osha air compressor safety valve free sample

An OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES should be placed immediately after the air control shut off valve and before the hose on a compressor, and after each discharge port that a hose is connected to.

Before starting the compressor the air control valve should be closed completely. When the compressor unloads, open the air shut off control valve very slowly. Full port ball valves tend to work better than gate or butterfly type valves.

The air shut off control valve must be fully open for the OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES to work. Some portable air compressor manufacturers recommend start-up with the air control valve slightly open. In this case you may have to close the valve and reopen it slowly to the full open position, or wait for the safety shut-off valve to reset itself.

If the OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES fails to operate despite meeting all condi-tions, check the hose line for obstructions or a hose mender restricting normal air flow.

• Turn on air supply slowly (to avoid tripping OSHA safety valve). Prior to fully reaching operation conditions, the OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES should suddenly activate and stop air flow.

• If the OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVE is not activated the unit should be disconnected and the lower flow range OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES should be used. This means you need to use a different valve with a lower scfm range.

• At temperatures below 40°F ensure that OSHA COMPRESSED AIR SAFETY SHUT-OFF VALVES are not subject to icy conditions which may prevent proper functioning.

Thank you for your letter dated January 31 concerning your constituent, Mr. James Lyle McCloy II, President of Compressed Air Parts Company. Mr. McCloy is concerned about the lack of enforcement by the Occupational Safety and Health Administration (OSHA) of its rules requiring safety check valves on compressed air equipment. I apologize for the delay of this response.

As Mr. Roy Gurnham of my staff discussed with Mr. Mark Staudohar of your office in mid-February when he called to explain we could not meet with Mr. McCloy at the time, OSHA continues to recognize the need for safety check valves and is concerned that accidents have occurred because such valves were not provided as required. We will remind our compliance officers of the importance of this provision and that their inspections should include a review of such equipment as appropriate.

As you may be aware, the State of Arizona is responsible for occupational safety and health enforcement within the State under a plan approved and monitored by Federal OSHA. Under its plan, Arizona adopts standards identical to those promulgated by Federal OSHA and utilizes equivalent enforcement procedures. If your constituent wishes to discuss safety and health enforcement in Arizona, we suggest that he contact the Arizona industrial Commission at the following address:

The enclosed information is sent for your consideration. Please investigate this matter and forward to me the information for response to my constituent, Mr. James Lyle McCloy II, President of Compressed Air Parts Company.

Introducing our product in mid 1972, with several other manufacturers, sales were quite brisk and the Department of Labor was very active insuring compliance. Since early 1976 enforcement has been very `spotty". As of this time only ourselves and one other manufacturer are still providing valves to meet Federal Regulations. Fortunately we have been the primary source.

Recently we were dismissed from a One Million Dollar ($1,000,000) product liability suit in which it was determined that the air compressor in use was not equipped with a safety check valve as required. This incident took place on a Federally funded Interstate bridge repair contract. Also, there is currently a multi-million suit concerning the lack of a safety check valve (actually there was a valve on the compressor but was removed for unknown reasons). In that case a worker has a severe head injury and has been in a nursing home for two years and cannot recognize his family.

Safety should be the priority in any workplace environment, whether it’s a construction site, a factory or another setting. Business leaders want to make sure their employees are safe, maintain high morale among their workforce and reduce the possibility of damaged or broken machinery. By employing practical safety measures, your company can benefit from increased uptime and fewer repair or replacement expenses.

Having safety measures in place is especially important when working with air compressors and other high-powered machinery. Compressed air should be treated with the same amount of care as other energy sources, as misuse or a lack of the proper precautions can present risks. It’s essential that all operators have the proper training, have read all instruction manuals thoroughly and understand how to mitigate safety risks and potential damage. Manuals contain an abundance of valuable information and will tell you how to keep your compressors running for longer periods without damage or injury.

There are also plenty of other resources that discuss how to maintain safety when operating pneumatic tools and air compressors. This guide will take you through the basics of using an air compressor, what to check before use, what to monitor and how to keep operators and workspaces safe to minimize air compressor dangers.

Air compressors are useful for many jobs, but they can also become dangerous when not maintained properly or misused. Compressor machines, hoses, pneumatic tools and electric connections can all pose hazards in the workplace. Air compressor accidents could potentially cause harm to workers and machinery.

What are some of the most common hazards related to air compressors? They include electrical dangers, fumes, flying particles, high pressures and high noise levels.

Flying particles and debris: Highly pressurized air and pneumatic tools can cause flying debris. If it strikes an operator, the pieces can cause bodily injury, or they can become lodged in the machine, causing damage.

High pressures:If high-pressure air is injected into the body, dangerous conditions and injuries, such as air embolism, ruptured eardrums and ruptured organs, can result.

Operators and workers can mitigate these dangers by following proper safety measures and air compressor precautions, which we will discuss later in the guide.

Depending on where you’re working, the intake air can contain pollutants and contaminants that are harmful to your health. From carbon monoxide to dust and debris, the air in the compressor collects from the surrounding space. To keep yourself safe while using the compressor unit, you must work in an area with proper airflow or natural air access, as well as protective gear, such as a respirator or dust mask.

While the likelihood of a workplace fatality due to an air compressor failure is low, it can happen in some extreme circumstances. If a compressor tank explodes, it can endanger your workers’ lives, but typically, the highest amount of danger lies with the operator. Due to the high pressures and pneumatic tools attached, operators must abide by all safety rules and regulations, including having the proper protective gear.

