THE BRITISH Compressed Air Society (BCAS) has appointed Steve Downham to further expand its technical team, working alongside Tim Preece as technical officer.

Boosting Vacuum Sector Support

"It’s a pleasure to join the BCAS team and to use my engineering knowledge to help advise members. I’m planning to meet with lots of members and end users over the coming months, using my skills and experience in the vacuum sector to provide timely and practical advice," said Downham.

As a chartered mechanical engineer with a PhD that researched centrifugal pump systems, Downham is no stranger to the world of vacuum technology. For more than 26 years, he has held engineering positions at Edwards Vacuum, latterly as technical lead for new product innovation and research and development.

This wealth of engineering knowledge will be a very welcome addition to the Society’s existing technical capabilities, particularly in supporting vacuum technology members and those who are keen to diversify their offer outside of traditional compressed air applications.

Navigating Legislation and Compliance

Preece will continue to be instrumental in developing standards and legislation and lobbying for the best outcomes for BCAS members.  In partnership, Downham will provide guidance on how members can apply and deliver against the requirements set.

He will also play an integral role in the Society’s Vacuum committee, as well as working with the training and development team to develop new training courses for members and end users.

"We send a very warm welcome to Steve. He has a wealth of knowledge in the vacuum and broader engineering sectors, which will help to strengthen our technical expertise further still," stated Ashley Quartermann, BCAS executive director.

"In an ever-changing legislative landscape, it is vital that trade associations remain abreast of new requirements as well as lobbying for the best outcomes for their members and end users. Steve will play an important advisory role in many of these areas of best practice and improved performance."

For more information:

www.bcas.org.uk

Tel: +44 (0) 207 935 2464

THE BRITISH Compressed Air Society (BCAS) has signed the Armed Forces Covenant in a ceremony held at Blighmont Reserve Centre in Southampton, marking a new commitment from the industry to those who have served.

The Covenant is a commitment from BCAS and its members to the Armed Forces Community. It acknowledges and understands that the armed forces, and their families, should be treated with fairness and respect in the communities, economy and society they serve with their lives.

Skills That Translate

Through its Armed Forces Working Group, the Society aims to provide meaningful support to ex-military personnel as they transition to a career in civilian life. 

"The compressed air industry is diverse. It requires specific technical and engineering skills to specify, commission and maintain equipment. It also offers a broad range of other career opportunities in sales and customer service, logistics and administration to name a few," explained BCAS executive director Ashley Quarterman.   

"We recognise that military experience will equip individuals with many of these skills that are in demand in our sector. Through our working group, we hope to encourage more veterans to consider a career in the compressed air industry.

"In return, we want to play our part in helping veterans as they transition into a role in civilian life, by offering fulfilling career opportunities; a transition which can be difficult for many.  We are therefore encouraging all our members, and the wider compressed air community to consider the benefits that employing military personnel could bring to their business."

Fulfilling Careers Beyond Service

BCAS has a number of members with military experience, such as RAF Veteran, James Shaw, MD of JDS Compressors. "My role as a weapons technician was high intensity, and you could never predict what might happen next. We were used to reacting quickly and solving problems. I enjoyed that challenge and, in many ways, we face the same challenges in the compressed air industry," he stated. "Responding quickly to avoid a compressor breakdown, analysing equipment performance and talking with customers to reach the best outcome. It requires a similar mindset."

Royal Navy Veteran, Nigel Palmer, who is managing director of SCC Air Compressors UK added: "I am proud to be part of the compressed air industry and its commitment to supporting veterans in their ongoing careers. It is an industry where our skills can be used with great impact - whether it's dealing quickly with equipment breakdown, commissioning a new installation or advising customers on new ways to improve efficiency and performance."

Ex Royal Navy Marine engineer and now national sales manager at Atlas Copco, Jason Pollard concluded: "When I left the military, I found that my skills were in demand and could be put to good use in the compressed air industry.  Unlike some of my fellow veterans, who have faced numerous barriers when transitioning to a civilian career, I found the compressed air industry to be very receptive to my skillset."

