air compressor safety valve keeps opening factory

If the tank is over pressurized, the pressure switch isn"t shutting off the motor when the air tank fills to the cut-out pressure. Move the pressure switch lever to the off position. If the compressor continues to run, replace the pressure switch, because the switch isn"t shutting off the compressor motor.

If the compressor shuts off when you move the pressure switch lever to the off position, pull the safety valve ring and release all air from the tank. Switch the pressure switch lever to the on position and allow the tank to fill. If the compressor doesn"t shut off when the air tank fills to the cut-out pressure, replace the pressure switch, because the switch isn"t shutting off the compressor motor when tank pressure reaches the cut-out pressure.

Today I am going to explain why this happens and how you can fix it. But first, I would like to give a short introduction about a safety valve and how it works, if you are not familiar with it.

It is also called a pressure relief valve as it reliefs pressure whenever the compressor pressure reaches a critical point. Usually, the pressure level of a safety valve is kept below to the maximum pressure that a compressor can take.

Whenever the pressure of your compressor is about to reach this maximum level, the safety valve will relief air from the compressor so that the pressure drops.

A safety valve follows a very simple mechanism to work. Here is how it actually works –There is a Nozzle inside the valve. From the inlet part of the valve, this nozzle first gets an amount of pressure on it. In other words, the nozzle is there to inlet the air at a certain pressure.

You have to set a pressure level initially for a safety valve. As I have already said, this pressure needs to be lower than the compressor’s maximum pressure level. When the nozzle reaches this pressure, the Disc inside the valve starts to lift and relief the air from the tank.

There is a Spring inside the valve, which is attached to the disc. The spring is made in such a way that it will only bend when the pressure reaches the level you have set. So, the disc is lifted up and drawn down by the spring.

There are a number of components inside a safety valve but it is typically three main components, the nozzle, the disc, and the spring. You have already known how these three components work.

However, if any of these three components get damaged, then the problem begins. For example –If the nozzle is not functioning properly, there will be a problem with the air inlet. In this case, it will accidentally push a lot of air inside the valve and the valve will open.

Finally, if the spring is old or damaged, then it will lift up the disc way before it reaches the set pressure. In this case, air will also discharge from the valve.

Another reason for a safety valve to pop open is when the pressure switch is damaged. A pressure switch has a very serious function in an air compressor. It is set with two pressure level, a cut-out, and a cut-in pressure.

When the pressure switch reads the cut in pressure from the pump, it starts to run the compressor. And, when the pressure reaches the cut-out level, it shuts the compressor down.

In this case, the compressor will go to critical pressure level. When it happens, the safety valve will automatically pop open. This is how the pressure switch is responsible for the safety valve to open suddenly.

There are a number of ways that you can follow to stop a safety valve from opening suddenly. Here are the best ways to keep your compressors safety valve from opening unnecessarily.At first, check if the internal part of the safety valve is damaged or not. If you find a damaged part (i.e. the nozzle or the disc) replace this part and it should be fine.

If you cannot replace the damaged part of the safety valve, you can simply change this safety valve and place a new one. A newer safety valve is always better than a repaired one.

The pressure switch is also responsible for this. So if you don’t find any problems with the safety valve, then check the pressure switch. If the pressure switch is broken, change it.

Sometimes, there are troubles with adjusting the pressure switch. If you are also having trouble, check out this article on air compressor pressure switch adjustment to adjust your pressure switch.

First of all, you need to find out how much pressure your air compressor can take. You will see there is an option to set a pressure level on the safety valve.

When you find out your compressors limit, you can set the pressure level on the safety valve according to that limit. Always use a lower pressure level than the maximum level of pressure that a compressor can take.

The purpose of a safety valve is to discharge air from the compressor when the pressure level reaches too high. High pressure can explode the tank and cause critical accidents. To stop this from happening, a safety valve is used on a compressor.

Most of the safety valves are built to last for years. An average safety valve can easily last for 18 to 24 months. However, you should frequently test your safety valve and change it if there is the slightest chance of malfunctioning. Never take the risk of keeping a faulty safety valve attached to your compressor.