Every operator needs to undergo proper training and learn the relevant safety standards before using an air compressor. If you upgrade your air compressors or make any repairs, it’s essential to update operators on any changes so they know how to use the machine correctly and know what to look out for. It’s also important to check air compressor safety regulations from the Occupational Safety and Health Administration (OSHA) and ensure you’re in compliance with any that apply to your uses or machines.

The way your equipment and workspace are set up can have a significant impact on safety. Some air compressor and workspace setup tips to keep in mind include:

Component pressure ratings: Make sure that all components, including hoses, pipes and fittings, are rated for the maximum pressure of the air compressor.

Relief valves: Relief valves automatically release air if the pressure in the tank gets too high. These valves are important air compressor tank safety features, so you should never attempt to adjust, bypass or remove them.

Drain valves: If your compressor has an electric drain valve, make sure it is at least a foot and a half above the ground. Electric drain valves must be kept away from moisture.

Workspace air circulation: Intake air contains pollutants and carbon monoxide that can be hazardous to your health. For these reasons and others, it’s essential to keep your workspace circulated with clean air at all times.

Workspace humidity: It’s important to keep the humidity in your workspace from getting too high. To decrease the moisture in the air, try increasing air circulation in the workspace, operating your compressor for longer periods, using a peripheral crankcase heater or adding a dryer to your compressed air system.

Before using a compressor, you need to check various components to make sure the machine will work properly. To keep track of any issues and ensure you’ve looked at all the necessary areas, create an air compressor safety checklist for your operators to complete before each job. Some of the elements you may want to look at include:

Oil level: It’s essential to check and see if the machine has an appropriate amount of oil. Using it without an adequate amount of oil can ruin it to the point of requiring costly repairs or replacement. If it needs more oil, add oil to the reservoir but be careful not to overfill it. Also, be sure to keep oil from spilling onto the exterior of the compressor.

Fuel level:To run an air compressor, you need to have a sufficient amount of fuel. It can be a pain to have to refill in the middle of a job, as it requires you to stop, allow the compressor time to cool off and then refill the tank. Don’t refuel your air compressor when it’s on or has been shut off for only a short time. You should only conduct refuels and oil changes when the machine is cold.

Air filter:Whether you use a given compressor every day or only every once in a while, check the air filter before use. If it appears dirty or clogged, you should remove and wash it — if you have the right kind of screen — or replace it with a new filter.

Air connection:Before turning on your air compressor, make sure that it is securely connected to the air source. If the connection is weak or loose, the compressor may not perform as expected, and parts could disconnect, potentially leading to injury.

Outlets: Ensure your air compressor is only used with outlets that have the proper grounding. If you plug an air compressor into an incorrectly grounded outlet, it could damage the machine’s electrical circuitry and even cause a fire.

There are also air compression safety tips and procedures for particular parts of the compressor. Three of these components include the pressure regulation devices, air receivers and distribution lines. Each of these is significant in maintaining a healthy machine and operating it safely.

Valves:Ensure that the safety valves on your air tank are set to at least 10% or 15 psi — whichever is greater — above the operating pressure of the compressor but never higher than the air receiver’s working pressure limit. If using an air compressor in freezing temperatures, check that the safety valves are positioned in a way that prevents water from collecting inside the unit. If a valve freezes, thaw it and empty the compressor tank before reactivating the unit. The machine should also have shielded blowoff valves so sudden blowoffs don’t result in equipment damage or injury.

Air intake: The air intake should receive air only from clean, outdoor sources. Place a filter or screen at the intake valve to keep the intake air clean.

Speed: Check the manual that came with your compressor for the maximum recommended speed and ensure that you never run your compressor at speeds exceeding this level.

Draining:If your air compressor doesn’t have an automatic drain, be sure to drain the air receiver regularly so liquid does not build up inside of it.

Gauges and valves: Ensure that your air receiver has a pressure gauge and a safety valve that meets the American Society of Mechanical Engineers (ASME) standards.

Air hoses:Don’t let air hoses become bent or kinked. Check distribution lines regularly for flaws, damage and imperfections and replace any defective air lines immediately.

Operators should also take certain precautions while operating air compressors and after completing a project using an air compressor. It’s essential to remain in control of compressor units at all times. Sound footing and standing on a level surface at a safe distance from the unit is crucial as is keeping your hands, clothing and hair away from the air nozzle and tools.

While you can use compressed air for cleaning certain objects at low pressures and with a nozzle, you should never use compressed air for cleaning clothing or human skin. Don’t use compressed air to pressurize a vessel, such as to empty oil from a gearbox, as these vessels aren’t designed to handle high pressures. Don’t dry bearings using compressed air, as doing so can cause excessive rotations speeds that can cause bearings to explode.

Also, be sure to wear the proper safety gear for the job. No matter what tool you’re using for a given project, it’s vital to wear protective gear for your ears and eyes at all times. According to the Center for Disease Control, an estimated 22 million workers face exposure to potentially harmful noise every year. The risks involved with failing to wear hearing guards might not always be apparent at first, but adverse effects due to exposure to noise are often experienced later, in some cases years down the line. Personal protective equipment (PPE) to consider includes goggles, face masks, rubber or leather gloves, steel-toed shoes and leather or PVC aprons. Cotton clothing is not an effective barrier to compressed air. Cover any part of the body that is at risk of coming into contact with compressed air or flying particles.

To prevent safety issues, it’s crucial to keep an eye out for any potential issues while you’re using an air compressor. Once you start the machine and begin your work, be sure to check the following items consistently:

Surroundings: In addition to managing your own safety, keep an eye out for other workers and ensure you’re keeping the surrounding area safe. Make sure that all your hoses, cables and wires are tucked away where no one can trip on them and that you keep your area clean.

