When it comes to the cost of owning a compressed air system, operators will be well aware that energy accounts for the biggest ongoing outlay.  But, maintaining the compressor over a potential 10-15-year lifespan will also represent a significant expense – making it of prime importance that the installation is serviced by a professional.

Safety first

A vital part of safely and efficiently managing a compressed air system is in the installation, servicing and auditing - all of which have varying amounts of regulation.

Just like other items of industrial equipment, the compressor needs to be installed and maintained correctly to ensure it offers maximum performance and operates safely.

As a result, BCAS continues to remind all compressed air end users to ensure that their employees are fully trained on the requirements of the Pressure Systems’ Safety Regulations 2000 (PSSR), and in particular, the importance of the written scheme of examination

If pressure equipment fails during operation, it can seriously injure or even kill people nearby and cause damage to property

As a result, the HSE states that ‘everybody operating, installing, maintaining, repairing, inspecting and testing pressure equipment should have the necessary skills and knowledge to carry out their job safely’, meaning suitable training is essential.

In particular, a written scheme of examination is required for most pressure systems, which should be drawn up (or certified as suitable) by a competent person – and the system should not be operated or hired out until the scheme is in place and the system fully examined.

The Pressure System Safety Regulations define the legal responsibilities of users and owners and these are many and varied.

It is therefore of prime importance that operators are aware of their duties. For example, before the system can be designed or installed it is the owner’s responsibility to ensure that the safe operating limits are specified (and that they are subsequently reviewed and kept up to date).  

This is where it is advisable to consult with a proven service provider, such as a verified BCAS member - who can help to determine which of the regulations apply to the pressure equipment subsequently provided.

In addition, the user of an installed system and the owner of a mobile system must ensure that the system is kept properly maintained and in good repair, so as to prevent danger.

BCAS is currently offering a 25% discount on its popular ‘Certificate in Understanding the Pressure Systems’ Safety Regulations’ course at (available to customers of BCAS members only, excluding trade) to help businesses train their staff.

This blended learning workshop, one of a number of specialist training courses in our portfolio, covers the written scheme of examination in relation to compressed air systems. It provides knowledge of the PSSR, related standards and codes of practice and is designed to provide the understanding required as a user, manager or provider of written schemes of examination.

Ongoing maintenance

Generating compressed air can be very energy intensive, representing between 5-30 per cent of a site’s total electricity bill.  Coupled with this significant overhead, poor practices and housekeeping can also contribute to unnecessary wastage.

A low cost and regular maintenance regime will help retain low leak rates and reliability of equipment.  Operators should also consider a policy that specifies that energy efficient options are purchased when replacing all equipment – whether it is a basic drain valve through to the actual compressor unit itself.  

Training and involving staff in the safe use of compressed air can also pay dividends. For example, not allowing benches or equipment to be cleaned down with compressed air will save a significant amount of air being vented into the atmosphere.  It is far safer to carry out such cleaning using a vacuum system to reduce the risk of injury.

Genuine spare parts

A compressor, like any piece of industrial equipment is a machine and all machines eventually breakdown.  At some point component parts will need to either be repaired or replaced.  

Therefore, operators should always specify genuine spare parts and avoid the temptation of using initially cheaper alternatives – because in the long term, genuine spare parts can result in significant savings in excess of 25 per cent.

It’s also advisable to question the manufacturer’s policy on spare parts availability and obsolescence.  Some cheaper options offer little in the way of on-going support. This is less of a concern for equipment that is purchased at a discount to only last for a couple of years, but a compressed air system is a long-term investment. End users should therefore take the time to check the credentials, the ongoing availability and the longevity of the spare parts they are investing in, to avoid costly mistakes at a later date.

Energy audits

As part of an ongoing compressed air maintenance programme, it is advisable to have regular energy audits taken out on all aspects of the compressed air system as they don’t always run to their best potential, with incorrectly specified equipment, leaks, poorly sized pipework, long distance, excessive bends, fittings and improper use all affecting energy efficiency levels.

