|
Edward Lowton
Editor |
|
1/14 (1 to 10 of 140)
| BCAS appoints new Learning Support Officer to further enhance training offer | 24/01/2025 |
|---|---|
|
FAY HUTCHINSON has joined the British Compressed Air Society (BCAS) in the newly created role of Learning Support Officer. Working alongside Terry Collier, BCAS’s learning and development officer, the new role will see BCAS further enhance the breadth and range of compressed air and vacuum training courses and approved accreditations available, with particular focus on increasing participation in its compressed air and vacuum technician (CAVT) apprenticeship. Hutchison has a wealth of training experience, gained in roles both within engineering and the higher education sector. Starting her career in the stainless steel and aluminium sector, she holds a first-class honours degree in business management and a master of business administration (MBA) and has recently completed a level 6 diploma in career guidance and development. "I am really looking forward to using my skills to help further enhance the training support available to our members. I am already speaking to members about our CAVT apprenticeship and some of the ways we can refine it further through progression routes, as well as being able to advise on the range of bursaries and levy funding that could be available," Hutchison stated. Of particular benefit to BCAS and its members is Hutchison’s experience gained during her work with higher education institutes. She has held several employer relationship roles, most recently at the University of Greenwich, where she has secured successful industrial work placements for students during their university studies. She has also been actively involved in encouraging businesses to offer degree apprenticeships, using their apprenticeship levy where appropriate to either bring new talent into the business or to upskill existing members of staff. "The industry is only too aware that recruiting and retaining skilled staff into the compressed air and wider engineering sector is challenging. Offering high-quality training, whether through our apprenticeship scheme or one of our many CPD-approved courses, can help to deliver the next generation of engineers that our sector needs," said Ashley Quarterman, BCAS executive director. "It is great to welcome Fay to the team and to be able to draw on all her experience in both the industrial and education sectors. She understands how effective learning environments can be created, alongside the pressures faced by employers to continually train their teams and this will be of genuine benefit to our members." |
|
|
|
|
| Tackling the skills gap | 26/02/2025 |
|
BCAS is driving upskilling efforts through flexible courses and resources, supporting employers in addressing the skills gap FIGURES FROM the recent Employer Skills Survey (2022) from the Department for Education show that the amount spent on training in England has dropped to its lowest ever level. In the manufacturing sector, there was also a decrease in employers providing training, a drop of six percentage points in 2017 to 54% in 2022 and the sector was one of the establishments most likely to have skills gaps at 19%. However, there are many employers that are bucking this trend, working with organisations like the British Compressed Air Society (BCAS) to ensure their employees are suitably trained and upskilled. Indeed, Make UK, the Manufacturers’ Organisation states in its 2030 Skills, Closing the Gap report that "The majority of those who will be working in manufacturing in 2030 are already in the workforce. As such, employers are increasingly focused on upskilling and retraining their existing employees, both to ensure that their technical skills keep pace with changing needs, and to retain that talent in the business over the longer term. This is the key priority for manufacturers over the next decade." Why learning and development? We’ll begin by exploring the purpose of learning and development (L&D) activities and how these fit within an organisation's people policies. In simple terms, L&D is about ensuring the right people are on board, with the right skills, at the right time. This is a significant challenge for all HR departments and individuals. However, BCAS is making positive strides, and working in a sector of professional, highly skilled specialists sets us apart, making this a key benefit of investing in one of our many training courses. The role of BCAS BCAS is committed to supporting users of compressed air and its members on this journey. We employ specialists in learning and development as well as technical standards. Some of the current initiatives we are working on with the industry include:
Feedback from individuals and businesses is crucial to the effectiveness of L&D. We are updating training materials and developing new initiatives continually. BCAS remains dedicated to helping member organisations achieve the necessary skill levels in the sector, and users of compressed air to be able to upskill their workforce and have access to unbiased information. Like all businesses, we adapt to the ever-changing external environment and communicate these changes as needed through committee meetings, discussions, and L&D events. A comprehensive range of training courses BCAS offers a diverse range of fully online and blended learning courses tailored to fit the convenience of trainees, whether they're learning from the office or at home. These courses are designed to be flexible, accommodating the pace and place that best suits the learner. Discounts and affordability Courses start at just £35.00, with additional discounts of up to 25% available for customers of BCAS members, along with free associate membership. To access these benefits, customers need only inform BCAS of their compressed air supplier when booking. eLearning Courses
Blended Learning Courses BCAS’s CPD-approved blended learning courses combine online tutorials with guided learning and assessments led by qualified tutors. This format allows for flexible study, with invigilated exams ensuring comprehension and competence.