In most cases, you should check your safety valve at least once a month to see if it is in good condition or not. But I recommend you to check at least once every time it discharges.

You already know how to fix it if the air compressor safety valve keeps opening, but it is also important to test the safety valve when it discharges.

Because after discharge it will leave debris around the nozzle and the disc. You have to clean this to keep the safety valve away from malfunctioning.

A question we commonly receive is why a valve appears to open, or actuate, earlier than expected. Often, we find that the valve is not, in fact, opening early. Rather, the perception that it is actuating early is due to a misunderstanding of set pressure.

The set pressure, also called the opening pressure, of a safety or relief valve is the inlet pressure at which the valve begins to open as required by code.

A valve should be set to open at the maximum allowable working pressure (MAWP) of the vessel the valve is intended to protect. There is some tolerance to actual set pressure, which means that a valve set at 100 psig may open slightly above or slightly below this level.

The first step is to determine if your valve really is opening early. Sometimes safety and safety relief valves appear to open before they reach the set pressure — there may be an audible or visible release of fluid between the seat and the disc. This is known as “simmer” or “warn,” and it is not the same as a full open.

Simmer, or warn, occurs when a valve opens slightly, discharging only a small percentage of its rated capacity. For example, direct spring-operated safety valves may simmer or warn at 90% of the nameplate set pressure. A valve that is simmering is not considered open.

The next step is to check your gauge to ensure that it is reporting the set pressure correctly. The gauge should be calibrated properly and located upstream of the valve, close to the valve inlet. Rapid increases in system pressure can make it appear that a valve is opening early because the gauge can’t accurately report the pressure.

If you still believe your valve is opening early, assess the operating factors that might be contributing to the situation. Valves are factory set using standard conditions, and factors like high temperature, vibration, and back pressure can cause them to open early. These conditions can be compensated for using cold set pressure, aka cold differential test pressure (CDTP). Learn more about CDTP from the National Board.

So about a year ago the original safety valve failed. It kept popping before full pressure. Tank pressure reads 145-150psi when it blows. Tanks rated and used to fill 170ish before it would cut off.

I can see there are markings on the valve,but I can"t read them in situ. Once I get the new valve, I"ll read the markings on the existing valve once I have it out.

You may not worry often, if at all, about whether or not your air compressor is running safely. And you really don’t have to, because compressor manufacturers do. From the pressure rating on the air storage tank to emergency stop buttons, air compressors are designed with safety in mind.

But that doesn’t mean you should never think about your compressor’s safety features. In most cases, they need to be inspected regularly to make sure they’re working properly. One key safety feature that should be inspected regularly is the air pressure relief valve (PRV), sometimes called a safety relief valve.

The pressure relief valve is a safety valve that protects the compressor component that it’s attached to from being exposed to a pressure above its rated maximum operating pressure. This rating, called the maximum working pressure (MWP), is the pressure that the vessel has been certified to continuously operate at safely.

So when a compressor is running at or below its maximum working pressure—in other words, when it’s running “normally”—the relief valve doesn’t do anything.

However, when the air pressure inside a compressor exceeds its MWP, the pressure relief valve will activate to “blow off” the excessive pressure within the compressor. Without a relief valve, the storage tank could rupture from the excessive pressure, damaging the compressor itself, possibly other property near it, and even causing injuries (or worse) to anyone standing nearby.

Before we can talk about how the air pressure relief valve works, we first need to look at how air pressure inside a compressor is managed when everything is running normally.

Under normal circumstances, the air pressure in a compressor is controlled by a pressure switch in an electro/mechanical control system or, in the case of an electronic controller, a pressure transducer and controller settings. When the cut-out set pressure for the pressure switch is reached, the compressor will stop compressing air (unload) until the cut-in set pressure is reached, at which time it will start compressing air again (load). If the pressure switch fails, the compressor would not be able to start compressing air again, or potentially worse, not be able to stop. Most compressors also have a high-pressure safety switch that should stop the compressor if the pressure exceeds the unload set point.