Around six years ago, the European Committee for Standardisation (CEN) made EN ISO 11011, the International Standard for compressed air efficiency, an approved European Standard.  

Prior to EN ISO 11011, individual manufacturers and suppliers had to decide for themselves how to measure compressor energy consumption, and what recommendations to make to their customers. With the introduction of EN ISO 11011, companies now offer advice and carry out assessment and auditing procedures on a level playing field. Like for like energy audits can only benefit the end-user and make it easier to decide what action to take.

BCAS would strongly encourage end-users to see the value in assessing their compressed air usage within a standardised framework. It’s likely that many businesses do not know how much compressed air they use, or how much it costs them. EN ISO 11011 will help deliver sustainable results for the businesses that take it on board, saving energy and reducing carbon emissions.

To find out more about the PSSR training course visit https://rebrand.ly/BCASPSSR. To find a BCAS member that can assist with your obligations under the PSSR and that can provide professional service and support visit hwww.bcas.org.uk/directory/default.aspx

BCAS is an event partner at this year’s Maintec event and will be exhibiting on stand M103, from the 3rd to 4th November 2021 at the NEC, Birmingham.

Throughout April, the Society is offering businesses the chance to purchase two of its popular Certificate in Working Safely with Compressed Air workshops for just £48 – and is continuing to offer an additional 25% discount for customers of BCAS members too (excluding trade customers)!

Compressed air is a safe and reliable form of power, accounting for approximately 10 per cent of all the energy used by industry.  However, it is important that both employers and their employees know how to work safely and understand the risks involved if good practice is not followed.

The one-hour, online workshop helps to fulfil employers’ health and safety obligations and provides evidence that each participant has understood safe working practices and their responsibilities.

Straighforward and easy to follow, the course covers the hazards of compressed air as an energy source, the use of personal protective equipment, employer and employee responsibilities with respect to health and safety when using compressed air and a list of safe working practices to be followed.

Vanda Jones, BCAS Executive Director commented: “BCAS is recognised within the industry as a provider of training and development for engineers, technical professionals and users of compressed air. Working with our members we develop training based on industry standards and best practice. These include specialist courses that are tailored to the needs of industry professionals, end users and suppliers; that combine the safe working and understanding of compressed air with its multiple uses.

“Now, more than ever, this training must be delivered to suit the needs of a dynamic and changing workforce.  It’s why we have invested in our new e-learning portal, allowing delegates to learn at a pace, and from a location, that suits – and the one-hour, Certificate in Working Safely with Compressed Air is a great place to start!”

To find out more about the Certificate in Working Safely with Compressed Air course from BCAS and to benefit from the two-for-one offer, please visit www.rebrand.ly/BCASWSWCA

IF PRESSURE equipment fails during operation, it can seriously injure or even kill people nearby and cause damage to property, which is why the Society is now offering a 25% discount on its popular ‘Certificate in Understanding the Pressure Systems’ Safety Regulations’ training course at https://rebrand.ly/BCASPSSR (available to customers of BCAS members only, excluding trade).

The blended learning workshop, one of a number of specialist training courses in the Society’s portfolio, covers the written scheme of examination in relation to compressed air systems. It provides knowledge of the Pressure Systems' Safety Regulations (S.I 2000 No 128), related standards and codes of practice and is designed to provide the understanding required as a user, manager, or provider of written schemes of examination.

According to the latest statistics from the Health and Safety Executive, although reportable workplace accidents in manufacturing continue on a downward trend, there were still 15 fatal accidents in 2019-20, with 13% of these as a result of exposure to an explosion.

Necessary skills & knowledge

As a result, the HSE states that ‘everybody operating, installing, maintaining, repairing, inspecting and testing pressure equipment should have the necessary skills and knowledge to carry out their job safely’, meaning suitable training is essential.