For more information: 

www.armedforcescovenant.gov.uk

Tel: +44 (0) 207 935 2464

THE BRITISH Compressed Air Society (BCAS) has launched its new NVQ Level 3 Diploma in Installation and Commissioning - an industry first that enables experienced compressed air technicians to prove their professional skills and gain a recognised qualification.

The NVQ was developed in part to address the competency concerns raised by the Construction Leadership Council regarding personnel working on construction sites. The resulting Compressed Air Pathway is recognised by the Building Engineering and Services Association as a formal industry standard, including Construction Skills Certification Scheme (CSCS) recognition.

Validating Expertise Without Additional Training

It is designed so that learners can demonstrate their existing knowledge and credentials, without requiring additional training. This gives confidence to end-customers of the engineer's competence, experience and commitment to safe working practices during the installation, commissioning and ongoing maintenance of compressed air systems.

The NVQ comprises mandatory units, which include complying with statutory regulations and organisational safety requirements and using and interpreting engineering data and documentation. Emphasis is also given to working efficiently and effectively in engineering and the handing over of maintenance or installation activities to the customer. 

"The launch of our new NVQ is testament to the significant strides made by the compressed air industry in recent months. We have now developed a recognised qualification which formalises the extensive experience many compressed air engineers already possess," said Terry Collier, BCAS learning and development officer.

"Working with our members and other industry bodies, we are proud to introduce this new Compressed Air Pathway to the industry. Together, we are making meaningful progress in enhancing the skills and qualifications of the industry.

"Not only does it demonstrate the expertise of our highly skilled sector, but it provides end users with additional reassurance that all health and safety and statutory requirements will be met," he continued.

A Collaborative Effort to Elevate Industry Standards

"In addition, we have partnered with an external assessment company, TSW Training, who are well respected within the wider engineering sector.  TSW Training will be responsible for assessing and quality assuring as technicians work towards assessment. This partnership not only ensures that candidates receive the highest standard of assessment but also aligns with the rigorous requirements mandated by the Construction Leadership Council." 

Ashley Quarterman, BCAS Executive Director said that the new NVQ further enhances BCAS' wide portfolio of training courses available to engineers and end-users in the compressed air industry. "It forms part of our continued effort to add further value for our members and their customers and would not have been possible without collective effort from the BCAS team and many of our colleagues and partners across the sector," he concluded.

The NVQ Level 3 Diploma in installation and Commissioning is now available on the BCAS learning management system website and open for applications. Please visit https://elearning.bcas.org.uk/nvq-level-3-diploma-in-installation-and-commissioning/

For more information:

www.bcas.org.uk

Tel: +44 (0) 207 935 2464

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."

www.bcas.org.uk

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:

• An employer's guide for apprenticeships: This guide aims to assist organisations from the initial strategic planning phase, through recruitment, and into day-to-day management. It provides templates that organisations can adapt or adopt, all based on best practices.
• Development of new resources focused on compressor energy saving: Launched as the 10% Taskforce, the initiative aims to reduce unnecessary energy wastage from compressed air use by 10%. Eight short modules cover topics such as heat recovery, managing air leaks, and correct specification. These brief, ‘coffee break’ sessions are CPD certified.
• ISO 11011 development: This training, based on the compressed air energy standard is in its final stages, with a planned launch in the coming weeks or months.

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

• Certificate in Working Safely with Compressed Air (WSWCA): This one-hour course highlights the safety responsibilities of employers and employees, covering the hazards associated with compressed air, the correct use of personal protective equipment (PPE), and safe working practices.
• Certificate in Compressed Air Treatment Technology (CATT): Focused on the origins of contaminants and methods for their removal, this course is relevant for manufacturers, distributors, and anyone requiring clean, dry compressed air systems.
• Certificate in Compressed Air System Technology (CAST): CAST provides a comprehensive overview of compressed air systems, including production, usage, relevant health and safety issues, legislation, and energy efficiency.
• Understanding Breathing Air (BS EN 12021): This one-hour course educates participants on the importance of providing clean breathing air, covering regulations, standards, and legal requirements for the safe provision of breathable air.
• Compressed Air Service Engineer Health and Safety Training: Designed for service engineers, this course integrates various aspects of health and safety related to compressed air systems, ensuring compliance with legislation and efficient equipment operation.

