temperature from the aftercooler.

Compressed Air Dryers have been designed and developed to help remove water vapor from the compressed air in a controlled manner in order to provide you with a required "quality of dry air" needed for your equipment and processes.

Ask a Question:
How DRY should my compressed air be?

ANSWER:
"Dryness" can be relative. Air that is dry for one type of application my not be dry enough for another. There will always some moisture present in your compressed air system regardless of the degree of drying.
There are different types of dryers available with varying degrees of moisture removal. First - you need to determine the required "degree of dryness" for your Compressed Air System, which is specified in the "Pressure Dew Point" (PDP) at a certain pressure.

It is not a good practice to specify a pressure dew point a lot lower than your application's requirements. This can result in more costly equipment and increased operating expenses. Determining the PRESSURE DEW POINT TEMPERATURE will help you determine the "dew point class" of the dryer you need.

Ask a Question:
What is "PRESSURE DEW POINT"?

ANSWER:
Pressure Dew Point - For a given pressure, the temperature at which water VAPOR will begin to condense INTO liquid water.

Ask a Question:
What pressure dew point do I need?

ANSWER:
First - here's some information to help you understand pressure dew point: The lowest pressure dew point class for a refrigerated dryer is Class 4. Class 4 delivers a pressure dew point of +38°F.
Refrigerated dryers should not operate below the Class 4 range because the water vapor will freeze in the dryer. The highest pressure dew point for a refrigerated dryer is Class 6. Class 6 delivers a pressure dew point of +50°F.
The highest practical pressure dew point because higher pressure dew point causes condensation in downstream piping.

WAYS TO DETERMINE PRESSURE DEW POINT:
1. Ask the Manufacturer what the pressure dew point (PDP) requirements are for your equipment.
2. You can CALCULATE PRESSURE DEW POINT TEMPERATURE you need.

Here's how:
1. Determine the lowest ambient temperature your compressed air piping system will be exposed to.
Check the location of air lines throughout air conditioned or unheated areas underground or between buildings. (For example, your compressor and piping is inside your facility and the lowest air temperature it would ever be exposed to is 58ºF.)

2. Now you need to take that temperature number and lower it by 20º. (For example, your 58ºF lowest ambient temperature -20º = (38º PDP NEEDED)
This will give the PRESSURE DEW POINT TEMPERATURE needed to prevent liquid water forming downstream.

Determining the PRESSURE DEW POINT TEMPERATURE will help you determine the "dew point class" of the dryer you need. These "classifications" are industry standards for compressed air dryers as established by the ISO (International Organization for Standardization).

ISO 8573.1 AIR QUALITY CLASSES of PRESSURE DEW POINTS
THAT APPLY TO REFRIGERATED AIR DRYERS:
Class 4 maximum pressure dew point +38 º F
Class 5 maximum pressure dew point +45 º F
Class 6 maximum pressure dew point +50 º F

The lower the dew point, the dryer the air. These "classifications" are industry standards for compressed air dryers are established by the ISO (International Organization for Standardization).

Ask a Question:
What is the most popular type of compressed air dryer?

ANSWER:
The REFRIGERATED AIR DRYER has become the most widely used dryer in general industrial plant air applications, providing a pressure dew point of 35°F to 39°F.

Refrigerated dryers deliver 33°F to 39°F dew point to provide the best value with low initial cost and low cost of operation. They are the best choice when the ambient temperature where the compressed air is used will remain higher than the pressure dew point. A 33°F to 39°F dew point is ideal for most indoor areas wherepeople comfort is maintained.

Ask a Question:
How does a Refrigerated Air Dryer work?

ANSWER:
The basic principle is similar to a domestic refrigerator or home air conditioning system. The compressed air is cooled in an air-to-refrigerant heat exchanger to about 35°F, at which point the condensed moisture is drained off. The air is then reheated in an air-to-air heat exchanger by means of the incoming air, which also is pre-cooled before entering the air-to-refrigerant heat exchanger.

This means that the compressed air leaving the dryer has a pressure dew point of 35°F to 40°F. A lower dew point is not feasible in this type of dryer as the condensate would freeze at 32°F or lower. In a non-cycling refrigerated dryer, the refrigerant circulates continuously through the system.

Because both the flow of compressed air and ambient temperatures vary, a hot gas bypass valve is often used to regulate the flow of the refrigerant and maintain stable operating conditions within the refrigerant system.
Usually in most designs, the refrigerant evaporated within the air-to-refrigerant heat exchanger (evaporator) and is condensed after compression by an air- or water-to-refrigerant heat exchanger (condenser.) This type of design provided a rapid response to changes in operating loads.

