Compressor safety: Concerns aired

For manufacturers across the UK, compressed air is just as important as gas and electricity - and yet this utility doesn't receive the same amount of focus. Here Andy Jones, general manager at Mattei, explains why this could be compromising safety



Compressed air is regarded as industry's fourth utility but, despite it being a vital part of the manufacturing process, when it comes to safety on the shop floor, it largely remains unconsidered, or even forgotten. While the risks that gas and electricity pose are widely publicised, understood and prepared for, anecdotal evidence suggests that the same cannot be said of compressed air.

For example, we still hear of employees using it to dust off machinery, work benches and their clothes - even though if it penetrated the skin and entered the bloodstream a fatal air bubble could reach the heart or lungs. And, as compressed air travels at a phenomenal speed, if it hits an eye or an ear it may lead to blindness or loss of hearing respectively.

Just like other pieces of industrial equipment, the compressor itself needs to be installed and maintained correctly to ensure it operates safely. If a compressed air system isn't properly and regularly maintained it could end up posing a danger (and of course won't perform correctly or efficiently either).

In very extreme cases a poorly maintained compressor might even catch fire or explode.

This is why every compressed air system, virtually without exception, should have a Written Scheme of Examination in place; the system should be regularly inspected in accordance with this. Written Schemes of Examination are a legal requirement under the Pressure Systems Safety Regulations 2000. The document contains a wide range of information, including the parts of the system that need to be examined, the nature of the examination required, the preparatory work needed and the maximum interval allowed between examinations.

The worry is that many businesses running compressed air systems either ignore this or are simply not aware of it, even though it's been in place for 13 years.

There is a potential fine of up to £20,000 for not having a Written Scheme of Examination - but no one seems to really police it.

Noise levels from a compressor are also worth checking to ensure employees aren't adversely affected. All compressor manufacturers have to state the noise levels of their machines in accordance to international standards, with the current one being EN ISO 2151:2008.

Our concern is that despite the risks there are currently no formal accreditation schemes for engineers designing, installing and maintaining compressed air systems - so some end users could well be receiving poor advice, and safety could be being compromised.

The British Compressed Air Society (BCAS) offers four courses - Safe Working with Compressed Air, a Certificate in Compressed Air System Technology, the Diploma in Compressed Air Management and a Competent Examiner course for those involved in carrying out examinations in accordance with Written Schemes of Examination. However, these are voluntary.

Mattei would ideally like to see the introduction of a recognised training programme and an official accreditation scheme for service engineers working on compressed air systems, and for those involved in design and installation. We would even go so far as to suggest that we need something similar to the Gas Safe Register that is in place for installers working with gas appliances, so that only people with proven competence can install and maintain compressed air systems.

In the absence of formal accreditation there are some voluntary schemes that users can look for when assessing compressed air companies. For example, companies working in the compressed air industry can demonstrate professionalism and competence as well as their commitment to health and safety and best practice by joining BCAS. Members have to adhere to its codes of conduct, and can choose to proactively participate in the BCAS AirSAFE register, which promotes the credibility and professionalism as identified via customer feedback.

Mattei is committed to improving health and safety practices in the compressed air industry; we are members of BCAS, have SAFEcontractor accreditation and an AirSAFE award. We have personnel qualified to carry out inspections in accordance with Written Schemes of Examination on behalf of customers.