Voltage:Pay close attention to your air compressor’s voltage. If repairs are needed, power down the machine, lock and tag out all power sources and release all pressure from the compressor. If your compressor is designed for indoor use, don’t use it outdoors, as rain or wet conditions can cause electrical problems.

Air source:Be sure to check the air source itself regularly to ensure optimal performance and efficiency. The air source should be clean and dry. You can use screens or filters to clean the incoming air.

Air inlet:At the inlet, the air that goes in should be clean and free of moisture and should not exceed the maximum recommended pressure. If the maximum pressure rating of a particular tool is surpassed, it could cause various dangers, such as cracks, undue velocity or faulty pressure or output torque.

Performing preventative maintenance is essential to keeping your compressor running smoothly and safely. It can increase the longevity of your machine and improve its capabilities. Running a clean, well-kept machine will also promote the wellbeing of your workers and operators and help manage air compressor risks.

Receive the proper training:Anyone performing maintenance on an air compressor should have received the appropriate training to ensure they conduct maintenance tasks correctly and safely.

Follow the manufacturer’s recommendations: To ensure safety in maintenance and operation, it’s important to follow the care and maintenace recommendations of your compressor’s manufacturer.

Disconnect power: Before performing maintenance work, shut off the machine and disconnect it from all power sources. Lock open the electrical switch for the compressor and tag it so no one starts it by mistake.

Clean the unit properly:Cleaning your air compressor regularly will improve its performance and extend its life. When it comes to cleaning carbon remnants from the various parts of an air compressor, it’s safe to use soapy water or a lye solution, but you should never use anything flammable, such as kerosene. Following every cleaning, completely purge the air system.

Lubricate properly:Don’t use oils with low flash points to lubricate compressor parts. These oils could combust due to the high temperatures produced by air compressors during operation. It’s essential, however, to keep parts lubricated with the proper oils and to avoid over-lubrication to prevent corrosion.

Take steps to prevent rust: One of the most dangerous possibilities when it comes to air compressors is a rusty tank. Rust increases the unit’s chances of combusting, putting anyone nearby in danger. To prevent rust due to the accumulation of liquid, use the underside valve to drain the tank daily. If a tank becomes rusted, don’t attempt to repair it. A rusted tank requires replacement.

Handle tools safely:Before you install, remove, fine-tune or perform any kind of maintenance on your pneumatic impact tools or accessory parts, shut off the source of air, bleed the air pressure and disengage the air hose.

Report faulty equipment immediately:If you notice that repair work is needed that goes beyond regular maintenance, tag out the machine so no one uses it. Then, report the issue as quickly as possible so the machine can be repaired.

Although proper maintenance can help extend the life of your air compressor, you may still occasionally need to troubleshoot issues. Follow these compressed air safety tips when troubleshooting your equipment:

Shut down your compressor:Turn off your compressor, disconnect it from power and bleed any remaining air pressure before doing any troubleshooting or repair work. Make sure that the shutoff valve is always within reach in case something goes wrong during operation.

Follow safety procedures for hose malfunctions:If a hose malfunctions or comes apart at the coupling, you can prevent whipping with two components. One is an air fuse of the proper size, which you should install in the hose upstream. The other is a whip-inhibiting device that is placed along the coupling of a hose. If an air hose does start whipping around uncontrollably or another similar air hose problem occurs, don’t try to stop and control it by grabbing the hose. To prevent injury, turn off the air source before touching the hose.

Use reliable parts: If a component becomes damaged or needs to be replaced for any reason, use only reliable, high-quality parts that are the correct size, material and type for your machine. Using the wrong parts or low-quality components can result in decreased compressor performance, damage to your equipment and safety hazards.

As one of the world’s leading sellers of compressed air products for nearly 100 years, Quincy Compressor offers an array of machines and parts for many industries. With our one-of-a-kind offers and round-the-clock support, we’ve supplied and serviced businesses in the automotive, manufacturing and construction sectors, among others.

People have various uses for compressed air, and at Quincy, we’ve got them all covered. With Quincy, there’s no application too demanding for our top-of-the-line products to handle with utmost ease and maximum efficiency. Everyone who shops with us receives support from our authorized partners, day or night, as well as industry-leading warranties on select compressor products.

If you’re in the market for compressed air devices or related equipment, explore our website, where you can download whitepapers for more information on our wide range of products. You can also contact your local authorized Quincy Compressor distributor for air compressor sales and service in your area.

We recognize that open, two-way communication between management and staff on health and safety issues is essential to an injury-free, productive workplace.

The following system of communication is designed to facilitate a continuous flow of safety and health information between management and staff in a form that

A labor/management safety and health committee that meets regularly, prepares written records of the safety and health committees meetings, reviews results of the periodic scheduled inspections, reviews investigations of accidents and exposures and makes suggestions to management for the prevention of future incidents, reviews investigations of alleged hazardous conditions, and submits recommendations to assist in the evaluation of employee safety suggestion.

Are approved safety glasses required to be worn at all times in areas where there is a risk of eye injuries such as punctures, abrasions, contusions or burns?

Are employees who need corrective lenses (glasses or contacts lenses) in working environments with harmful exposures, required to wear only approved safety glasses, protective goggles, or use other medically approved precautionary procedures?

Where stairs or stairways exit directly into any area where vehicles may be operated, are adequate barriers and warnings provided to prevent employees stepping into the path of traffic?

Are doors, passageways or stairways, that are neither exits nor access to exits and which could be mistaken for exits, appropriately marked "NOT AN EXIT", "TO BASEMENT", "STOREROOM", and the like?