BCAS’s training courses are a valuable resource for anyone involved in the compressed air industry, offering a range of qualifications from basic safety to advanced technical management. For more information, visit the BCAS eLearning portal at e-learning.bcas.org.uk or email training@bcas.org.uk For more information: Tel: +44 (0) 207 935 2464 |
|
|
|
|
| CSCS card update: The current state of play | 03/01/2025 |
|
THE BRITISH Compressed Air Society’s (BCAS) important work to support and influence the proposed changes to the CSCS card continues at pace. The Construction Leadership Council (CLC) is requiring proof of competency in CSCS scheme, covering all industrial sectors. It intends to enforce this from January 2025, using approved apprenticeship schemes to measure competency. The Building Engineering Services Association (BESA) is the industry body that is overseeing the work of the compressed air industry. The skill cards’ situation is exceptionally difficult for everyone in the industry and BCAS understands the pressure that this is placing on organisations. Through numerous meetings and requests for information, the Society continues to lobby for a better outcome. Obtaining a CSCS card via an apprenticeship So far, there is one way to achieve a skills’ card for the compressed air sector. That is through the Compressed Air and Vacuum Technician apprenticeship, which was developed by the BCAS members on the Training and Development Committee. Once an employee is on this scheme, they receive a red trainee card. When they qualify, they can then apply for a gold card. BCAS has formally objected to this requirement for a full apprenticeship qualification on several grounds, as an apprenticeship may not be suitable for many currently serving engineers in this field. The Society is waiting to present to the panel of experts, where it will be highlighting what it considers to be flaws in this argument. Working towards a formal qualification It is the Construction Skills Council’s clear decision that from January 2025 work will not be completed on new construction projects without a skills’ card. To obtain such a card the employee must have an industry-recognised qualification. BESA oversees the compressed air industry. BCAS has had many meetings with the BESA team to find the best outcome for its members and the wider sector. The society argues that allowing an NVQ to be an alternative qualification for our sector is the best way forward. We have worked to:
Next steps BCAS remains committed to apprenticeships where appropriate and working collaboratively with the Construction Skills’ Council to ensure the safety of all employees. The time importance is critical, and the Society continues to push for a swift resolution. Terry Collier is training and development Officer at BCAS Tel: 0207 935 2464 |
|
|
|
|
| Ensuring workplace safety with compressed air | 18/12/2024 |
|
SAFETY IS a fundamental concern in all workplace settings, including construction sites, factories, and other industrial environments to name a few. Business leaders have a duty to prioritise the safety of their employees and to protect their assets. Compressed air is a versatile energy source, accounting for approximately 10% of all the energy used by industry and must be handled with care. Although the incidence of injuries related to compressed air systems is relatively low in the UK, compressed air systems can pose significant hazards if not properly maintained or the proper precautions taken. Components such as compressors, hoses, pneumatic tools, and electrical connections all have associated risks and the high pressure within these systems can cause serious injuries. Continuous efforts to enhance safety standards and reduce complacency are therefore essential. Barriers to safety Research indicates a strong correlation between complacency and workplace incidents. AA research paper headed Identifying Root Causes of Construction Accidents published in 2000 by the Journal of Construction Engineering and Management identified human factors, particularly complacency, as significant contributors to accidents in the construction industry. This underscores the necessity of constant vigilance and strict adherence to safety protocols. One challenge in promoting a culture of safety is the generational gap in safety perceptions. While younger workers often view new safety measures as standard practice, older employees that have been carrying out their duties for some years may regard them as unnecessary. Bridging this gap is vital for the successful implementation and acceptance of safety protocols. The importance of compressed air safety Training and education Comprehensive training is crucial for all operators working with compressed air systems. Training programs should include detailed instructions on the safe and efficient operation of compressors, awareness of potential hazards, and strategies for risk mitigation. Air compressor safety tips
Conclusion Safety is an ongoing commitment in any workplace. Implementing thorough training and safety measures for compressed air systems is essential to protect workers, prevent accidents, and ensure equipment longevity. To find out more about the Certificate in Working Safely with Compressed Air course from BCAS, please visit: tinyurl.com/5z9e8ppm Terry Collier is training and development officer at BCAS Tel: 0207 935 2464 |
|
|
|
|
| Best practice for sensor calibration | 18/11/2024 |
|