In particular, a written scheme of examination is required for most pressure systems, which should be drawn up (or certified as suitable) by a competent person – and the system should not be operated or hired out until the scheme is in place and the system fully examined.

One such company to have benefitted from the PSSR training course is BCAS member, Cambs Compressor Engineering Limited, who has recently trained its team using the mix of online learning and virtual classroom teaching.

Based in St Ives, Cambridgeshire, the company has been a BCAS member since 1996. Managing director, Mark Fryer is a firm believer in the importance of continuous training of his sales and service engineers, having worked his way up from an apprenticeship at an early age and experienced the benefits of personal and professional development firsthand:

Fryer explains: “It is really important to our business that our team is trained fully in all aspects of compressed air safety and performance if we are to offer consistent advice that can help reduce costs and improve safety for our customers.

“This is particularly the case when it comes to the PSSR regulations, which have such a direct impact on the safe and efficient use of pressure systems. So, when BCAS launched the new PSSR course, we were really keen for our engineers to take part and gain this valuable CPD-accredited certification, to help support the written scheme of examination service that we already offer to all new customers.

“The blended approach has been an excellent way of learning for our teams. An online e-learning module allows each engineer to train at a pace that suits, supported with the virtual classroom sessions where delegates come together to interact and learn from each other, before the final online examination.

“The BCAS training courses are proving an excellent way for our employees to supplement their learning and to achieve a verified qualification.”

As well as benefitting from the PSSR certificate training, Mark and his team have also undergone the ISO 8573 air quality standard course from BCAS, which is also delivered through a blend on online and virtual classroom sessions.

To find out more about the Certificate in Understanding the Pressure Systems’ Safety Regulation training course from BCAS and to book a place, please visit https://rebrand.ly/BCASPSSR

For further information email training@bcas.org.uk

As many as 90% of all industrial manufacturing sites rely on compressed air for some aspect of their operations, so ensuring a high-quality source of air at all times is vital for uptime and productivity.  While compressed air is inherently safe and reliable, it is not clean and contains many hazards in the form of contamination, which need to be treated correctly.

A full understanding of ISO 8573, the international standard for air purity (quality) is therefore vital before any decisions on equipment selection and testing methods are undertaken. This latest course in the Society’s portfolio explains the importance of considering all parts of a compressed air system during the specification process, for suppliers, energy consultants, service providers or end users alike.

With compressed air containing up to 10 different contaminants, the course is designed to help demystify not only the selection of the correct air treatment equipment but to provide practical advice on the impact that these contaminants can have on the processes that the compressed air is being used for.  The standard allows users to select a ‘classification’ for particulates, water and oil, with each classification have a defined limited of contamination.

Learners complete a self-study e-learning module followed by a virtual classroom with a BCAS tutor to help cement learning and understand the most frequently asked questions. The course is completed with an online examination leading to the BCAS certificate in ‘Understanding ISO 8573 – The Compressed Air Quality Standard.’

Roy Brooks, technical development officer at BCAS adds: “In a typical compressed air system there are a wide range of contaminants that require treatment if the system is to operate safely, efficiently and cost effectively. Selecting the right compressed air treatment equipment is essential as it can affect everything from maintenance schedules to the ongoing costs associated with achieving the required standards.

“That’s why, at BCAS, our range of blended and e-Learning courses are designed for the industry, providing practical guidance to help ensure high quality, to cut costs and to improve efficiency for compressed air applications.

“The course is aimed at typical industrial compressed air applications operating at low pressure, with a range between 7 bar g to 20 bar g and provides guidance on the differences between indicative testing and air quality verification, which is a key component of compliance with the ISO 8573 standard.

“We have a number of our virtual classroom courses running throughout the year, so delegates have plenty of opportunity to train at a time to suit them. Coupled with our exclusive 25 per cent discount on course fees for customers of registered BCAS members, there really has never been a better time to book!”

About the 25% discount

To benefit from the offer, end-users should simply contact their supplying BCAS member, who will provide a unique booking code. This code can then be used to redeem the 25 per cent discount off the complete range of e-Learning and blended learning training courses available.  

