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July 26th 2007 BCAS is the UK’s trade association for compressed air and vacuum manufacturers, distributors and users. It provides the industry and its users with an impartial source of technical and legislative advice. Here BCAS reviews the main aspects of compressed air systems management of prime concern to end users
Understanding compressed air systems. How much you know about your compressed air system will depend in part on the nature of your responsibility for it. It may be as a production, health and safety, energy, environment, quality, lean production, six sigma, technical, utilities and even purchasing group leader or manager job function which has some aspect of responsibility for the compressed air resource on site. This range of responsibilities is not surprising considering the wide ranging impact compressed air has in terms of productivity, product quality, employees’ health and safety, and energy use.
If responsible for the day-to-day running, you should
know:
• What compressed air is used for on site – both approved and unregulated/indiscriminate uses
• Annual energy (usually electrical) costs
• Reliability issues and the processes affected
• Sources of impartial authoritative information on technical and production related compressed air issues.
• Key hazards and risks employees face in using compressed air, e.g. blow guns, hand-held air tools. The main health and safety and legislative issues are: • Employer responsibility and compliance with health and safety legislation related to compressed air, noise and vibration of hand held air tools
• Compliance with the Pressure Systems Safety Regulations 2000.
The key environmental impacts are:
• Energy (electrical) consumption
• Proper disposal of condensate (may be classed as hazardous waste)
So, whatever your involvement in compressed air systems knowing where to find the relevant information from an independent source, is key to keeping your air supply, safe, reliable and efficient. BCAS publications and fact sheets are a good place to start.
Choose a reputable supplier You need to be confident that the company you choose to install and service equipment and advise you on your compressed air system follows a code of conduct so that you can be confident of a minimum standard of performance. The assurance that comes with choosing a BCAS member will be further strengthened with the launch of a BCAS Member Code of Conduct. From July 1st 2007 BCAS members have to comply with the code which promotes a minimum benchmark for ethical business practices, and best practice in design, installation, maintenance, of compressed air and vacuum related products and services and be committed to the ongoing training of
employees.
The quality of the installation work will determine in part, the energy and other running costs of your compressed air system during its working life, so it pays to choose a competent installer at the outset. Check that the company has employees with the required training and skills to do the job properly, as well as adhering to a safe system of work whilst carrying out installation, maintenance or commissioning on your site. Don’t choose a supplier or product on price alone, or without checking credentials - this carries the risks of an installation or maintenance service with higher energy costs, reduced safety and less protection if things subsequently go wrong.
Although health and safety pre-qualification schemes accredit a company and its systems, these are not applicable to individuals, so seek additional evidence of the competence of those employees carrying out the work. For example, international standards dictate that only adequately trained personnel may service compressors. The training would usually be in the form of certificated manufacturer training. SKILLcards for compressed air personnel (installers, maintainers and commissioning engineers) provide evidence of an individual’s competence, skills, and qualifications. In addition, there are BCAS qualifications such as the Competent Examiner which provides the necessary training to undertake examinations of pressure vessels required by the Pressure Systems Regulations 2000:128.
Buy compliant equipment We all love a bargain, whether it be from ebay, Amazon or Primark. The risks of buying say, a CD on ebay where the origin cannot be verified, are low e.g. the play list order on the sleeve may not match the CD. However, buying more critical items such as parts for a compressed air system – e.g. compressor spares, pressure relief (safety) valves, filter elements and pneumatic hand tools, has far greater risks in terms of reliability for the system as well as safety. Always check for the CE mark – evidence that the product complies with European law. It should also have printed instructions – if one or both of these are missing, then the product may be counterfeit, noncompliant and not perform as it should. See BCAS fact sheet FCT305 Machinery Conformity. Perhaps the greatest risk is that it injures employees (e.g. high levels of vibration or noise from a non-compliant tool) then you are faced with litigation. Ignorance is no defence in court. If a product does fail within 12 months, you are still entitled to a refund from the supplier, though this is hardly sufficient consolation for the disruption to your process and personnel time involved, neither does it constitute good business practice to be fixing problems caused by purchasing on a ‘lowest initial cost’ basis.
Ensure that when buying replacement parts that any non-OEM product is fit for purpose e.g. a filter element has sufficient pressure rating. OEM products may have a patented design or employ different technology so that the dirt holding or oil removal capacity, of the filter element is greater such that the service life is longer and offers better protection for downstream product. So, when purchasing equipment, remember the old maxim – if something appears too good to be true – then it probably is!
Keep up to date with information from BCAS BCAS provides information covering legislation, technology, health and safety via training courses, workshops, and factsheets. There is an array of legislation affecting compressed air systems, some of it specific, i.e. Pressure Systems Safety Regulations, some general such as The Health and Safety at Work Act, Hazardous Waste Regulations. Although most employers are aware of risk assessment and the importance of protecting their employees, some are less informed about their environmental impact and the compliance required. For example condensate if not properly treated is considered hazardous waste.
Condensate from compressed air systems can be disposed of down the foul sewer only if treated by an oil-water separator, and provided the oil content is within the local sewage works’ specified limit. This varies with regional authorities, so check first that you comply.
BCAS will be working with enforcers within local authorities to ensure they are aware of the illegal practice whereby some businesses discharge condensate directly to the foul sewer without treating it first with an oil-water separator to the required limits. BCAS also provides energy efficiency information and during 2007 is leading a Carbon Trust funded project initiative addressing the two greatest causes of avoidable waste in compressed air systems: leaks and over-pressurisation.
In summary, BCAS as the independent UK trade body is the first port of call for compressed air users who need the right information and advice on developing and maintaining a safe, reliable and efficient compressed air system to meet their needs.
Useful Links
www.bcas.org.uk
www.compressedairenergy.org.uk
www.compressedairaudits.org
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