Are exit stairways which are required to be separated from other parts of a building enclosed by at least two hour fire-resistive construction in buildings more than four stories in height, and not less than one-hour fire resistive construction elsewhere?

Where exiting will be through frameless glass doors, glass exit doors, storm doors, and such are the doors fully tempered and meet the safety requirements for human impact?

Are appropriate safety glasses, face shields, and similar equipment used while using hand tools or equipment that might produce flying materials or be subject to breakage?

Do powder-actuated tools operators have and use appropriate personal protective equipment such as hard hats, safety goggles, safety shoes and ear protectors?

If machinery is cleaned with compressed air, is air pressure controlled and personal protective equipment or other safeguards used to protect operators and other workers from eye and body injury?

Does the lockout procedure require that stored energy (i.e. mechanical, hydraulic, air,) be released or blocked before equipment is locked-out for repairs?

Is it prohibited to use compressed air to clean up or move combustible dust if such action could cause the dust to be suspended in the air and cause a fire or explosion hazard?

Is the total relieving capacity of the safety valve capable of preventing pressure in the receiver from exceeding the maximum allowable working pressure of the receiver by more than 10 percent?

Are cylinders with a water weight capacity over 30 pounds equipped with means for connecting a valve protector device, or with a collar or recess to protect the valve?

Are cylinders containing liquefied fuel gas, stored or transported in a position so that the safety relief device is always in direct contact with the vapor space in the cylinder?

Before entry, are all lines to a confined space, containing inert, toxic, flammable, or corrosive materials valved off and blanked or disconnected and separated?

Is there an assigned safety standby employee outside of the confined space, whose sole responsibility is to watch the work in progress, sound an alarm if necessary, and render assistance?

If employees will be using oxygen-consuming equipment such as salamanders, torches, furnaces, in a confined space, is sufficient air provided to assure combustion without reducing the oxygen concentration of the atmosphere below 19.5 percent by volume?

Are all local exhaust ventilation systems designed and operating properly such as airflow and volume necessary for the application? Are the ducts free of obstructions or the belts slipping?

When pipelines are identified by color painted bands or tapes, are the bands or tapes located at reasonable intervals and at each outlet, valve or connection?

When pipelines carrying hazardous substances are identified by tags, are the tags constructed of durable materials, the message carried clearly ad permanently distinguishable and are tags installed at each valve or outlet?

When pipelines are heated by electricity, steam or other external source, are suitable warning signs or tags placed at unions, valves, or other serviceable parts of the system?

Are hooks with safety latches or other arrangements used when hoisting materials so that slings or load attachments won"t accidentally slip off the hoist hooks?

Is the volume and velocity of air in each exhaust system sufficient to gather the dusts, fumes, mists, vapors or gases to be controlled, and to convey them to a suitable point of disposal?

Does your HVAC system provide at least the quantity of outdoor air required by the State Building Standards Code, Title 24, Part 2 at the time the building was constructed?

Before youbuy compressed air receiver tank, take some time to learn about the device itself. Our guide to compressed air receiver tanks explains how they work, what they do, and how you can use them to maximize the efficiency of your compressed air system.

An air receiver tank (sometimes called an air compressor tank or compressed air storage tank) is what it sounds like: a tank that receives and stores compressed air after it exits theair compressor. This gives you a reserve of compressed air that you can draw on without running your air compressor.

An air receiver is a type ofpressure vessel; it holds compressed air under pressure for future use. The tanks come in a range of sizes and in both vertical and horizontal configurations.

An air receiver tank provides temporary storage for compressed air. It also helps your air compression system run more efficiently. The air receiver tank has three main functions in your compressed air system:

The primary role of an air receiver tank is to provide temporary storage for compressed air. Storing compressed air allows the system to average the peaks in compressed air demand over the course of a shift. You can think of your air receiver tank as a battery for your compressed air system, except it stores air instead of chemical energy. This air can be used to power short, high-demand events (up to 30 seconds) such as a quick burst of a sandblaster, dust collector pulse, or someone using a blowgun to dust themselves off. The air in the tank is available even when the compressor is not running. Storing compressed air reduces sudden demands on your air compressor, prolonging the life of your system. Using an air receiver tank may also allow you to use a smaller horsepower compressor for larger jobs.

The air receiver tank provides a steady stream of air to compressor controls, eliminating short-cycling and over-pressurization. Uneven compressed air utilization causes uneven demand on the air compressor, resulting in rapid cycling of the compressor controls as the compressor turns on and off to meet moment-by-moment demand. Each time the system turns on and off (or loads/unloads) is called a “cycle”; it is better for the compressor motor to keep these cycles as long as possible. Over time, frequent short cycling will lead to premature failure of switches and other compressor components. Rapid cycling can result in excessive wear of the motor contactor or even a direct motor short because of winding insulation. The air receiver tank eliminates short cycling and provides more consistent system pressure to controls.

As air is compressed under pressure, its temperature increases; this is a simple law of physics known as thePressure-Temperature Law. Depending on the type of air compressor you are using, the air discharged from the compressor may be as hot as 250 – 350°F. This is too hot for most air-operated equipment to use directly. Hotter air also contains more moisture, which will result in excess water vapor that will condense in control lines and tools if it is not removed. The condensed air must be cooled and dried before it is utilized. Aheat exchangeris used to remove excess heat caused by compression. The air receiver tank acts as a secondary heat exchanger; as air sits in the tank or slowly flows through it, it naturally cools over time. The air receiver tank supports the work of a primary heat exchanger; lowering the temperature of the air an additional 5 – 10°F is not uncommon.