Four Advantages of Refrigerated Air Dryers:
• Low initial capital cost
• Relatively low operating cost
• Low maintenance costs
• Not damaged by lubricant in the air system

*Refrigerated air dryers do have a limited dew point capability. Where a pressure dew point of less than 35°F is required, a refrigerant-type dryer cannot be used.

For more in-depth information visit www.AirDryers.biz

Compressed air definitions you should know from Compressed Air & Gas Institute:
Dew Point - The temperature at which moisture in the air will begin to condense if the air is cooled at constant pressure. At this point the relative humidity is 100%.Dew points may be expressed at an operating pressure or at atmospheric pressure. Operating pressure should be specified when using "pressure dew point."

Pressure Drop - Loss of pressure in a compressed air system or component due to friction or restriction.Typically, the pressure drop through a compressed air dryer is 3 to 5 psi and should be taken into account in system requirements.

SOURCES:"Improving Compressed Air System Performance- A sourcebook for industry" U.S. Department of Energy Energy Efficiency and Renewable Energy; "Best Practices for Compressed Air Systems" by CA; Compressed Air & Gas Institute (CAGI).

Keys to maintaining an efficient compressed air system

Ask a Question:
"What are the keys to maintaining an efficient compressed air system?"

Answer:
Key #1: PREVENTIVE MAINTENANCE

"What is the key to maintaining an efficient compressed air system?" The best reply would have to be -- Preventive Maintenance.

WHAT IS PREVENTIVE MAINTENANCE?
According to "Wikipedia": Preventive maintenance (PM) has the following meanings:

"The care and servicing by personnel for the purpose of maintaining equipment
and facilities in satisfactory operating condition by providing for systematic
inspection, detection, and correction of incipient failures either before they
occur or before they develop into major defects. Maintenance, including tests,
measurements, adjustments, and parts replacement, performed specifically to
prevent faults from occurring."

*Source: from Federal Standard 1037C and from MIL-STD-188 and from the Department of Defense Dictionary of Military and Associated Terms

Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on. In addition, workers can record equipment information and deterioration so they know to replace or repair worn parts before they cause system failure.

The ideal preventive maintenance program would prevent all equipment failure before it occurs.

BENEFITS OF PREVENTIVE MAINTENANCE:
-Improves system reliability and helps keep equipment working and/or extend the life of the equipment.
-Decreases system downtime and actively helps prevent unbudgeted maintenance expenses from cropping up.
-Decreases the cost of having to replace equipment as often.
-Records operational data that can help you troubleshoot an emerging problem (called "Data Trending")
Data trending is the recording of basic operation parameters including pressures, temperatures, and electrical data. For example, a slowly increasing temperature indicates a variety of maintenance requirements including cooler core cleaning, overloading of system and possible mechanical problems. Another example might include slowly decreasing pressure, indicating increased system flow requirements, reduced compressor performance or increased system leakage. Make sure someone is looking at this data on a regular basis. If the data is never reviewed then the benefit is lost.

THE VALUE OF PREVENTIVE MAINTENANCE:
To determine how valuable regular air compressor PM is to you and your business... you need to know what your "down-time" is worth. In some operations, down-time can cost hundreds, even thousands of dollars an hour.

There are many misconceptions about preventive maintenance...one being that it costs too much. This line of thinking says regularly scheduled downtime for maintenance costs more than operating the equipment until repair is absolutely necessary...or until the equipment breaks. This may be true for some components, but don't forget to consider the long-term benefits and savings associated with preventive maintenance that have been previously mentioned.

If regular Preventive Maintenance can help reduce unexpected downtime that results in loss of production, time and materials or the ruining of an expensive plant process--then it is well worth the investment. Not to mention that unscheduled shut-downs can be extended if the correct equipment parts or repair technicians are not readily available.
"How effective is your PM program?"
The answer is: "If your PM program isn't finding problems, it isn't effective."

Key #2: CORRECTIVE MAINTENANCE
Corrective maintenance, usually called "repair", is conducted to get equipment working again or fix any problems found during Preventive Maintenance.

The primary goal of maintenance is to avoid or reduce the consequences of failure of your compressed air equipment. PM is designed to preserve and restore equipment reliability by replacing worn components before they actually fail.


Key #3: ASSESSING YOUR EQUIPMENT: When to maintain and when to replace.

Here are several factors to consider when assessing your compressed air equipment:
-How critical is your compressed air equipment? If equipment fails, what is the impact on production or safety.
-What is the age & history of your equipment.
Equipment histories will prove that most failures occur during infancy (newly installed or recently overhauled) and old-age (self-explanatory).
How many times has this equipment failed in the past?
-How much do you trust this equipment to perform as designed when scheduled to run?
-Do you need newer technology on your equipment?

Assessing the answers to these questions will help you determine when your older equipment needs fixing or replacing. Preventive Maintenance will help your equipment last longer, run better, and save you loads of money in the long haul.