The offer also includes free, associate membership of BCAS for each customer (excluding trade customers). This provides a host of additional benefits, such as discounted publications, as well as access to compressed air guidelines and the society’s social events.

To find out more about the ISO 8573 training course from BCAS and book a place, please visit http://bit.ly/BCAS-ISO8573. For further information, contact your local BCAS member, email training@bcas.org.uk or call 0207 935 2464.

ANNOUNCED TO celebrate the launch of the Society’s new e-learning portal (e-learning.bcas.org.uk), the offer also includes free, associate membership of BCAS for each customer (excluding trade customers). This provides a host of additional benefits, such as discounted publications, as well as access to compressed air guidelines and the society’s social events.

To benefit from the offer, end-users should simply contact their supplying BCAS member, who will provide a unique booking code. This code can then be used to redeem the 25% discount off the complete range of e-Learning and blended learning training courses available.  

Details of all BCAS members can also be found on the Society’s website at www.bcas.org.uk/directory.  

BCAS has long been recognised as a provider of training and development for engineers, technical professionals and users of compressed air.  It offers a wide range of specialist courses that are tailored to the needs of industry, combining safe working practices, with specific guidance on all aspects of compressed air performance.

These include specialist eLearning courses, which provide practical training for compressed air and vacuum users, alongside a host of health and safety tutorials, with popular courses including:

- Certificate in working safely with compressed air (WSWCA)

- Certificate in compressed air treatment technology (CATT)

- Certificate in compressed air system technology (CAST)

- An employee certificate in maintaining a Covid-19 secure workplace

Blended learning courses combine online tutorials and training with guided learning and assessment by a BCAS qualified tutor.  This helps delegates to learn at a time and place to suit, combining at-home study with invigilated examination. Courses include:

- Certificate in understanding the Pressure Systems’ Safety Regulations (PSSR)

- Certificate in understanding ISO8573

- Diploma in Compressed Air Management (DipCam)

Vanda Jones, BCAS Executive Director comments: “The start of a new year is always a good time for companies to consider their training requirements and help their staff to brush up on their skills!  With home and remote working now making it more challenging to organise face-to-face training for every requirement, we are delighted to launch our new eLearning portal, helping engineers, compressed air users and industry professionals to learn at a pace - and from a place - that suits.

“Add to this the exclusive 25 per cent discount available to all our members’ customers, and there really has never been a better time to train.”

Visit e-learning.bcas.org.uk/ to search the full range of courses. For further information, contact your local BCAS member, email training@bcas.org.uk or call 0207 935 2464.

https://www.bcas.org.uk/

Many compressed air system improvements will require elements of maintenance or equipment/system upgrade, but the human element should not be overlooked. Operators can make substantial efficiency improvements by implementing new processes and encouraging staff to use compressed air more efficiently and safely.

Take a system approach

A compressed air system is just that; a system, and every element of it impacts on its energy consumption. When discussing efficiency and the potential savings that could be realised, it is important to take a full, system approach. – from generation to air treatment to distribution and finally, the point of use.

Identify wastage

An ideal place to start is to identify some of the key areas where valuable compressed air can be wasted by processes or people downstream of the compressor.  

For example, if you install the most efficient compressor available, but connect it to a system with a 30 per cent leak rate, then all the benefits are lost.  Customers should aim to improve the overall system efficiency. Efficiency in the generation of compressed air is one aspect but targeting avoidable waste in the system is even more important.

Detect and fix leaks

Reducing air leaks can have a big impact on overall system efficiency. Leak rates in industrial systems are typically between 20 and 40 per cent, meaning the compressor has to work harder, and therefore consume more energy, to compensate for the pressure loss.

A tiny leak of just three millimetres can cost more than £700 a year in wasted energy, but an out-of-hours survey can identify leaks easily. Simply walk the site listening for leaks.

