Compressed Air HSE
Compressed Air HSE
Compressed Air HSE
Executive
HSE Books
Page 1 of 50
Page 2 of 50
Contents
INTRODUCTION 5
COMPRESSOR PLANT 6
Groups of compressors 6
Hazards 6
General information and advice 6
Precautions 7
Safety valves 7
Pressure indication 7
Thermal protection 7
Coolant protection 8
Lubricant protection 8
Explosion protection 8
Air inlet/outlet monitoring 8
Other instrumentation 8
Air inlet/outlet control 9
AIR RECEIVERS 11
Statutory requirements 11
Hazards 12
General information and advice 12
Precautions 12
COOLERS 13
Hazards 13
General information and advice 13
Precautions 13
AIR DRYERS 14
Hazards 14
General information and advice 14
Refrigerant 14
Dessicant 14
Precautions 14
INSTALLATION OF COMPRESSORS 16
Precautions 16
Small compressors 16
Medium and large compressors 16
Noise 16
MAIN LINE SYSTEMS 18
Hazards 18
General information and advice 18
Precautions 18
Pipe-runs 18
Filters, traps, separators and lubricators 21
Pressure regulators 22
PORTABLE PNEUMATIC EQUIPMENT 23
Statutory requirements 23
Hazards 23
General information and advice 23
Precautions 24
Flexible hoses 24
Page 3 of 50
Blow guns 24
Portable tools 25
PNEUMATIC POWERED MACHINERY 26
Hazards 26
General information and advice 26
Precautions 26
ACTUATORS 28
Hazards 28
General information and advice 28
Precautions 28
INTERLOCKING METHODS AND CIRCUIT DESIGN 31
General information and advice 31
Interlocking systems 31
Single control system interlocking 31
Dual control system interlocking 32
Power interlocking 40
Circuit design 41
Piston arrest 41
Piston arrest and hold 41
Overriding locked position 41
Predetermined position 41
INSPECTION AND MAINTENANCE 42
Statutory requirements 42
Hazards 42
General information and advice 42
Maintenance of compressors and ancillary plant 42
Supervision and procedures 42
Daily 43
Checks mainly directed to reciprocating compressors 43
Weekly 43
600 hours 43
Six-monthly 43
2000 hrs or annually 44
Precautions 44
Maintenance of air powered equipment 44
Supervision and procedures 44
Daily 44
Weekly 45
Monthly 45
Three monthly 45
Six monthly 45
Precautions 45
TRAINING 46
Statutory requirements 46
Hazards 46
Precautions 46
Further information 46
British standards 47
Health & Safety Executive publications 48
Legal requirements 49
FURTHER INFORMATION 50
Page 4 of 50
Introduction
1
This guidance booklet aims to promote the safe use of compressed air
by giving advice to designers, manufacturers, installers, users and others
concerned with or responsible for health and safety at work. It was originally
produced in 1990 during a rapidly changing situation in Europe arising from
the preparation for the single market and was further revised under the
Review of Regulations and Guidance undertaken by the Health and Safety
Executive (HSE) in 1996.
There are many ways in which compressed air can be dangerous, for
example:
(a) it can enter body orifices such as the mouth, ears and anus, causing
severe and often fatal injuries;
(b) at high pressure it can penetrate the skin;
(c) particles or oil carried in an air jet can damage the eyes;
(d) oil-coke deposits in a system can spontaneously ignite and cause an
explosion;
(e) vessels containing compressed air, even at comparatively low pressure,
can explode violently once their integrity is lost; and
(f) dirty or wet air can lead to corrosion and blocked valves which may
make the system unsafe.
Page 5 of 50
Compressor plant
Groups of compressors
For the purposes of this booklet compressors are divided into three groups:
small, medium and large.
A small compressor delivers up to 40 litres per second of free air and/or has
a power input of no more than 15 kW. Such compressors may be mobile or
fixed and may be supplied as packaged units. A typical one would comprise
a reciprocating compressor driven by an electric motor on top of or alongside
an air receiver.