Key #4: KNOWING YOUR EQUIPMENT WHAT IT NEEDS:
-Every piece of compressed air equipment should come with a set of MAINTENANCE INSTRUCTIONS and some type of operations& parts manual. Your operators should review the equipment information and keep it handy for future reference. If you purchased used equipment and don’t have the manuals, contact your equipment distributor for a copy.
- Follow the maintenance guidelines for your equipment.


BASIC PREVENTIVE MAINTENANCE CHECK LIST FOR
RECIPROCATING (PISTON) AIR COMPRESSORS:

Before performing any maintenance function, switch main disconnect switch to "off" position to assure no power is entering unit. "Lock Out" or "Tag Out" all sources of power. Be sure all air pressure in unit is relieved. Failure to do this may result in injury or equipment damage.

DAILY MAINTENANCE

1. Check oil level of both compressor and engine if so equipped. Add quality air compressor lubricant as required.
2. Drain moisture from tank by opening tank drain valve located in bottom of tank. Do not open drain valve if tank pressure exceeds 25 PSIG.
3. Stop, Look & Listen for any unusual noise, failure to compress, overheating, vibrations or belt slippage and correct before damage of a serious nature develops.
4. Turn off compressor at the end of each day's operation. Turn off power supply.

WEEKLY MAINTENANCE
1. Clean dust and foreign matter from cylinder head, motor, fan blade, air lines, intercooler and tank.
2. Remove and clean intake air filters
WARNING
Do not exceed 15 PSIG nozzle pressure when cleaning element parts with compressed air. Do not direct compressed air against human skin. Serious injury could result. Never wash elements in fuel oil, gasoline or flammable solvent.

3. Check V-belts for tightness. The V-belts must be tight enough to transmit the necessary power to the
compressor. Adjust the V-belts as follows:
a. Remove bolts and guard to access compressor drive.
b. Loosen mounting hardware which secures motor to base. Slide motor within slots of base plate to
desired position.
c. Check the manufacturer’s specifications for correct belt tension. Apply pressure with belt tension checker to one belt at midpoint span. Make further adjustments if necessary.
d. Check the alignment of pulleys. Adjust if necessary.
e. Tighten mounting hardware to secure motor on base.
f. Re-install guard and secure with bolts.

WARNING
Never operate unit without belt guard in place. Removal will expose rotating parts which can cause injury or equipment damage.

EVERY 90 DAYS OR 500 HOURS MAINTENANCE
1. Change crankcase oil. Use type and grade oil as specified.
2. Check entire system for air leakage around fittings, connections, and gaskets, using an ultrasonic leak detector or using soap solution and brush.
3. Tighten nuts and cap-screws as required.
4. Check and clean compressor valves, replace gasket valve asssembly when worn or damaged.

CAUTION
Valves must be reinstalled in original position. Valve gaskets should be replaced each time valves are serviced.

5. Pull ring on all pressure relief valves to assure proper operation.

GENERAL MAINTENANCE NOTES:

PRESSURE RELIEF VALVE: The pressure relief valve is an automatic pop valve. Each valve is properly adjusted for the maximum pressure permitted by tank specifications and working pressure of the unit on which it is installed. If it should pop, it will be necessary to drain all the air out of the tank in order to reseat properly. Do not readjust.

TANK DRAIN VALVE: Drain valve is located at bottom of tank. Open drain valve daily to drain condensation.
Do not open drain valve if tank pressure exceeds 25 PSIG. The automatic tank drain equipped compressor requires draining manually once a week.

PRESSURE SWITCH: The pressure switch is automatic and will start compressor at low pressure and stop when the maximum pressure is reached. It is adjusted to start and stop compressor at the proper pressure for the unit on which it is installed. Do not readjust.

BELTS: Drive belts must be kept tight enough to prevent slipping. If belts slip or squeak, see V-belt maintenance in preceding section.

CAUTION
If belts are too tight, overload will be put on motor and motor bearings.

COMPRESSOR VALVES: If compressor fails to pump air or seems slow in filling up tank, disconnect unit from power source, drain air tank, and remove valves and clean thoroughly, using compressed air and a soft wire brush.
After cleaning exceptional care must be taken that all parts are replaced in exactly the same position and all joints must be tight or the compressor will not function properly.
When all valves are replaced, perform a timed pump-up test and check to see that it meets factory specifications.
Valve gaskets should be replaced each time valves are removed from pump.


Bottom Line:

One of the main keys to maintaining an efficient compressed air system has been and still is “Preventive Maintenance.”

Tommy McGuire

Owner of McGuire Air Compressors, Inc.

“Real People with Real Air Compressor Experience”

For FREE information about Champion Industrial Air Compressors and Filters -

visit www.industrialaircompressors.biz

Email: compressors@mcguire.biz

Call 1-888-229-9999