CALIBRATION IS essential in the compressed air industry to ensure systems operate efficiently, safely, and reliably. In an industry where precision is crucial, routine sensor maintenance and calibration are indispensable for maintaining the high standards required in modern manufacturing. Calibration of sensors in a compressed air system should be conducted regularly to ensure accurate measurements. The frequency of the sensor checking should be proportional to the safety-critical nature of the process or dependant on the sensor’s impact on process variability. For critical measurements, sensors should be checked frequently to ensure accuracy. If a measurement point significantly influences process control - for example, 10% or higher - the sensor should be checked regularly until sufficient data is collected to extend the checking interval. For less critical measurements that have, for instance, only a 0.01% influence on the control of the process, the checking interval can be extended or, in some cases, stopped altogether based on collected data. Methods for checking and calibrating sensors There are two primary methods for checking and calibrating sensors in a compressed air system: routine in-situ checking and laboratory calibration. Both methods require accurate recording and documentation of the check/calibration procedure. Routine in-situ checking: This involves using a portable checking device to verify the accuracy of the installed sensor without removing it from the process. The portable device is brought to the sensor's measuring point, and readings are compared with the live online sensor. To ensure reliability, a minimum of three measuring points should be checked across the sensor's likely working range. This is known as an ‘as found’ check as opposed to a calibration or recalibration. It is quick and non-disruptive to the process, but less accurate than laboratory calibration. Laboratory calibration: This is a more thorough and accurate method, which involves removing the sensor from the compressed air system and calibrating it in a controlled environment, such as an approved laboratory or workshop. The sensor is calibrated using a reference standard with an inaccuracy factor lower than the device being checked. It is a controlled process, using a trained operator to calibrate the sensor, across multiple points, ensuring accuracy throughout its range. This method typically includes both an ‘as found’ check and, if necessary, an ‘as left’ (adjusted) calibration to bring the sensor back into specification. While laboratory calibration is more accurate, it requires more time and a spare calibrated sensor to be installed temporarily to avoid process interruption. Examples of routine checks These two examples of routine checks in a compressed air treatment system illustrate the importance of regular sensor maintenance and calibration:
Tel: 0207 935 2464 |
|
|
|
|
| Mitigating rising supply costs with on-site nitrogen generation | 09/12/2024 |
|
FROM FOOD preservation, to chemical manufacturing, to electronics’ production - industry uses nitrogen gas extensively for its inert properties, helping to prevent oxidation and combustion. Yet purchasing supplies of the gas externally can be costly, meaning many manufacturers are turning to their compressed air systems to generate guaranteed-purity nitrogen on site. Nitrogen generation - how does it work? Ambient air typically consists of approximately 78% nitrogen, 21% oxygen, and 1% made up of other gases, including water vapor and carbon dioxide. Once the ambient air is drawn into the system, it is then compressed to a higher pressure before downstream filters and dryers purify the air to remove particulates and moisture. The purified air is then directed to a nitrogen generator, using either membrane separation or pressure swing adsorption technologies - effectively separating the nitrogen gas from the other components in the treated air. The generated nitrogen is then stored in a buffer tank to ensure a steady supply and consistent pressure. Advanced control systems monitor and regulate the purity and flow rate of the nitrogen, ensuring it meets the specific requirements of the application. One of the key advantages of on-site nitrogen generation is its seamless integration with existing compressed air systems. These systems can be tailored to specific needs, offering precise control over nitrogen purity and flow rates. Adjustments can be made quickly and easily, providing flexibility for industries with varying nitrogen demands. The cost-saving benefits of on-site nitrogen production
By generating nitrogen on-site, manufacturers can eliminate the recurring expense of purchasing nitrogen cylinders or bulk liquid nitrogen – and the associated time and expense of scheduling deliveries. Logistics are also simplified, with less time and labour required for managing nitrogen supplies, allowing factory personnel to focus on core activities.
On-site nitrogen generation systems only produce nitrogen as it is needed, adjusting production rates in real-time to align with operation needs. This reduces the necessity for large and expensive storage tanks or cylinders and the ongoing management of inventory.
As these systems produce nitrogen only when needed, operators can avoid the energy waste associated with overproduction and storage. In addition, on-site systems can be scaled up or down based on demand, ensuring cost-effective nitrogen production without overcapacity or shortages.
On-site generation ensures a continuous supply of nitrogen, minimising production downtime due to delayed or missed deliveries. Routine maintenance can also be planned around peaks and troughs in demand, enhancing operational efficiency.
Self-generating the nitrogen supply required helps operators mitigate for market fluctuations and price increases associated with a bought-in supply, enabling a more predictable and stable cost structure.