As the air compressor cycles on and off, compressed air can be wasted. Every time arotary screw air compressorunloads, the sump tank (oil tank) is vented. Compressed air is released during the venting. Over time, this adds up to the loss of thousands of cubic feet of compressed air that could otherwise have been used to power processes in your facility. A properly sized air storage tank reduces frequent cycling and venting.

Compressed air storage also allows you to reduce the pressure at which your air compressor operates. Without a store of compressed air to draw on, the system will have to operate at higher pressures, so it is always ready to meet peak demands. In essence, you are asking your system to operate as if your facility is always running at maximum demand. This leads to increased energy use and wear and tear on the system. On average, for every 2 PSI that you increase the pressure of your system increases the energy demand by 1%. This can lead to hundreds or thousands of dollars added to your energy bills annually. As explained above, adding an air receiver tank to your compressed air system will even out these peaks in demand, allowing you to meet intermittent periods of high demand without increasing the overall pressure of your system.

The heat exchanger function of the air receiver tank helps to improve the efficiency of your air dryer. As air passes slowly through the receiver tank, it cools. Cooler air can’t hold as much moisture as warm air, so excess moisture condenses and falls out of the air as a liquid. The water drains out of a valve at the bottom of the tank. By removing some moisture in advance, the air receiver tank reduces the amount of work the air dryer needs to do. This improved efficiency translates to additional energy savings for your system.

When shopping for an air receiver tank, you may be asked whether you want “wet” or “dry” compressed air storage. The difference is in the location of the air storage tank in your compressed air system; there is no difference in tank construction or design.

“Wet” storage tanks are locatedbeforethe air drying system. Air flows through the tank in this configuration, entering through the bottom port from the compressor and exiting out the top to the dryer.

“Dry” storage tanks are locatedafterthe air dryers to store compressed air that has already been dried and filtered. It is not necessary to flow the compressed air through the tank for dry storage.

With wet air storage, the receiver tank is positioned in between the air compressor and the air dryer. Wet air enters the receiver tank from the air compressor through the lower port in the tank and exits through the upper port to enter the air drying system. A wet air receiver tank has several benefits.

As explained above, wet storage increases the efficiency of your air dryer by allowing excess water and lubricant to condense out of the air before it hits the dryer.

A wet air storage tank also prolongs the life of the pre-filter element, which is located in between the wet storage tank and the dryer. Since the air going through the filter is cleaner and dryer than it would be directly out of the air compressor, slugging of the filter with liquids is minimized, along with resulting pressure drop on the air dryer side of the system.

The compressor does not experience backpressure because the air does not go through filtration before entering the tank. This results in a steadier pressure signal to the compressor controller.

Without a dry air tank, air from the wet tank will have to go through the air dryer before it is used. During periods of high demand, the dryer is at risk of becoming over-capacitated as the system tries to pull air through at higher volumes than the dryer is rated for. If the dryer cannot keep up with the demand, drying efficiency is reduced, potentially leading to unwanted water in the air lines.

The ideal ratio of compressed air storage is1/3 wet to 2/3 dry capacity. For example, if you have a total of 1,200 gallons of compressed air storage, 800 gallons should be dry storage, and 400 gallons should be wet. Dry air is ready to use on-demand. The wet air tank increases the efficiency of the dryer and acts as a secondary reserve when dry air is exhausted. Dry air storage needs to be greater than wet storage to minimize the risk of over-capacitating the air dryer during periods of high demand.

An exception to this rule is for applications that have steady airflow without sharp peaks in demand. In this case, there is no need for a dry storage tank because air will simply flow through it without being stored up. This is often the case in robotic manufacturing facilities where airflow is consistent and predictable.

A good rule of thumb for most applications is to havethree to five gallons of air storage capacity per air compressor CFM output. So if your air compressor is rated for 100 CFM, you would want 300 to 500 gallons of compressed air storage. As explained above, 1/3 of the total storage capacity should be wet storage, and 2/3 should be dry storage.

While the standard rule works well for many applications, you will also want to consider other variables in determining your compressed air storage needs. Flow consistency has a large impact on storage requirements.

Facilities with very steady airflow, such as robotic facilities, typically don’t need as much stored air. That’s because they don’t have frequent high bursts of demand that rely on stored air. In this case, air storage can be reduced to 2 gallons per CFM of air compressor capacity. All storage should be wet storage in this case, as explained above.

Facilities with high variability in airflow and large peaks in demand may require larger volumes of stored air. This extra capacity will ensure that the system will be able to keep up with periods of high demand. Testing to determine CFM at peak demand will be needed to calculate air storage requirements.

The final consideration in determining compressed air storage requirements is the size of the pipework in the system. The pipes also store air for your compressed air system, and the larger the pipes, the more storage they provide. For systems with pipework of 2” or greater diameter, it may be worthwhile to consider that volume into the calculation.

Compressed air receiver tanks can be bulky, so many compressed air system owners would prefer to store them outside. Outdoor storage saves precious floor space in the facility.

It also helps to reduce strain on your HVAC system in warm weather. The compressed air storage tank radiates heat as hot air from the compressor cools within the tank, raising temperatures in the compressor room. Storing your tank outside avoids excess heat buildup in the compressor room and also helps the storage tank perform its secondary job as a heat exchanger more efficiently.

However, outdoor storage only works in milder, non-freezing climates. Make sure your climate is suitable for outdoor placement of your compressed air tank.

Outdoor storage of the air receiver tank is only appropriate for environments that stay above freezing year-round. In freezing temperatures, outdoor tanks can ice up and even rupture—a costly and potentially dangerous outcome. If your area experiences freezing temperatures during part of the year, it is safest to keep your tank indoors.

