Train to gain improved compressed air system efficiency

With this in mind, the British Compressed Air Society (BCAS) continues to recommend that businesses are prioritising the importance of an effective compressed air maintenance regime, helping to guarantee reliable operation, while also ensuring improved energy performance.

Since the purity (quality) and the uninterrupted supply of compressed air is often user critical, investment in appropriate training as part of a thorough maintenance regime can pay dividends.

The importance of compressed air maintenance

Compressed air equipment can cause considerable risks if not maintained properly and checked on a regular basis. It is therefore recommended to establish a regular maintenance routine to ensure compliance and the proper operation of all system components. 

Regular maintenance will ensure optimal performance, increase reliability and durability, and maintain air purity (quality). For that reason, a service log for each component should be kept up to date and be available for the purpose of inspection, alongside equipment user guides which must be retained by the owner/operator of the equipment. 

Inspection routines

While most mechanical equipment will have specific maintenance requirements recommended by the OEM, it is the user’s responsibility to ensure that the equipment is kept at its optimal operating parameters by carrying out specified inspection activities. These inspections can contribute to maintaining efficiency and reliability. 

Some examples of inspections could be: 

• Checking of individual equipment status displays
• Checking of oil levels
• Checking dewpoint readings on dryers
• Checking for the presence of condensate

Levels of competence 

As with any piece of industrial equipment, maintenance activity should be carried out in
accordance with the manufacturer’s/supplier’s recommendations. However, there is an important distinction to be made between a person that is qualified and a person that is deemed competent to undertake these tasks in a safe manner.

‘Qualified’ implies that the person has undergone a level of training and assessment appropriate to the task expected of them. In contrast, ‘competent’ implies that the person has the necessary skills, experience, and physical ability to perform the required work. 

Some examples of the levels of competence within an organisation using compressed air may be: 

• User/operator - These are the personnel with the most day-to-day responsibility for the compressed air provision on-site and therefore are the most critical in maintaining safe operating procedures and behaviours. Their role will require knowledge of how to start and stop the system safely, as well as basic emergency procedures for example. 
• Checker - in addition to the above, this person carries out basic checks including checking warning/indicator lamps, gauge or meter readings, fluid level checking and any obvious visible or audible abnormalities. In this role, there is no expectation to take any corrective actions beyond reporting any issues and initiating an emergency shut down or local isolation if appropriate. 
• Basic maintenance provision - personnel in this role should be able to carry out replenishing procedures and tasks safely, which may be specified as a regular requirement in the user manual or to rectify minor problems reported by the checker. 
• Comprehensive maintenance provision - these individuals should have sufficient manufacturer or supplier training to undertake all routine maintenance.
• Comprehensive repairs - Unlike comprehensive maintenance, comprehensive repairs by their nature can be unpredictable, costly and can cause major disruption to production. It is therefore most critical that the organisations and individuals undertaking this work have the resources (stock) and knowledge/training, to diagnose, and undertake the repair in an expedient and cost-effective manner.

Division of responsibility 

During the period where compressed air equipment is covered under the manufacturer/ supplier’s warranty, there will likely be an ongoing requirement for the owner/user to carry out basic checks and inspections and to be able to show recorded evidence of these. In some cases, it may be specified that the manufacturer’s approved engineer carries out any relevant service work. Failure to follow this well-defined requirement can void any warranty agreements and/or subsequent claims. 

Outside of the warranty this no longer applies to the manufacturer’s/supplier’s policy but may however apply to the service provider. There needs to be a clearly identified division between what is expected of internal staff and an external service provider. 

Where a user lacks any suitably competent internal staff, it may be appropriate to have an external specialist attend site more frequently to perform even the ‘low level’ requirements. If the user has a well-equipped maintenance department with experienced staff, then total responsibility may be appropriate if personnel are suitably trained. 

User training

As discussed, the user of the compressed air system should ensure that any person operating the system or any equipment using compressed air is suitably instructed and trained. 


Appropriate training for routine checks may be carried out by the service provider, either at the point of handover or during a scheduled visit, with supporting documentation and instructions left on site for reference. 

Training may also need to be carried out periodically, and should also allow for any changes in personnel, with an appropriate system of record keeping.

BCAS has long been recognised as a provider of training and development for engineers, technical professionals and users of compressed air - and through its eLearning portal, delivers relevant training direct to users. 

Its certificate in working safely with compressed air (WSWCA) training course is an ideal starting point. The hour-long course covers the hazards of compressed air as an energy source, the use of personal protective equipment, and employer and employee responsibilities with respect to health and safety when using compressed air and a list of safe working practices to be followed. 

For further information about the training courses available from BCAS, please visit https://elearning.bcas.org.uk

British Compressed Air Society

Tel: +44 (0) 207 935 2464

Email: enquiries@bcas.org.uk

Web: https://www.bcas.org.uk/