The location can then be confirmed by using an ultrasonic leak detector, a leak detection spray or even a soap solution brushed on to pipe fittings.

Switch off

Even when off-load, compressors can consume up to 70 per cent of their full load power, so switch off units overnight where there is no demand for air.  Operators should check the time switch settings regularly to ensure they are optimising running hours as this can also help to reduce maintenance costs.

Where appropriate, energy management systems should be installed to turn compressors off when they are not being.

Review compressed air usage

Compressed air is energy intensive to run, and cheaper options exist for certain jobs.  For example, there may be more energy-efficient alternatives for drying and ventilation.  However, for applications where there are risks of explosion or electrical interference, compressed air remains the best option.

Train and involve staff

Simple awareness sessions to advise staff about the costs and safe use of compressed air can be highly effective. For example, not allowing benches or equipment to be cleaned down with compressed air will save a significant amount of air being vented into the atmosphere.  

Don't over treat air

Treating air to remove dirt, water and oil is necessary but can use a lot of energy. Most processes are likely to only need a proportion of the compressed air to be treated to a very high purity. In these cases, excellent savings are achievable be treating all the generated air to the minimum acceptable level and improving the purity (quality) to the desired level at the usage point.

Further reading

BCAS’s Reducing Energy Consumption from Compressed Air Usage’ best practice guide
BCAS’s ‘The Filtration and Drying of Compressed Air’ best practice guide

www.bcas.org.uk

Working safely with compressed air (WSWCA)

The hour-long course covers the hazards of compressed air as an energy source, the use of personal protective equipment, employer and employee responsibilities with respect to health and safety when using compressed air and a list of safe working practices to be followed.

Compressed air system technology (CAST)

CAST provides a comprehensive introduction to the main principles of compressed air systems. It is a unique qualification to meet the needs of employers for compressed air training. 

This course is highly relevant to anyone needing to know more about compressed air production and use, relevant health and safety issues, legislation and energy efficiency. It is of relevance to manufacturers, distributors, installers and for any business using compressed air equipment and systems.

Maintaining a Covid-19 secure workplace

The course is based on the Government guidance on understanding how to safely work during the coronavirus pandemic, issued 11th May 2020.

It covers the workplace types identified by Government, including outdoor work, factories and warehouses, offices, branches, vehicles and is designed to fulfil the employer’s requirement to provide information and training to their employees in maintaining a Covid-19 secure workplace.

An introduction to PSSR 2000

This course provides the candidate with a comprehensive understanding of the Pressure Systems Safety Regulations 2000, which cover the safe design and use of pressure systems.

The single aim of PSSR is to prevent serious injury from the hazard of stored energy (pressure) as a result of the failure of a pressure system or one of its component parts.

If you are an owner or user of a compressed air system this course is highly relevant. It will guide you through your obligations under the regulations and demystify some of the terminology used when required to implement the regulations.

It will help to clarify the written scheme of examination process and how competent persons are defined.

This course is applicable to anyone needing to know who has responsibilities under PSSR 2000 and its relevant health and safety issues, and legislation. It is of relevance to manufacturers, distributors, installers and for any business using compressed air equipment and systems.

An Understanding of IS08573 – Compessed air purity verification or indicative testing

This course provides the candidate with a comprehensive understanding of ISO 8573 - the compressed air purity standard.

As compressed air is considered a utility, this course is beneficial to anyone who has responsibilities for pre-requisite programmes and their elevant health and safety issues, and legislation. It is of relevance to manufacturers, distributors, installers and for any business requiring clean and dry compressed air systems.

An introduction to air treatment

There are a wide range of compressed air applications that require very different levels of purity and therefore need different air treatment equipment and methods.

For example, clean air is not needed for tyre inflation on a garage forecourt, so very little would be invested in air treatment equipment. If however, the air is to be used in a micro-electronics process or a medical application, all contaminants must be reduced to very low levels and therefore, sophisticated air treatment systems are required.

