Air compressor

Main components of a compressor

•Electric motor
•Compressor
•Coolers
•Air Receiver
 Compressor hazards
•Overpressurisation leading to explosions
•Mechanical hazards associated with the
Belt and pulley drives
•Projections due to rupture of hoses
•Noise
 Overpressurisation
Overpressurisation,which may arise from:
(a)A blocked outlet or some other restriction to flow;
(b)failure of automatic controls combined with low air
consumption;
(c) compressor malfunction,eg overspeeding;
(d) an external fire near the pressure system; and
(e) overheating and the build-up of carbonaceous deposits, both
of which can lead to fires or explosions. Although they are rare,
fires and explosions can also occur as a result of oil or oil vapour
being ignited in the pressure system.
(f) Dirty or ‘wet’ air can cause a system to fail eg by causing
fine particles of debris to agglomerate, blocking safety related
valves.
Mechanical hazards
 Safety Features of a compressor
Safety valves
On all medium or large multi-stage positive displacement
compressors a safety valve should be fitted between each stage
and, where appropriate, in the inter or after cooler circuit.

Pressure indication
An accurately calibrated air pressure gauge with a readily visible
appropriate scale-reading should be provided after each stage of
compression.

Thermal protection
To minimise the risk of overheating, large compressors should be
provided with a suitable thermal protective device as near as
practicable to the last stage discharge valve
 Safety Features of a compressor (2)
Coolant protection
If the compressor is water cooled, a thermostat should be
provided to the cooling water outlet or water return to the
radiator header tank to shut down the compressor when the
water temperature exceeds the manufacturer’s recommended
maximum.

Lubricant protection
On medium and large compressors a pressure-sensing device
should be provided to shut down the compressor and activate
visible and audible alarms if the lubricating oil pressure drops
below the manufacturer’s recommended minimum.
 Precautions with air receivers
•Air receivers must be cleaned and examined at regular
intervals
•When connected to an air compressing plant a
receiver should either be constructed to withstand the
compressor’s maximum pressure safely, or be fitted
with a safety valve and a pressure-reducing valve
•The receiver should be fitted with a suitable safety
valve
•There should be a suitable appliance, either manual or
automatic, for draining the receiver
•A receiver should have a suitable manhole or other
means
 Coolers
•Many aftercoolers are pressure vessels and the
associated hazards are similar to those of air
receivers
•Intercoolers and aftercoolers lower the
temperature of the compressed air. These
coolers are usually water or atmospheric air
cooled.
 Noise
Noise control measures, if required, include the
following:
(a) Siting the compressor away from work areas;
(b) providing the compressor with an acoustic
enclosure( the need for access and removal for
maintenance will need to be addressed);
(c) providing anti-vibration mountings;
(d) the fitting of or improving the performance of
silencers;
(e) access to enclosures provided for compressors
should only be permitted to persons wearing suitable
and effective ear protection.
 Section 59 of OSHA 2005 - Air receivers
(1) Every air receiver and every part thereof and all its fittings shall be of good
construction, sound material, adequate strength and free from patent defect, and shall be
properly maintained.

(2) Every air receiver shall–

(a) have marked upon it, so as to be clearly visible, the safe working pressure;
(b) in the case of a receiver connected with an air compressing plant, either be so
constructed as to withstand with safety the maximum pressure which can be obtained in the
compressor, or be fitted with a suitable reducing valve or other suitable appliance to prevent the
safe working pressure of the receiver being exceeded;
(c) be fitted with a suitable safety valve so adjusted as to permit the air to escape as soon
as the safe working pressure is exceeded;
(d) be fitted with an accurate pressure gauge indicating the pressure in the receiver and
have marked on the face of the gauge in a distinctive colour the safe working pressure.
(e) be fitted with a suitable appliance for draining the receiver other than a vessel
specified in paragraphs (b) and (d) in the definition of “air receiver”;
(f) be provided with a suitable manhole or other means which will allow the interior to
be thoroughly cleaned; and
(g) where there is more than one receiver in use in the place of work, bear a
distinguishing mark which shall be easily visible.
 Section 59 of OSHA 2005 - Air receivers
(3) For the purpose of subsection (2), relating to safety valves and pressure
gauges, any set of air receivers supplied with air through a single pipe may be treated
as one receiver but in the case where a suitable reducing valve or other suitable
appliance to prevent the safe working pressure being exceeded is required to be
fitted, this subsection shall not apply unless the valve or appliance is fitted on the said
single pipe.

(4) Every air receiver shall be thoroughly cleaned and examined at least once
every 12 months except that in the case of a receiver of solid drawn construction if it is
so constructed that the internal surface cannot be thoroughly examined, a suitable
hydraulic test of the receiver shall be carried out in lieu of internal examination at
least once every 24 months.

(5) Every examination and test specified in subsection (4) shall be carried out by
a registered machinery inspector and the original report of the result of every such
examination and test in the form set out in the Eighth Schedule shall be sent by the
owner to the Director, Occupational Safety and Health within 28 days of the
completion of the examination.