Long-term operational savings often outweigh the upfront costs of the nitrogen generation equipment, and it is not uncommon to achieve savings in the region of 90%, compared to the cost of bought-in nitrogen cylinders. Ashley Quarterman is executive director designate at BCAS Tel: 0207 935 2464 |
|
|
|
|
| Maintenance best practice for compressed air | 04/11/2024 |
|
COMPRESSORS ARE the workhorses of many industrial applications, often running continuously in challenging conditions. Add to this the rising cost of energy and it is vital that compressed air systems operate efficiently. Here are 10 essential steps to maintain and extend the lifespan of your compressed air system - with a handy troubleshooting guide for the most common issues. 1. Implement a regular maintenance schedule Regular maintenance is vital for the efficiency and longevity of your compressed air system. Always follow the manufacturer’s recommended service intervals and procedures. Routine checks help avoid energy losses due to poorly performing equipment and prevent unplanned outages. Establish a maintenance regime that includes regular checks of all components of the system, from the compressor to the ancillary equipment. 2. Consider compressor location The location of your compressor significantly impacts its efficiency, with high temperatures likely to increase energy consumption and the potential for equipment failure. Ensure that compressors are situated in a dry, clean and cool area, installing additional ventilation if necessary to help prevent costly repairs. 3. Conduct regular air leak inspections Air leaks are very costly. Even a small 2mm hole can waste over £1,249 annually in energy costs, but as air leakage presents no danger, it is often left unchecked. High leak rates can cause pressure fluctuations, slowing down production and causing the compressor to work harder (and therefore consuming more energy) to generate the same volumes of air. Inspect the compressed air pipework for leaks and implement a robust repair regime by tagging the most serious leaks first and remedying before moving on to smaller leaks. 4. Monitor and replace inlet filters Inlet filters prevent contaminants from entering the compressor and causing unnecessary damage to components parts. Check and replace these filters routinely before the pressure drop across them becomes significant. Clean filters ensure the compressor operates efficiently, reducing energy consumption and extending the equipment's lifespan. 5. Don’t neglect ancillary equipment A compressed air system comprises more than just the compressor alone. Regularly maintain ancillary equipment such as dryers, filters, air receivers, and pipework. Neglecting these components can lead to inefficiencies and system failures. 6. Embrace predictive maintenance Moving from reactive to predictive maintenance can save time and money. Predictive maintenance uses data analytics and Industry 4.0 technologies to anticipate potential failures before they occur - and with so many technologies now available, investment can prove very cost effective. Indeed, the payback period can be rapid, compared to the costs of unexpected downtime, helping keep your compressed air system operating reliably and with high energy efficiency. 7. Use genuine spare parts Always opt for genuine spare parts designed specifically for your compressor. While cheaper alternatives may seem cost-effective, they can compromise system performance and lead to failures. Genuine components are designed specifically for the equipment they are intended for, helping avoid unnecessary maintenance or rework, while maintaining excellent system performance. 8. Train personnel properly Good housekeeping techniques can soon pay dividends, so ensure that all personnel involved in the operation and maintenance of the compressed air system are trained. A competent operator can help in the early identification of issues and thorough maintenance practices, helping avoid a small, easily rectified problem from becoming a major equipment breakdown. 9. Implement energy management practices Good energy management isn’t only crucial for cost control. It also plays a strategic role in a site’s environmental sustainability commitments. Installing energy-efficient compressors, variable speed drives and ancillary equipment will clearly help in the drive to reduce electricity consumption, but there are numerous maintenance regimes that will help to lower consumption too. For example, switch off compressors when they are not in use to avoid idling, identify and fix air leaks and replace inefficient components with energy-efficient alternatives. 10. Perform regular system audits Regular audits of the compressed air system can identify inefficiencies and areas for improvement. BCAS members can assist with data logging - helping you to understand your system’s performance and pinpointing specific issues that may not be apparent during routine maintenance. Troubleshooting common issues Inconsistent pressure Inconsistent pressure is a common issue in compressed air systems. It can be caused by air leaks, clogged filters, or malfunctioning pressure regulators. Inspect the piping and components regularly for blockages or build-up of debris that could restrict airflow. If pressure fluctuations persist, consider consulting a BCAS member to perform a thorough system analysis. They can install pressure regulators to ensure consistent pressure throughout the system, which are easy to adjust to maintain the system’s requirements. Excessive noise Excessive noise can indicate air leaks, loose components, or worn-out parts. Start by inspecting and tightening all components, ensuring they are secure. Check for worn or damaged parts such as bearings and belts, lubricating or replacing them as necessary. Clean or replace dirty air filters to improve airflow and reduce noise. If the problem persists and it is not feasible to install the compressor away from the point of use, your compressed air specialist may be able to add soundproofing materials or enclosures. Contamination Contaminants like oil or particulate matter can degrade product quality and damage pneumatic equipment. Install and replace air filters regularly to