If you are storing your air receiver tank outdoors, be sure to conduct frequent inspections to monitor for corrosion. Any signs of corrosion should be addressed immediately to maintain the integrity of the tank.

The majority of air receiver tanks are bare steel on the inside with a primer coating on the outside to reduce corrosion. The exterior paint is commonly matched to the compressor equipment. A basic steel tank works well for most applications and is the least expensive option. However, they may be prone to corrosion if too much liquid is allowed to build up inside the tank.

Epoxy coatings are sprayed onto the interior as a liquid and then cured into a tough, anti-corrosive coating. Epoxies work by creating a moisture-proof barrier between the air and the base metal of the tank.

Both methods provide long-lasting protection for the interior of the tank, but they do add to the cost and lead time. Coated or galvanized tanks are better at maintaining air purity because they reduce the risk of particulates caused by corrosion entering the airstream. Applications needing higher purity air, or users concerned about the longevity of their air tanks, may want to consider one of these options.

Stainless steel air receiver tanks are primarily used for specialty applications where very high-purity air is required. They are the most expensive option, but they are highly durable and corrosion-resistant and maintain exceptional air purity. Hospitals, labs, electronics manufacturers, and other applications requiring high-purity air should consider a stainless steel tank.

Air receiver tank accessories are essential for tank safety and operation. While the tank itself is just a large sealed metal tube, all tanks must have at a minimum:

Automatic drain valves eliminate the need for daily manual draining of liquid inside the air receiver tank. Anelectric automatic drain valveis programmed to open at set intervals to let accumulated liquid drain out.

Zero air-loss condensate drainsalso provide automatic drainage of the tank. Instead of draining at set intervals, they use a float mechanism to control drainage. The drain will only open when needed, saving energy and reducing air loss from the tank.

The pressure gauge provides a visual indicator for the interior pressure of the air in the tank. You need the gauge to monitor pressures and ensure that the tank is not under stress from over-pressurization.

A pressure relief valve is required for all air receiver tanks per OSHA and ASME guidelines. The pressure relief valve opens automatically to release some air if pressures in the tank are too high. This safety mechanism is essential to minimize the risk of a dangerous rupture due to over-pressurization. The relief valve is typically set to 10% higher than the working pressure of the compressed air system but never more than the rated pressure of the tank’s ASME certification.

Vibration pads are not required for all applications, but they are recommended if the air compressor is mounted on top of the tank. Vibration pads absorb vibrations from the compressor motor and reduce fatigue on the tank.

Many buyers wonder if ASME certification is important for air receiver tanks—and the answer is yes. All air receiver tanks used in industrial applications must be certified by ASME for safety and performance.

The American Society of Mechanical Engineers, or ASME, is an organization that sets engineering codes and manufacturing standards for a variety of machines, parts, and system components. ASME acts as an independent quality assurance organization to ensure the safety and quality of manufactured items. An ASME certification stamp means that the manufacturer has met all safety and engineering standards for their product.

ASME has developed a set of codes and standards for pressure vessels, including air receiver tanks. The ASMEBoiler and Pressure Vessel Certification Programsets rules governing the design, fabrication, assembly, and inspection of pressure vessel components during construction. These rules include engineering standards for the thickness of the tank body, welds and joints, connections, and other components of the tank. Tank manufacturers must conform to all of the rules to obtain ASME certification.

Some big box stores carry non-code air receiver tanks. While these may be cheaper, they have not undergone the rigorous manufacturing processes and quality testing needed to ensure that they are safe and reliable. Using a non-code air receiver tank could put your life and the lives of your coworkers at risk.

If you are not sure whether or not your air receiver tank meets code requirements, you should have it inspected. Your local Fire Marshall may provide this service. They will stop in and test your tank with ultrasonic metalthickness testing technology. If your air receiver tank does not pass the inspection, it should be decommissioned and replaced immediately.

All air receiver tanks must also be inspected periodically once they are installed. OSHA does not mandate a specific testing interval, but it is recommended that all air receiver tanks be inspected at least annually. Your insurance company or local governing board may have different requirements. OSHA requires that formal inspections be performed by an inspector holding a validNational Board Commissionand in accordance with the applicable chapters of the National Board Inspection Code. Manufacturers are required to keep records of formal inspections and make them available to OSHA representatives upon request.

In between formal board inspections, manufacturers should conduct frequent visual inspections of the air receiver tank to look for signs of corrosion, damage or weld failure. Check drains daily and pressure relief valves quarterly to make sure they are operating correctly. Contact your manufacturer or compressed air system installer immediately if you see any signs of problems with your air receiver tank.

Pressure vessels must be built to withstand high internal pressures over a long period of time. Over time, corrosion, stress, and fatigue can make tank failure more likely. The most common causes of air receiver failure are:

The high internal pressures within an air receiver tank make failure extremely hazardous. Cracking or weld failure can cause the tank to burst with explosive force, projecting large pieces of metal or fragments of shrapnel at high speed. Air receiver tank failure may result in extensive damage to the facility and nearby equipment and severe injury or death for nearby workers.

An appropriately-sized air receiver tank will improve the efficiency of your system—and can even reduce your operating costs for your compressed air system. Your air receiver tank reduces energy consumption and saves wear and tear on your system.

Your compressed air receiver tank is like a battery for your facility, providing an extra reservoir of compressed air you can draw on during periods of high demand. This lets you reduce the overall operating pressures for your system, resulting in lower energy costs. You may also be able to purchase a smaller air compressor with lower CFM capacity by relying on your air receiver tank for high-demand events.