This course details where contaminants come from and how to remove them using some of the air treatment processes available – and is of relevance to manufacturers, distributors, installers and for any business requiring clean and dry compressed air systems. 

For further information about the full range of BCAS training courses on offer, including class-room based training, please email training@bcas.org.uk or call
the number below.

www.bcas.org.uk

During this crisis, many organisations have had to change their focus and BCAS is no different. On the 16th of March, along with many other businesses, we closed our London office and the team started working from home.

With this change, it soon became clear that what our sector needed from BCAS was clear and concise interpretation of the Covid-10 guidelines. I am pleased to say that we rose to the challenge and have improved our links with Government departments in the process; finding them very responsive to the industry challenge and keen to listen, learn and adapt.

Building back better

The choices very early on in the pandemic were to furlough or not to furlough and fortunately, with the support of the Board, most of the BCAS team has continued to work.  We took this time as an opportunity to renew our commitment to member support and an interpretation of guidance as well as lobbying for the clarity and changes our sector required on a daily basis.   

Indeed, it is in times of challenge and change that trade associations come into their own, offering impartial support and advice - not only to their members but to the wider supplier and end-user community.

Improving our online training and producing new technical advice and guidance materials for end users was our second key deliverable during this time. We have delivered a new learning management system and by the time we return to our routine committee and standards meetings in September, we will have transferred all of our learning modules online. This will provide easier access for our members and a host of valuable online materials for users of compressed air, vacuum and downstream air treatment products. A great investment for the future supporting best practice and creating a safer and better-informed customer and industry at large.

A quick bounce back?

Our industry statistics are always an excellent barometer of industry performance. They use order volumes for our manufacturing sector and revenue figures for our service delivery sector, to provide an instant indicator of where the broader economy is heading.

The sharp downturn in the equipment orders is unsurprising, as is the fact that the service sector suffered less. Our industry did not stop working during the crisis. Key sectors still needed service support and our engineers did a sterling job in keeping industries such as health, utilities, food and beverage as well as manufacturing working safely.

Building on the past

For many years BCAS has been the secretariat for many standards’ committees, producing technical standards for our industry on a broad range range of products and services. BSI and ISO for example, depend on industry participation to ensure these standards are balanced, workable and add value.

Standards are core to the trade association and as we move into the post EU era, it will be critically important to ensure members and users are well informed of any changes and potential divergence in this important area. As well as the day-to-day standards development work, we are working closely with BSI to ensure that our industry key players are well represented at this important crossroad. We are a ‘go-to’ service for standards’ interpretation in our sector and this new era brings with it challenges that we are ideally placed to support.

Working in the present

As we get used to working in our new normal, we are refocussing on the industry’s requirements.   We have now left the EU and uncertainty still abounds as we advise our members to prepare for a hard Brexit. This is primarily on the basis that business needs time to prepare and that is simply a commodity that we don’t have as we near the end of the transition period.

We continue to work together with other trade associations in our sector to ensure that the voice of the sector is heard in the most efficient way.

Support for the future

Often referred to as the fourth utility, it is estimated that 10 per cent of global industrial energy usage is used to compressed air. It is therefore incumbent on BCAS, and its members, to ensure that we use our planet’s valuable resources wisely.

The UK’s 2050 net zero target is one of the most ambitious in the world. Net zero means any emissions would be balanced by schemes to offset an equivalent amount of greenhouse gases from the atmosphere, such as planting trees or using technology like carbon capture and storage. These new schemes require industry input and at BCAS we are rising to the challenge, working with the Energy Related Products directive through our colleagues at Pneurop and understanding how this will be implemented or amended to the UK’s requirements.

BCAS has long held ambitions to demonstrate the ability of users to cut their carbon footprint by using a safe and efficient approach to the whole compressed air system - as well as providing a comparative structure for users of air to clearly understand their systems’ energy requirements and how to reduce them.