remove contaminants. Ensure that the compressor is operating within the recommended parameters to minimise oil carryover. And remember to dispose of waste oil in line with the Hazardous Waste Regulations 2005 Moisture in the air system Excess moisture can cause rust, corrosion, and damage to pneumatic tools and equipment – and in stringent hygienic environments, will not provide the high air quality levels demanded by the application. First, ensure that condensate drains are functioning correctly and are emptied regularly. Next, audit your downstream air dryers to ensure they are removing the necessary moisture from the compressed air. Finally, check and replace filters and moisture traps periodically to ensure they are working effectively. Insufficient flow When a compressed air system is unable to deliver the required volume of air, it can impact significantly on production output. Begin by measuring the flow rate to ensure it meets the demands of the system, using flow meters to monitor and diagnose. The issue could be at the point of generation and require additional air compressors, or a system redesign using base load compressors to handle the main demand, with speed-regulated units to handle peaks and troughs. Alternatively, it may be that the system has inadequate storage, in which case, check the capacity of air receivers to ensure they can handle peak loads. Finally, continue to monitor the air pipework network to ensure it is sized appropriately and free from any obstructions that could restrict airflow. Ashley Quarterman is executive director designate at BCAS Tel: 0207 935 2464 |
|
|
|
|
| Selecting the right air compressor for your business | 14/11/2024 |
|
CHOOSING THE right air compressor for your business is crucial to ensuring operational efficiency, reducing energy costs, and minimising downtime. This guide will walk you through the process of selecting an air compressor based on your application demands. Step 1: Assess the air demand Begin by identifying the pressure range required for the different applications the compressed air will be used for. Different tools and processes may have varying pressure needs, so consideration needs to be given to the most air-intensive demands, without oversizing the system. The basic principle should be to operate the system at the lowest possible pressure that meets operational needs to helps save energy. Use advanced control systems to dynamically adjust pressure settings based on real-time demand. In the food and beverage industry for example, packaging machines may require air at a higher pressure than pneumatic conveyors. Ensuring the highest-pressure requirement has been factored in is crucial. A good way to help identify the pressure range required is to measure the total air consumption of all equipment using data logging devices. Operators should consider both the peak demand and average usage to ensure the compressor can handle the workload without frequent cycling. For example, in automotive manufacturing, air tools, spray painting, and assembly line equipment will consume significant volumes of air. Using a data logger can help track the peak air usage during production shifts. Step 2: Select the right compressor type There are a multitude of compressor types available on the market, so careful consideration needs to be given to the technology best able to deliver the performance and efficiency required. The best option is to speak to a BCAS member who can carry out a full site audit to assess the technology that will best suit the plant demands, but here is an overview of some of the most common compressor types. A small-scale food processing facility might use a reciprocating (piston) compressor for batch processing tasks that require high pressure but are not continuous. These types of compressors are best suited for intermittent use and lower air volume requirements. They are robust and can deliver high pressures but may not be ideal for continuous operation due to higher maintenance needs and noise levels. Where a consistent and reliable air supply for tools and equipment is required for 24/7 shift patterns, a rotary screw compressor is ideal. Designed for continuous operation and large air volume requirement, they offer lower maintenance and noise levels. Scroll compressors are ideal for applications requiring oil-free air, such as in the food and pharmaceutical industry, while centrifugal compressors can handle large volumes of gas at high pressures where a constant flow of air is required. Also, manufacturers should consider compressors with heat recovery systems to utilise waste heat for other processes, such as space heating or water heating. Step 3: Consider speed-regulated technology Variable speed drive (VSD) compressors adjust their motor speed to match the air demand, leading to significant energy savings. They are most effective when air demand fluctuates and can be used very effectively in a compressed air system combining fixed load machines to handle the constant, full load demand. Step 4: Size the air receiver correctly An appropriately-sized receiver prevents cycling and maintains a stable pressure to help buffer peak demand. The air receiver size in litres should be at least 6-10 times the compressor’s free air output (measured in litres per second). The receiver should also be positioned as close to the point of use as practical to help minimise pressure drops, ensuring it remains easily accessible for maintenance and draining. Step 5: Optimise piping and distribution A critical component in any compressed air system is the pipework used to carry air around the network. The pipework should be designed for minimal pressure drop, using large radius bends instead of elbows to reduce friction losses and ensure efficient air delivery to all workstations. Corrosion-resistant materials, like aluminium or stainless style for hygienic environments ensure longevity. In additional, implement zoning to supply different pressure levels to the assembly or production line to match specific process requirement and isolate unused sections to avoid unnecessary air loss. Finally implement regular leak detection programmes using ultrasonic detectors to identify and fix leaks