As explained above, the air receiver tank reduces cycles counts for your air compressor by evening out peaks in compressed air demands. Lower cycle counts add up to lower energy use and less wear and tear on other system components, extending the life of your air compressor.

The air receiver tank functions as a pulsation dampening device, absorbing vibrations from the air compressor motor and pulsations in the air stream. This reduces fatigue on piping and other system components.

As the air cools in the air receiver tank, the excess liquid condenses and falls out of the air. This results in less work for the air dryer and less energy consumption.

Particulates can enter the airstream due to corrosion within the system, motor exhaust from the air compressor, or particulates in facility air. Many of these particulates will fall out of the air along with condensate within the air receiver tank. The excess dirt is then simply drained away with the liquids. As a result, the air entering the air dryer is both cleaner and drier than air directly from the air compressor.

Your air receiver tank is an essential component of your compressed air system. Having a properly sized air receiver tank ensures the safe and efficient operation of your system and provides a reservoir of extra power for use during periods of peak demand.

If you’re not sure how much air storage capacity you need, or if you have questions about maintaining your tank for safe operation, the experts at Fluid-Aire Dynamics can help. We will perform an assessment of your compressed air usage patterns and recommend an air receiver tank that will fit your needs. We can also help you inspect, repair, or upgrade your current storage system.

This section applies to compressed air receivers, and other equipment used in providing and utilizing compressed air for performing operations such as cleaning, drilling, hoisting, and chipping. On the other hand, however, this section does not deal with the special problems created by using compressed air to convey materials nor the problems created when men work in compressed air as in tunnels and caissons. This section is not intended to apply to compressed air machinery and equipment used on transportation vehicles such as steam railroad cars, electric railway cars, and automotive equipment.

Out on the plant floor, workers often innovate on ways to get something done faster or more efficiently, and that"s great, but sometimes, these shortcuts can run a company afoul of OSHA regulations. In operations where workers end up getting covered in dust or chips of some sort, they might turn a compressed air gun at themselves in order to clean themselves off quickly. The problem is that this can be exceptionally dangerous depending on the output pressure of the air line, and even whether the worker has an open cut on their skin. And even in more standard use of compressed air, there"s many ways companies could accidentally create a dangerous or non-compliant situation. In order to get some insights into the nuances of what is safe and approved, we spoke with Mark Yorns, the director of engineering with Guardair Corporation.

Mark Yorns:Guardair Corporation developed the first “safety air gun” in 1942. It incorporated a safety air shield to protect the operator from “chip fly-back.” This feature was patented, as were further technical innovations which followed. Occupational Safety and Health Administration (OSHA) was established by the US Department of Labor in 1970 to help tackle safety concerns in the workplace. In the early days of OSHA, Guardair worked closely with OSHA officials to craft the standards and consequently was in a unique position to introduce the first safety air gun designed to meet these newly minted regulations.

Output Pressure:Factory air lines normally operate between 80 psi and 120 psi. Most pneumatic tools, including air guns, need high pressures to operate effectively. OSHA requires that when an air gun is dead ended (the tip of an air gun is blocked), the static pressure at the point of blockage is no more than 30 psi.

Chip Guarding:Whenever blowing off debris with an air gun in close quarters, workers are subject to chip fly-back. This term refers to the tendency of loose particles or chips to fly back into the operator’s face, eyes or skin. For operations which require close-in work, OSHA requires that effective chip guarding be incorporated into the workplace.

Noise:Excessive noise generated in the workplace can be harmful. To address this problem, OSHA has developed permissible daily noise exposure specifications. Since safety air guns often contribute to high levels of occupational noise, the use of low-noise, safety air guns can be an important component in noise compliance.

Yorns:Factory air lines normally operate at pressures between 80 and 120 psi (pounds per square inch). Most pneumatic tools, including air guns, require such pressures to operate effectively. However, OSHA regulations require that in the event the pneumatic tool is dead-ended (i.e. if the tip of an air gun is blocked) the static output pressure at the point of the blockage may not exceed 30 psi. Manufacturers incorrectly set their compressed air lines to 30 psi to operate safety air guns rather than maintaining an 80 to 120 psi level. OSHA-compliant safety air guns such as the ones we manufacture at Guardair have built in features that divert the air away from the main orifice if a tip becomes blocked, or make it physically impossible to block the tip. This allows manufacturers to operate between 80 and 120 psi.

End users use air guns or homemade devices to clean that are unsafe and do not meet OSHA regulations. For example we have seen a device constructed out of a ball valve and a piece of pipe. If the tip on this homemade device were to become blocked, full line pressure would be built up behind the blockage — this could be hazardous. Many of Guardair safety air guns feature a Venturi nozzle which has two side ports that serve two purposes. First, it enhances the thrust by drawing in more air from the outside during normal operation. In addition, the side ports vent the pressure should the tip become blocked.

End users thinking they will yield better performance will modify OSHA compliant guns in a way that makes them non-compliant. We have seen users tape the side ports of the nozzle or remove the nozzle entirely thinking it will produce more thrust, but this actually decreases performance. Not only that, but removing the nozzle will greatly increase the amount of air usage

Manufacturing.net:OSHA dead-end regulations ensure a user is not injured if a safety air gun is pressed against their skin. Even so, it’s also not allowed to blow yourself off with these tools. Why? What are the other options?