Just a 10 per cent reduction in leaked/generated air usage would have a significant and positive impact on the climate for future generations to come. The BCAS board and our members recognise that this has to be a strategic focus in the coming months.

Why BCAS

With increased emphasis on the value of using a responsible supplier, the BCAS website is there to provide a wealth of practical, free advice.  Once you have downloaded the energy reduction guide (https://www.bcas.org.uk/websiteform/reducing-energy-consumption-from-compressed-air-usage-form-8.aspx), use our ‘find a member’ section to source your partner in this energy challenge. All members adhere to our code of conduct, so you can be sure that you are receiving trusted advice.

About BCAS

BCAS is the only UK technical trade association representing manufacturers, distributors and users of compressors, vacuum pumps, pneumatic tools and allied products.

The society actively represents the interests of the compressed air industry to the UK government as well as to many European and other overseas institutions. The society and its members have an active input into all proposed compressed air systems’ energy and environmental legislation and standards through its membership of EURIS taskforce, the European body PNEUROP, and by its association with the prime voice of the EU engineering industry, ORGALIME.

The society’s mission is to be the united voice of the UK compressed air industry, serving as the unbiased authority on technical, educational, promotional and other matters that affect the industry and its customers.

Early in the pandemic there were claims that compressed air may be a potential source of Coronavirus COVID-19, requiring the installation of sterile air filters (or more frequent filter sterilisations and element changes) to prevent the contamination of food, beverage or pharmaceutical products.

At this time, BCAS issued a statement of guidance quoting the World Health Organisation’s (WHO) position that Coronavirus COVID-19 was not an airborne virus.

On 9th July 2020 the WHO updated its guidance to include the possibility of airborne transmission of the virus, stating that: “Short-range aerosol transmission, particularly in specific indoor locations, such as crowded and inadequately ventilated spaces over a prolonged period of time with infected persons cannot be ruled out.

“However, the detailed investigations of these clusters suggest that droplet and fomite transmission could also explain human-to- human transmission within these clusters. Further, the close contact environments of these clusters may have facilitated transmission from a small number of cases to many other people (e.g., superspreading event), especially if hand hygiene was not performed and masks were not used when physical distancing was not maintained.”

BCAS has therefore updated its guidance to include the possibility of airborne/aerosol transmission, but would like to reassure users that this does not impact or change the previously stated advice about the risk and management of Coronavirus in relation to their compressed air system.

The simple facts:

- Compressor rooms are well ventilated.

- There is minimal risk of short-range aerosol transmission at the point of compressor intake.

- At the point of compression, the air temperature is high, the heating time is short and with the compression processes, viruses do not tend to survive.

- During compression, the compressed air temperature is higher than the temperature needed to kill COVID-19. It is documented that heat at 56oC kills the Coronavirus.

- Appropriate downstream purification systems typically treat the compressed air to aerosol sizes significantly smaller than those referenced by the WHO (human generated aerosols <5 micron, good filtration down to <0.01 micron)

- The compressor has two-stage filtration (panel and intake filter) prior to compression. Air is drawn into an air compressor, through panel filters and then through intake filters on its way to the compression chamber. Ambient air contaminants would have to remain in aerosol form to pass through panel and intake filters in order to enter the compressor intake.  This is highly unlikely, but even if panel and intake filtration was compromised, the contaminant would not remain in aerosol form during compression.

Best practice guide 102

BPG102 includes guidance on the installation of appropriate inline coalescing filtration and its regular maintenance, as these will remove multiple contaminants include micro-organisms, oil and water aerosols.

In addition, the guidance recommends using a dewpoint of -40 oC to inhibit the growth of micro-organisms, and filtration to reduce the micro-organisms and particulate.

The specification requires the installation of a minimum of two aerosol reduction filters (down to 0.01mg/m3 of oil aerosol and particle reduction down to 0.01 micron).

These protective measures will ensure that, in the unlikely event that the COVID-19 or other virus still survive the heat of compression, aerosol reduction filters in the compressor room combined with a very low dewpoint and point-of-use dry particulate filters will remove the risk from compressed air.