promptly, thereby reducing energy waste. Step 6: Select appropriate air treatment equipment BCAS’s ‘The Filtration and Drying of Compressed Air Best Practice Guide 104’ provides an excellent starting point when selecting the appropriate air treatment equipment. Air dryer technologies should be specified based on the demands of the application, and there are multiple types to select from. For example, a beverage bottling plant requiring very dry air may commission desiccant dryers to prevent moisture-related issues in the bottling process, whereas refrigerant dryers may be sufficient for general use. Filtration equipment removes particulates, oil and moisture from the compressed air. The filtration level should match the quality requirements of the application, for example, to deliver breathing air standard quality for paint booth applications in the automotive industry. Step 7: Plan for maintenance and monitoring To keep your compressor running at optimum efficiency, it’s important to maintain it regularly. A programme of routine maintenance can save time, energy costs and expense in the long term. Consider preventative, or even predictive monitoring - helping to identify potential compressor problems before they become a major issue. Predictive maintenance practices using IoT and AI technologies help monitor compressor performance and anticipate maintenance needs, thus avoiding unexpected downtime. Step 8: Consider future expansion A compressed air system is likely to operate for many years, so it’s worth considering likely future demands when specifying. Operators should choose a compressor that can be upgraded or expanded easily to meet future air demand increases, prioritising modular systems that can be scaled up as needed. Sites should also ensure the compressor, and its control system, can integrate with other industrial systems such as HVAC and process control, helping improve overall plant energy management. BCAS offers a wealth of information to help operators when specifying a compressed air system. Visit the Society’s 10% Taskforce website for free, downloadable guides to help improve energy efficiency at taskforce10.bcas.org.uk/simple-steps/ or go to the online shop to purchase a range of best practice guides at elearning.bcas.org.uk/publications/ Ashley Quarterman is executive director designate at BCAS Tel: 0207 935 2464 |
|
|
|
|
| Navigating industry regulations | 29/11/2024 |
|
LAST YEAR, we wrote about the specific GB/UK legislative and regulatory landscapes, with a focus on the desire for avoidance of ‘double regulating’ and the ongoing state of flux regarding UKCA and CE Marking requirements. Since then, we have had a subsequent change of administration. This brings with it some fresh challenges, not least the big picture change of focus and prioritisation. 2019 saw Civil Service re-structuring, with the loss of BEIS (the Department for Business, Energy and Industrial Strategy) and the creation of DBT (the Department for Business and Trade) and the DESNZ (the Department for Energy Security and Net Zero). Some of the responsibilities for enforcement now rest with Defra (the Department for Food and Rural Affairs) and EA (the Environment Agency). UKCA and CE Marking In May 2024, a Statutory Instrument (S.I. 2024/696) was passed through parliament. This will come into force on the 1 October 2024, allowing the placing of CE marked equipment on the GB market ‘indefinitely.’ The Product Safety and Metrology etc. (Amendment) Regulations 2024 (S.I. 2024/696) covers regulations for (but not limited to) machinery, pressure equipment, simple pressure vessels, EMC compatibility, PPE and electrical equipment. This means that the UK/GB market (Northern Ireland continues to have its own specific set of rules) can continue with the status quo of supplying goods with CE markings applied, without the need for costly duplicate UKAB (‘Authorised Bodies’, vs the EU NoBo = ‘Notified Bodies’) assessment requirements in most instances. Regarding European activity, BCAS continues to support the activities of Pneurop, as the majority of European directives still apply in most cases. Most of the product we work to support is European manufactured and we continue to push for alignment. It would appear that this message has been listened to and with new regulation in the EU, we have an open door for conversation and consideration which had not always been the case. Working with other associations such as EURIS and EAMA allows a wider machinery and engineering voice to be presented when lobbying on topics relevant to our industry. Specific topics currently under scrutiny are: EU F-Gas While the current UK F-Gas situation is unclear, as we currently follow the 2014 EU Regulation which was transposed into UK Law, the EU F-Gas Regulation has been revised. When the latest revision of the EU F-Gas Regulation was published in February 2024, Pneurop PN14 (Air Treatment Committee) generated a technical position paper. The intention of the paper was to clarify the classification of Compressed Air Refrigerated Dryers (CARDs) as the F-Gas Regulation doesn’t recognise the CARD product/application. So, at a ‘local’ level with EU Member States, which does not include UK/GB as it is classed as a ‘third country’, there is a risk that enforcement agencies could apply their own interpretation and disagree with the PN14 position paper. This position paper has been endorsed by the Commission, in so far as DG CLIMA has said that the logic is ‘defendable’, but the very next comment was “Still, we need to underline that only the Court can make binding interpretations of EU law”. So, we don’t necessarily have a complete endorsement, but we do have a position of support toward the logic applied to the argument. BCAS continues to work closely with Pneurop and Orgalim on the next steps, which could be a possible derogation for four years, and PN14 is preparing another position paper on that topic. EU REACH (PFAS) PFAS (per and poly fluoroalkyl substances) are currently a global hot topic. Known as “forever chemicals”, these substances are in widespread use, most commonly in oil and water repellent textile treatments. They are also used throughout many industries and applications, are ‘persistent’, and have known health risks. PFAS substances used commonly in the compressed air industry include HFC refrigerant gases (used in compressed air refrigerated drying), common sealing compounds (PTFE, FPM, etc.) and coatings such as anti-friction treatments used for meshing metallic components. BCAS was involved in this topic initially at European level (PN14 - Air Treatment) for applications using paper filter media. PN14 then expanded the topic to the other Pneurop Committees and a series of position papers were published. The biggest single affected application for the compressed air market is F-Gas, which is already regulated. But the implications for the common sealing compounds, which will potentially affect all machinery manufacture and installation, are more wide-reaching. There was an EU REACH/ECHA public consultation that closed in September 2023, which received over 6,000 unexpected and unprecedent responses and saw the submissions portal crash under the heavy load. More than 5,000 of these responses came from private companies, trade associations, academic institutions, NGOs, member states, and trade unions. The Pneurop/BCAS response was that the blanket approach is not appropriate, and needs to be considerably more granular in its approach. The ECHA Risk Assessment & Socio-Economic Committees are significantly delayed, and the individual national authorities are reviewing their approaches. EU PED / EU SPVD The Swiss/French national authorities have made public comments that the EU SPVD is being applied incorrectly and proposes a merger of EU SPVD into EU PED. They claim that some compressor manufacturers try to classify compressor pressure vessel components, such as oil separators, as EU PED by defining a second fluid, where the EU SPVD definition is ‘to contain air or nitrogen.’ EU SPVD is well established for over 30 years, and with an estimate that three million compressors have been placed on the market, the health and safety obligations are clearly understood and executed. EU PED does not include the design, approval and production control phases for smaller vessels which are produced in that highest quantities. It is estimated that 30 per cent of equipment placed on the market will be EU PED Cat I and market surveillance authorities have recorded ZERO safety incidents. Concerns Safety expectations for smaller vessels will likely be diminished and the extra cost burden will likely be placed on compressor manufacturers due to the EU PED assembly classification. Pneurop Working Group PN06 (pressure vessels) is developing an EU PED/EU SPVD position paper so that the different market sectors, including PN02 compressors and PN14 air treatment can align effectively. The European Commission has not yet stated its intention (there has been a call for ‘evidence’, which is being reviewed, but Pneurop PN06 is are preparing for all possible eventualities. Machinery Regulation The new Machinery Regulation (EU/2023/1230), which replaces the current Machinery Directive (2006/42/EC), was adopted on 14 June 2023. All machinery placed on the market before 20th January 2027 must comply with the current Machinery Directive, but manufacturers are also allowed to state on an EU Declaration of Conformity that such machinery also conforms with the new Machinery Regulation, if applicable. This sets out to update the 2006 regulation by including concepts such as paperless supply, except for basic safety information for non-professional users, which could allow documentation to be accessed digitally via a QR code, and machine-learning (AI), particularly where the learning techniques ensure safety functions. It also sees a change in the legal status as a regulation does not require transposition into local national law, as directives do. This falls into line with the New Legislative Framework (NLF) which sets out the main rules for market surveillance and conformity assessment bodies. EU Harmonised Standards An interesting development in the world of Harmonised European Standards (HeNs) is that there has been a legal challenge made to the European Court of Justice by an American public domain advocate, called Carl Malamud. Malamud applied the concept to the safety of toys regarding the legal status of harmonised standards requiring the free availability (i.e. free of charge) of the published standards. This goes against the established commercial model of the National Standards Bodies (NSBs), such as BSI, DIN and ANSI, who incur costs in the development of said standards and balance their costs by the generation of revenue through the legitimate sales of said standards to end users. The legal action was recently appealed but upheld, so the NSBs are reviewing currently how they support the development activity of ISO standards which become adopted HeNs and looking to revise their commercial models. With all this activity ongoing it is more important than ever that you remain in touch with the proposed changes and have your say on what could be our new legislative landscape. As the independent trade association for the compressed air and vacuum industry, BCAS can provide the most accurate source of information alongside technical experts to enable specific industry queries to be answered. Tim Preece is technical officer at BCAS Tel: 0207 935 2464 |
|
|
|
|
| Understanding PSSR 2000 | 29/11/2024 |
|