A pressure relief valve is a straightforward safety backup to the pressure switch and high-pressure switch, or the controller set points, should any of these components fail with the compressor running. The safety relief valve is set above the high-pressure safety switch and generally at or below the vessel’s maximum operating pressure. Inside the valve is a spring, and the pressure created by the spring’s tension keeps the valve closed under normal operating conditions. However, as the air pressure increases in pressure vessels (like the storage tank), it eventually exceeds the rated pressure of the relief valve, causing the relief valve to open and the excess pressure to be “blown off” to the atmosphere.

If the pressure relief valve fails open, air will continually vent to the atmosphere, preventing the air stream from becoming fully pressurized. The compressor should be shut down and the relief valve replaced before the compressor is restarted. The open relief valve will likely cause a loss of production and possible danger to personnel as a result of the flow of high-pressure air with flying debris and an unsafe sound level.

A pressure relief valve failing closed presents a potentially more dangerous situation. As noted earlier, the relief valve exists to allow excessive pressure to be “blown off” so that the air pressure inside the compressor’s pressure vessels don’t exceed their rated specifications. If the valve fails closed, this pressure venting can’t happen. Unless compressed air demand matches the compressed air supply, the pressure inside the compressor will continue to build. Eventually, the pressure increase would cause the storage tank to rupture, damaging the compressor and possibly causing additional damage and injury to property and people nearby.

If the relief valve is opening because the air pressure in the compressor has exceeded the valve’s pressure set point, that means the valve is working and doing what it was designed to do. But because this indicates the MWP of the compressor has been exceeded, the condition that’s causing excessive pressure should be diagnosed and corrected.

If the relief valve opening wasn’t caused by excessive pressure inside the compressor, then the valve is most likely “failing open”. Most likely, this is because the valve has become “soft” over time, i.e. the valve spring is providing less counterpressure, so it’s opening at a lower pressure than it should.

Whether the valve opened because of excessive pressure in the compressor or because the valve is failing, you should have your local air compressor distributor inspect your compressor before running it again for two reasons:

First, your distributor can determine whether the valve opened due to a failing relief valve or excessive compressors pressure and perform any needed maintenance or service to get your compressor running efficiently and safely again.

Second, regardless of why the pressure relief valve opened, replacing it may be recommended to ensure safe compressor operation, depending on the valve manufacturer. (Replacement is recommended for Sullair compressors.)

Important: Running the compressor after the relief valve has opened, regardless of the reason why it opened, can put both your property at risk of damage and people at risk of injury (or worse). While this may be obvious if the compressor is building up excess pressure, it also applies if the valve failed open. As noted above, even a valve that fails open poses some risk, and next time it could fail closed.

Given how critical a working air pressure relief valve is to the safe and efficient operation of your air compressor, you may wonder whether you need to do any regular inspecting or testing of the valve to make sure it is working. Because this can vary by manufacturer, you should consult your owner’s manual or contact your local air compressor distributor for frequency and type of inspection needed. For most Sullair compressors, inspection for damage or leakage is recommended, but testing is not recommended, as doing so may compromise the valve’s performance.

However, one thing you should do is schedule regular maintenance with your local air compressor distributor. As part of regular maintenance, a service technician can inspect the PRV and let you know it’s at an age or in a condition at which the manufacturer recommends replacement. Also, problems with the compressor’s performance, e.g. not reaching normal operating pressure, may help the service technician identify a failing relief valve after ruling out other possible causes.

When a pressure vessel like a receiver, sump tank or other storage vessel is purchased separately from the compressor, it may not be supplied with a pressure relief valve. To ensure its safe operation, you should add a PRV.

When selecting a PRV to add to the pressure vessel, you must choose a valve with a pressure set point set at or below the maximum working pressure of the vessel. You will find the MWP (and other useful information) on a tag welded to the pressure vessel. Also, flow capacity of the PRV must meet or exceed the total compressed air supplied to the vessel.

For example, if you have two compressors with capacities of 500 and 750 cfm (14.2 and 21.2 m³/min), and a pressure vessel with a maximum working pressure of 200 psi (13.8 bar), the minimum settings for a pressure relief valve would be 1250 cfm (35.4 m³/min) and a set point 200 psi (13.8 bar) or less.