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.

• Certificate in Understanding the Pressure Systems’ Safety Regulations (PSSR): This workshop delves into the Pressure Systems’ Safety Regulations, offering insights into the written scheme of examination for compressed air systems.
• Certificate in Understanding ISO8573: The course provides an in-depth understanding of ISO 8573, covering all aspects of compressed air systems for various professionals, including suppliers, consultants, and users.
• Diploma in Compressed Air Management (DipCam): This comprehensive qualification covers the technical aspects of compressed air systems, designed for individuals responsible for installations who seek advanced technical knowledge.
• Certificate in Compressed Air Systems’ Testing and Examinations: This course covers the essential knowledge and skills required for conducting competent examinations of compressed air systems, as required by Regulation 9 of the Pressure Systems Safety Regulations.

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 [email protected]

For more information:

www.bcas.org.uk

Tel: +44 (0) 207 935 2464

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:

• Demonstrate the value of a standalone extended diploma NVQ for the compressed air industry, as a means of assessment for less experienced staff. This would enable proof of on-the-job skills and on-site/operational training. It would replace the time and resources needed for a full apprenticeship.
• Reinforce that this NVQ already exists for experienced employees, and that BCAS is already developing a second diploma. This NVQ will bring installation, commissioning, and maintenance into one pathway.  This would enable BCAS members to achieve the highest safety (Gold) standard, thereby helping to drive up safety further still in our industry.
• Both diplomas now have a new compressed air pathway which has been accepted by Excellence Award in Learning (EAL), part of the larger Engiunity Group
• Create a win-win situation. Existing employees who have many years’ experience can prove their capability with an on-the-job NVQ assessment. Newer employees may need to undertake an extended diploma.

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

www.bcas.org.uk

Tel: 0207 935 2464

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

• Training: BCAS recommends comprehensive training for all operators, including an understanding of relevant safety standards before operating any equipment.
• Equipment and workspace setup: Operators should follow the manufacturer’s guidelines for the setup of equipment and workspaces, including the installation of safety devices such as pressure relief valves.
• Pre-operation checks: Sites should standardise regular pre-start safety checks for all components of the compressor system to ensure safe and efficient operation.
• Maintenance: Regular maintenance, including checks of filters, dryers, air receivers, and pipework is vital for extending the life of the system and maintaining air quality.
• Good housekeeping and staff involvement: Compressed air is a valuable resource, and leaks should be addressed promptly. Common sources of wastage include leaks, leaving air-consuming equipment running during breaks, and using compressed air unnecessarily for cleaning benches and equipment.  Encouraging staff to report and identify instances of wasted air usage is critical. 

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

www.bcas.org.uk

Tel: 0207 935 2464

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:

• Dew-point transmitter on dryer outlets: Regular spot checks of the dew-point transmitter are necessary to verify moisture content at the dryer outlet, ensuring air quality standards are met. Accurate dew-point measurements prevent moisture-related issues like corrosion in downstream equipment
• Temperature PT100 sensor on dryer inlet: The temperature of compressed air entering the dryer impacts the efficiency and life cycle of the dryer columns. As the air temperature increases, so does the water vapour content, requiring the dryer to work harder. Regular spot checks of the PT100 sensor at the dryer inlet ensure optimal dryer operation, preventing excessive wear and maintaining consistent air quality.

www.bcas.org.uk

Tel: 0207 935 2464

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

• Eliminates purchase and delivery costs

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.

• Lower storage costs

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. 

• Energy efficiency

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.

• Reduced downtime

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.

• Mitigation from market volatility

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 investment

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

www.bcas.org.uk

Tel: 0207 935 2464

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

www.bcas.org.uk

Tel: 0207 935 2464