TIM PREECE, technical officer at the British Compressed Air Society (BCAS), sheds light on some of the critical requirements of the Pressure Systems Safety Regulations (PSSR) 2000. The regulations, introduced in February 2000 under statutory instrument S.I.128, are designed to ensure the safe operation of compressed air systems ‘in use’. Unlike regulations that govern systems being placed on the market as goods, PSSR 2000 focuses on systems that are actively used, emphasising safety and compliance. Even though the regulation has been in force for nearly 25 years, BCAS still receives more enquiries on this one topic than all other technical enquiries combined – a measure of both the importance and complexity of the regulations. Scope and application of PSSR 2000 PSSR is not limited to large or complex compressed air systems, that might involve components like steam and liquified gases. It also covers smaller systems, including those for compressed air and gases. A typical pressure system consists of a rigid pressure vessel (often made of steel), protective devices, and pipework. It is important to note that ‘pipework’ refers to all parts of a pressure system except the pressure vessel and protective devices. This definition is crucial because, in many cases, pipework can be excluded from a compressed air Written Scheme of Examination. However, this exclusion is only valid if a thorough risk assessment is conducted by a competent person who can certify that such an exclusion does not compromise safety. There is a common misconception that small, tank-mounted compressors (self-contained compressor/receiver assemblies typically with 24-litre receivers and a 10-bar working pressure) are exempt from PSSR requirements. This is not the case. While there is an exemption for the necessity of a Written Scheme of Examination for systems with a total stored energy below 250 bar litres, these systems must still comply with all other aspects of the regulation. The stored energy of a system is a critical factor that needs careful consideration, as it relates directly to the potential hazards posed by the system. Responsibilities of owners and users Under PSSR, the 'user' of an installed system typically bears full responsibility for ensuring compliance with the regulations. In scenarios involving mobile, hired, or leased systems, the ‘owner’ may also have certain obligations. Regardless, both owners and users must ensure that the system complies with PSSR. Given the technical nature and complexity of these regulations, it is often unrealistic to expect system owners or users to fully understand all the requirements. Consequently, the compliance activity is frequently outsourced to a ‘competent person body’; an entity that possesses the necessary competence and skills to interpret and apply the regulations correctly. Clarifying misconceptions: Insurance inspections versus competent person examinations A common misunderstanding is that the PSSR mandates that inspections must be conducted by insurance companies. In reality, the regulations only stipulate that the ‘Examination in accordance with the written scheme’ (Regulation 9) must be carried out by a ‘competent person’… using suitable techniques, including testing where appropriate.’ Refer to BCAS fact sheet 315 - Competent Person Description for the definition of a competent person in this specific instance. Even the term examination has a specific definition within the regulations. ‘Examination’ means ‘a careful and critical scrutiny of a pressure system or part of a pressure system, in or out of service as appropriate’ and only applies to ‘examinations carried out under the written scheme of examination, i.e., ones conducted to assess the condition of those parts of the system which may give rise to danger (as defined) in the event of an uncontrolled release of stored energy.’ BCAS's role in addressing industry needs Recognising a gap in the industry, BCAS has taken a proactive role in providing competent examination services for compressed air systems. It seems relatively clear that the most appropriate “competent person” to carry out the examination of a compressed air system should be the valued service provider who also provides the necessary maintenance and supply expertise and function. To address this need, BCAS developed the Compressed Air Systems' Testing and Examinations course. This course helps provide the necessary knowledge and skills required to conduct examinations in accordance with PSSR Regulation 9. The course is available in a blended format, combining online modules with a practical, face-to-face classroom component. The qualification lasts for five years, after which participants are required to take a refresher module, updating on changes to regulations, guidance, and techniques and providing valuable feedback for continuous improvement. Additionally, BCAS offers a one-day Understanding PSSR course. This course details the responsibilities associated with owning, using, or installing pressure systems. It is particularly useful for company directors, senior managers, facility managers, and sales and service personnel who deal with pressure systems within their organisations. However, it is open to anyone interested in gaining a better understanding of the regulations and their implementation. The importance of learning, development, and training Terry Collier, BCAS learning and development officer Learning, development, and training can enhance both employee satisfaction and organisational performance. Investing in these areas not only boosts employees' skills but also demonstrates the organisation's commitment to their growth.
These investments create a mutually beneficial cycle where employees gain new capabilities, while the organisation benefits from increased agility and performance. For training to be effective, it must be timely and at the appropriate levels. BCAS offers a variety of development events, from short ‘coffee break’ sessions on targeted topics to comprehensive diploma programs in compressed air systems. Training needs can be categorised as statutory, mandatory, and optional:
BCAS's blended learning approach BCAS supports these learning and development initiatives with its CPD-approved, blended learning courses. These courses combine online tutorials and training with guided learning and assessment by BCAS-qualified tutors. This flexible learning model allows participants to study at their own pace and convenience, balancing at-home study with invigilated examinations. In summary, the PSSR 2000 regulations are a critical framework for ensuring the safe operation of pressure systems. BCAS plays a crucial role in helping organisations and individuals understand and comply with these regulations. Through comprehensive training and development programs, BCAS not only fills a vital gap in the industry but also contributes to the ongoing professional growth and safety awareness of those involved in the management and operation of pressure systems. Tim Preece is technical officer at BCAS Tel: 0207 935 2464 |
|
|
|
|