Finally, when attaching the valve to the vessel, the porting must not be reduced to a size less than the size of the inlet port of the pressure relief valve.

Because the pressure relief valve is critical to the safe operation of your compressed air system, if you’re not sure how to select the correct PRV and properly and safely add it to the pressure vessel, contact your local air compressor distributor. They have the experience and expertise to ensure that the PRV is sized and installed correctly.

The relief valve"s pop off point is a function of exposed surface area vs spring pressure. A light spring, but a very small surface area, will result in a high pressure pop-off point. Using a large valve with a very heavy spring would be the same circumstance, however, the forward flow rating would be substantially different.

An air compressor is not just compressing AIR... it is changing an atmospheric mixture"s pressure, which means MOISTURE will be packed in there, too. Those lines, that cylinder, etc., will all be subject to moisture, and if that moisture content becomes extreme, the internal volume of the cylinder will skyrocket. The pressure relief valve will protect against hydraulic locking, just as much as pneumatic over pressure.

Now... your tank"s inlet valve serves several functions, the obvious being simple reversion. The second, is that the line coming from the compressor TO the tank must be discharged when the pump stops running. Failure to do so, will allow leakback to defeat the reed valves, pressurizing the cylinders and crankcase, blowing out the crank seals and dispersing the crankcase oil around your shop walls and floor, or if not, pushing cool, compressed air, and accumulated condensation, into the crankcase, contaminating, and eventually displacing it"s oil. Bad mojo.

Next, a pressurized compressor does NOT like to start- it needs to come up to speed with no load, which is the UNLOADER"s function. When the compressor stops, the unloader mechanism VENTS the outlet line (from compressor pump to tank) so that the volume is at standard atmospheric on next motor start. Motor start current is high enough across-the-line WITHOUT a load, the unloader facilitates that, in conjunction with the output line, by providing a large-enough-volume for a couple turns of the pump before any substantial pressure builds. It"s a mechanical/pneumatic soft start.

I would certainly renew that main check valve, and also look very closely into the unloader"s operation, and make sure you don"t have a blocked or binding / inoperative unloader... typically it"s a small tube going from that check valve, over to the pressure switch.

What happens when you pressurize an air tank beyond its rated pressure? It fails catastrophically and ruptures in a spectacular way that you wouldn’t want to witness firsthand.

Most air compressors have a number of precautions built in to avoid the risk of a tank rupture. The compressor itself will probably have an automatic shut-off control that turns off the motor once the maximum tank pressure is reached.

In case the auto-shutoff switch fails, there will typically also be a safety valve built into the tank. Such safety valves, such as the Conrader hard seat valve shown above, are rated to specific pressures. A 100 PSI valve will open up at ~100 PSI in order to vent excess air to keep the pressure at or below 100 PSI.

Essentially, safety valves have spring-loaded pistons. Below their factory-set pressures, internal springs hold the pistons downward, creating a seal. But once the pressure inside a tank or device overcomes the built-in pressure limit of a safety valve, the piston is pushed upwards, opening the valve seal to lower and equalized the air pressure.

Safety valves typically also have loops attached to the pistons so that you can manually rapidly depressurize a device or air tank. You should check safety valves every now and then to ensure they can open freely.

There are two main types of safety valves – hard seat and soft seat valves. Hard seat valves are rugged and inexpensive, but typically leak a little bit. Soft seat valves are a little less rugged and more expensive, but they are built with better seals that aren’t as prone to leaking.

I went with Conrader hard seat valve for a recent project, but there are other good brands as well. Safety valves are available in a wide range of pressures and in different styles.

Amazon carries a couple of valves directly and through 3rd party vendors, but your best bet is to check with Grainger, Zoro, McMaster Carr, or another industrial suppliers that have wider selections.

In the manufacturing industry, we’re taught to look at the big picture when it comes to troubleshooting. If a pressure relief valve experiences failure, is releasing pressure before a system reaches maximum pressure, or is constantly leaking or chattering, it’s always best to assume that there’s something wrong with the system.