Yorns:Using air guns to self-clean blows debris into skin, clothing, and potentially unprotected eyes if the operator is not wearing safety goggles Pneumatic vacuums are viable alternatives for self-cleaning. For example, we recently introduced the Personnel Cleaning Station. This high efficiency vacuum runs off standard shop-compressed air and features a proprietary, on-demand air-agitator brush attachment. Thumb-switch activated, the air-agitator loosens and lifts particles airborne where the vacuum sucks them away safely and effectively. It is safe to use and captures the debris versus blowing it back into the air. Additionally pneumatic vacuums have no motor to burn out and are virtually maintenance-free.

Yorns:Using air guns to self-clean blows debris into skin, clothing, and potentially unprotected eyes if the operator is not wearing safety goggles. Should the operator have an open wound, the dust and particles can get lodged in the wound and become infected.

Compressed air is used in a wide range of ways in most facilities. Things like operating tools to controlling machines, and much more are all done by compressed air. This is why it is so important to take compressed air safety very seriously.

No matter how much or how little you use it in your facility, make sure you look at the following five common hazards that are present when using compressed air. In addition, consider the safety tips that are associated with them so that you can minimize the risk to your employees and your facility.

In a perfect world where people practiced common sense, this hazard would not be present. Unfortunately, that is not the world we live in. There are many times when people use the compressed air hoses as something like a toy, which can actually cause many serious injuries.

By blowing the air at another person, or even themselves, it can quickly result in problems. The following are some major medical concerns that may be present when people are playing with compressed air:Internal Ruptures – Some people may think it would be funny to blow the air into their mouth. Since the air comes out so quickly, however, it can be forced down into the lungs, stomach or even intestines. When this occurs, they can rupture and cause very serious injury or even death.

Broken Skin – When blowing compressed air on the skin it can actually break through it, and enter the bloodstream. In addition to the serious skin damage, this air in the blood stream can cause death as it makes its way through to the heart and brain.

Blindness – The pressure from the air can cause very serious injury when it comes in contact with your eyes. The damage can happen in an instant, and result in permanent blindness.

Blowing Objects – If someone blows the compressed air at different objects, such as tools, they can be accelerated to very fast speeds. This can cause a major projectile risk within the facility.

Damaging the Facility – Compressed air not only puts people at risk when it is not treated properly, but also the facility. The high pressure air can, for example, blow off paint from a machine. It could also potentially blow floor marking tape, labels or any number of other things from where they need to be.

Remember, it doesn’t take too much air pressure to cause these types of injuries. Just 12 pounds of compressed air pressure can easily blow an eye right out of its socket. It can also break the skin and cause air pockets to form inside the body, which can be extremely dangerous. Make sure you keep this in mind when teaching about compressed air safety.

Another potential risk of working with compressed air is when the hose is damaged. If people are working with old or frayed hoses the air can leak out, which reduces the pressure. This lack of pressure can cause machines to malfunction or cause other problems.

With this in mind, it is absolutely essential to make sure the air hoses are inspected on a regular basis to minimize the risk. If there is damage, they should either be replaced or repaired following the proper procedures.

Many facilities will use compressed air to inflate tires, or even to inflate lifting balloons. Since compressed air can move so quickly, this is a very efficient way to get these types of jobs done. If someone accidently over-inflates the objects, however, they may be putting everyone at risk.

This happens most often when using a compressed air machine to fill up tires for any type of vehicle. When the tires are over-inflated, they could burst right on the spot. When this happens, it can cause an extremely loud noise, which can cause hearing damage. It could also cause severe injury to the person doing the actual inflating.

Putting a label on the side of a company truck, for example, that says ‘inflate tires to 40 PSI’ will help ensure there are no mistakes made. Since these safety labels are so easy to make and inexpensive, you can put them in every area where people will be using compressed air to fill objects.

When people think about compressed air safety, they often only consider the actual air pressure as a hazard. The fact is, however, that the tools that are powered by this compressed air must also be very well maintained.

On the other end of the system is the actual machine that is used to compress the air. This is a fairly simple type of machine, where a motor forces the air into a tank where it is stored until it is needed. Keeping this machine in good working order is very important.

Whenever providing employees with compressed air safety training, the most important thing is to make sure they all recognize the seriousness of the risks that are there. While compressed air normally works well with very few problems, the risks are real and very serious.

Pneumatic tools, powered by compressed air, can be a useful and portable addition to electrical tools on construction sites, in industrial workshops, and at any work site where power tools are used. The air compressors that power pneumatic tools must be used correctly to ensure the safety of all workers on the job site.

All workers who are authorized to use pneumatic tools should be trained on safe tool operation as well as inspection, compressed air hazards, proper PPE requirements and tool storage.

Air compressors can be vulnerable to changes in moisture, temperature and position. Perform a basic safety check at the beginning of every shift or before using any pneumatic tools for the first time each work day.Check gauges, connectors, hoses and guarding during the inspection.

Getting hit by an attachment or fastener that flies off can cause serious injury.  >>  Always use a safety clip or retainer to prevent attachments from being ejected during tool operation.

Electrical contacts within the air compressor motor or pressure switch can spark, creating a risk for fire or explosion.  >>  Operate air compressors in a well-ventilated area away from combustible materials.

Always wear appropriate PPE when working when pneumatic tools.Pneumatic tools can by noisy so it is important to wear hearing protection when using air powered tools or when working in the area where they are used regularly.

IMPORTANT: Cleaning with compressed air is dangerous. Do not use compressed air to blow debris or to clean dirt from clothes.OSHA Construction Standard 1926.302(b)(4) and OSHA General Industry Standard 1910.242(b)Compressed air shall not be used for cleaning purposes except where reduced to less than 30 p.s.i. and then only with effective chip guarding and personal protective equipment.Do not operate any pneumatic tool at a pressure above the manufacturer’s rating.