To see the previous guidance, please visit https://www.bcas.org.uk/article/covid-best-practice-84.aspx.

BPG102 is available for free download from the BCAS website. Visit https://www.bcas.org.uk/websiteform/food-beverage-grade-compressed-air-best-practice-guideline-102-5.aspx

For further information please visit the BCAS website at www.bcas.org.uk or call the technical helpline on 0207 935 2464.

Simulation of an operator using a compressed airline to remove MWF from a machined component, resulting in personal contamination with MWF droplets. The MWF was dosed with a blue dye, which under an ultra-violet lamp shows up as blue deposits on, left, the end of the arm and upper leg, and right, the upper torso and face

Metalworking fluid (MWF), often referred to as coolant or suds, is used during the machining of metals to provide lubrication and cooling. Compressed air guns (blowguns) are commonly used in the engineering industry for ‘blowing down’ to clean and remove MWF from machined parts and the bed of the machine. This blowing down creates mist/aerosol which can be breathed in by operators and others working in the vicinity.

Inhalation of MWF mist can cause serious lung disease, including occupational asthma and occupational hypersensitivity pneumonitis. The prosecution of a company after three workers developed debilitating lung conditions is a stark reminder of the need to control the risk. One worker has been so severely affected they have become virtually paralysed, another will never be able to work with MWF again, and a third must have special measures in place to ensure he never comes into contact with MWF. 

MWFs can cause dermatitis through direct contact with unprotected skin, particularly on the hands and forearms, or when MWF contaminates clothing and soaks through. Metalworking machine operatives are in the top five occupations with the highest annual rates of occupational dermatitis. Using compressed air for blowing down, increases the risk of inhaling MWF mist and causes splash contamination of skin and clothing, as can be seen in the photographs. 

The use of compressed air for blowing down also creates a number of safety hazards for those involved. Noise levels are normally high and there is a significant risk of permanent hearing damage from prolonged exposure. There is a risk of compressed air entering the operator's bloodstream, which can result in death. Eye injury including blindness can occur if dust particles or swarf bounce back at the operator.

You should look first to prevent exposure at source, so instead of blowing down components using compressed air guns, you should consider using alternatives. Examples include vacuum guns, absorbent materials, low-pressure coolant guns, spindle-mounted fans or automatic compressed air hoses (operated with computer numerically controlled (CNC) machine enclosure doors shut). Finished components can be cleaned in industrial washing/degreasing machines. The cleaning of machine surfaces using compressed air should be avoided, suitable swarf vacuums should be used to remove wet swarf and chips from machine surfaces.

Reduce exposure

However, where there is no practical alternative to using compressed air guns there are still measures you can take to reduce exposure. You should reduce the exit pressure of the compressed air to as low a level as practicable (as a guide 30psi/2.1bar is effective at cleaning). Different nozzle designs will also allow guns to be operated at a lower pressure and reduce noise levels. 

In addition, you should blow down components inside the CNC machine enclosure with the local exhaust ventilation running or provide a separate enclosure for cleaning purposes. You should also consider using compressed air guns with longer lances (e.g. 30 cm) as this increases the distance from the source of mist and reduces splashing on to the skin.

According to the British Compressed Air Society reducing the operating pressure of blowguns down to 2 bar, from the fixed system pressure of around 7 bar, can reduce operating costs by up to 60%. They suggest you check the operating pressure on all blowguns and discuss with the blowgun manufacturer whether it can operate at a reduced pressure. The pressure can be reduced by fitting pre-set tamper-proof regulators at the take off point from the fixed pipe system. It may be worth considering a separate pressure reduced supply for all blowguns.

Further information  
https://www.hse.gov.uk/engineering/faqs.htm   
https://www.hse.gov.uk/metalworking/index.htm   
https://www.bcas.org.uk/media/Download.aspx?MediaId=67