Boost production while cutting costs
June 09th 2009 Compressed air systems are safe, reliable and versatile, but often taken for granted with scant regard to maintenance and cost. Chris Dee, executive director of the British Compressed Air Society (BCAS), outlines some of the factors that users of compressed air systems should consider.
An essential resource for industry, business and the public sector, compressed air is often referred to as the fourth utility after electricity, gas and water. However, unlike these three, compressed air is unregulated and generated on-site; users therefore need to have much more control of maintenance and costs.
Three important reasons why it is worth investing time and effort in the correct maintenance programme:
Reduces energy costs and eliminates waste
Reduces environmental impact by saving electricity consumption and so lowering carbon emissions
Improves reliability of the system and improves production and profit levels.
A correctly designed, installed and maintained compressed air system that is energy efficient could save you thousands of pounds per year. Every pound saved goes straight to your bottom line and is an effective way of increasing profits.
User responsibility
Under the Pressure Systems Safety Regulations (PSSR) 2000 Statutory Instrument 128, it should be noted that while manufacturers, suppliers and installers have duties under these Regulations, it is you, the user of the installed compressed air system who has the ultimate responsibility for compliance. Does your system have a 'compressed air system manual' based on these regulations containing not only the regulatory requirements such as the written Scheme of Examination but also the maintenance issues of regulation 12?
Do you have one? If you would like a template of a typical compressed air system written Scheme of Examination email: technical@bcas.org.uk
This article will assume that you have a correctly designed and installed compressed air system, but if you would like a free and impartial checklist of a typical well designed system please email BCAS requesting a copy.
Up-to-date log
It is always good practice to keep a log of relevant data including compressor hours run, power consumption, oil consumption, temperature and pressure, inter-stage and final temperatures, pressures, water inlet and outlet temperatures, so that any deviation from normal running will be noticed quickly. Unfortunately the common practice is not to do this. Does your company record such information and, if so, when was the last time you looked at it?
When an abnormality is noted the matter should be investigated immediately. Suppliers recommendations regarding filters and elements should be observed before your energy bill goes up, and the system tested regularly for leaks. If you would like a copy of the BCAS Pressure and Leak Testing Code of Practice please email: technical@bcas.org.uk
During maintenance
Ensure that all air pressure is completely released from the system and that it is isolated from any other air systems. In multi-compressor installations maintenance on any of the compressors shall not be carried out without first closing the isolation valve and venting and disconnecting the delivery pipe of the compressor being maintained.
Ensure that the compressor cannot be started inadvertently; isolate the unit and lock the isolator in the safe position; place warning notices on the isolator (for example Danger Men at Work).
Ensure that any access door that opens upwards is securely fastened when opened and that it cannot slam shut.
When working on the plant:
Use the correct lifting gear of adequate capacity
Examine that the lifting gear is in good condition before using
Use the correct tools for the job
Do not weld or in any way modify any pressure vessel.
Before restarting the compressor:
Check that the oil reservoir is filled with the correct grade of oil.
Check the direction of rotation of the air end (if electrical work has been carried out)
On water cooled units, check that the water is flowing
Check that the operating pressures, temperatures and speed are correct and that the controls and shut-down devices work correctly.
Trusted Trader
Finally, how do you choose the right compressed air system maintenance service company? A Trusted Trader scheme, such as the one run by Referenceline, helps you make a more informed choice when looking for a firm. Go to www.referenceline.com and click on the Compressed Air tab for reputable compressed air service companies across the UK.
For further information related to the design, installation or maintenance of your compressed air system, please contact the British Compressed Air Society for expert and impartial advice technical@bcas.org.uk
More articles from British Compressed Air Society (BCAS): | 