When maintained properly, a pressure relief valve can stay in service for up to 30 years, and if you’ve been having your valves tested regularly, it’s likely that there’s something else in your system that’s to blame. That said, pressure relief valves can and do fail, and it’s important to be able to recognize the signs in order to quickly solve the problem, and keep your facility safe. Here are 3 signs of pressure relief valve failure to watch out for when you’re troubleshooting your facility’s system:

If your system isn’t reaching pressure, this could be a sign of pressure relief valve failure. In some cases, this could be fixable. If the valve was calibrated to the wrong set pressure, it could simply be releasing early. This happens occasionally when changes are made to your facility’s plant design, and technicians forget to recalibrate pressure relief valves for the system’s new normal operating pressure. Your valve technicians can go in and adjust the valve’s set pressure to address this issue.

If that doesn’t solve the problem, and all other aspects of your system seem to be functioning properly, then it’s possible that your pressure relief valve needs to be changed. After years of service, the valve could have become damaged or eroded by dirt and debris in the environment, blocking the valve from fully closing. This often causes chattering, where the valve isn’t fully open, but is opening and closing rapidly, preventing it from properly doing its job.

When your system cannot reach pressure, you’ll likely experience production slowdown, if not total downtime. It’s good to know that checking your pressure relief valves can help you determine the problem.

Pressure relief valves and safety relief valves are what keep your facility safe. In the event that your system builds up above the maximum pressure for safe functionality, safety relief valves open up to let off additional pressure, keeping your facility, your employees, and your equipment safe.

If your system is above pressure and your pressure relief valves have not released, this is likely a functional pressure relief valve failure. Again, you’ll need to make sure that the valves are set to the correct set pressure, and you’ll want to take a look at the big picture of your system to understand why it’s functioning overpressure in the first place. Outside of those two concerns, if your pressure relief valves haven’t released, it’s likely that they’ve failed.

Contaminants, like dirt, lint, rust, sludge, or even the misalignment of the valve can cause the pressure relief valve to stick. At this point, you might see that your system is above pressure, or you’ll notice other pressure relief valves in the system releasing to make up for this valve’s malfunction.

While the other two signs are pretty obvious, this last sign is more noticeable when you’re directly inspecting your pressure relief valves. Leaking valves are a problem, and can contribute to slower, less efficient production, but they can be more difficult to notice as their effect on the entire system can be much smaller. This is part of the reason that preventative valve testing and maintenance is so important.

If your pressure relief valve has no pressure, it’s likely that the balance hole has become plugged, the spring is broken, or the valve simply has a loose fit. In the case of a loose fit or broken spring, replacement is a must. The valve isn’t able to function properly within your system, which means it’s not protecting your facility, your employees, or your equipment in the event that there is a larger problem.

Pressure valve leakage is a little more complicated to troubleshoot, as there are a variety of potential causes. It could be the valve itself, it could be that misalignment is causing a failure to reseat after a correct opening, or it could be that there is greater pressure in your system than the valve’s set pressure. A quality inline safety relief valve testing system can help you here. Systems like AccuTEST offer a leak check capability that allows you to test specifically for pressure leaks.

The greatest takeaway from this article should be that a malfunctioning pressure relief valve is most often a symptom of a greater problem, rather than a problem itself. As we mentioned earlier, pressure relief valves that are properly maintained can last for up to 30 years. In most cases, it’s important to look at the “why” behind pressure relief valve failure, rather than just replacing the valve in question.

This article from the Journal of Emerging Technology and Advanced Engineering provides a helpful flowchart outlining the troubleshooting procedure to take in the event that you experience any sort of pressure relief valve failure.

If your facility is having trouble diagnosing a pressure relief valve failure, inline testing can help. Instead of removing the valve and either replacing it or sending it out for testing, use inline testing equipment like the AccuTEST system to quickly and efficiently test your pressure relief valve and safety valve’s functionality. You’ll get accurate, real-time results helping your facility get back on track quickly, and safely. For more information about AccuTEST, give us a call at 616-394-1401 or request a live demo today!

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.