A medium compressor delivers between 40 and 300 litres per second of free
air and/or has a power input of between 15 and 100 kW.
A large compressor delivers more than 300 litres per second of free air and/
or has a power input of more than 100 kW.
Hazards
(a)
(b)
(c)
(d)
(e)
11 Dirty or wet air can cause a system to fail eg by causing fine particles of
debris to agglomerate, blocking safety related valves.
12
Page 6 of 50
Precautions
13
14
Safety valves
On all medium or large multi-stage positive displacement compressors a
safety valve should be fitted between each stage and, where appropriate, in
the inter or after cooler circuit.
15
16
Pressure indication
An accurately calibrated air pressure gauge with a readily visible appropriate
scale-reading should be provided after each stage of compression. However,
on small two-stage compressors this is not required after the first stage
of compression, but a suitable tapping to enable a test device to be fitted
should be provided. Gauges should be constructed to comply with BS EN
837-1 Part 1- Bourdon tube pressure gauges- Dimensions, metrology,
requirements and testing and installed to comply with BS EN 837-1 Part 2
Selection and installation recommendations for pressure gauges.
Thermal protection
To minimise the risk of overheating, large compressors should be provided
with a suitable thermal protective device as near as practicable to the last
stage discharge valve or, where there is more than one valve, at a common
point of discharge which would automatically shut down the compressor
when a predetermined temperature is exceeded. Note - where automatic
compressor shut-down may adversely affect the safety of pressuredependent systems, additional high temperature warning devices
may be required so that action can be taken prior to automatic
shut-down.
19
Page 7 of 50
20
21
22
Coolant protection
If the compressor is water cooled, a thermostat should be provided to the
cooling water outlet or water return to the radiator header tank to shut down
the compressor when the water temperature exceeds the manufacturers
recommended maximum. Where the thermostat device does not give no
water or no flow protection, a water flow detection device should also be
provided. Sufficient good quality cooling water is required to cool all parts
of the system and inhibit blockages and corrosion. The supply may require
protection against freezing in low temperatures.
Lubricant protection
23 On medium and large compressors a pressure-sensing device should be
provided to shut down the compressor and activate visible and audible
alarms if the lubricating oil pressure drops below the manufacturers
recommended minimum. Gravity-feed lubrication systems should be fitted
with a level sensing device. A thermal sensing device should be fitted to set
off an alarm and shut down the compressor if the oil in the crank case, sump
or scavenge systems exceeds the temperature specified by the lubricant
manufacturer. There can be safety advantages to using synthetic ester-based
oils for lubricating compressors.
24
Explosion protection
If components run hot, or oil coke deposits spontaneously ignite, there may
be an explosion. BS 6244 describes the chemistry of such conditions and
explains how oil coke deposits can be prevented. To reduce the explosion
risk on medium and large compressors, a fusible plug can be fitted on the
underside of the pipe between the compressor and the receiver as close as is
practicable to the compressor. When ordering such a plug, users will need to
provide the following information for the manufacturer:
(a)
(b)
(c)
(d)
25
Fusible plugs are generally available for pressure up to 340 bar (5000 psi).
As an additional precaution regular inspections of the compressor should be
carried out (see paragraphs 142 to 170).
26
27
Other instrumentation
On medium and large compressors consideration should be given to fitting
temperature reading or recording instruments to indicate:
Page 8 of 50
(a)
(b)
(c)
28
Page 9 of 50
KEY
Fusible plug
Thermal protective device
Water flow protective device
Oil level protective device
Oil pressure gauge
Air pressure gauge
NOTE
It is unlikely that any installation will require all the safeguards
indicated. However, a combination of these should be fitted,
taking into account the statutory requirements and the degree of
supervision the installation will receive.
A
B
C
D
E
F
F
B
Air inlet
filter
Intercooler
I
B
I
Low
pressure
cylinder
High
pressure
cylinder
Stop
valve
B F
Receiver
Receiver
identification
I J K
AR1
SWP
Manhole
Total
closure
unloader
I
B
D
E
G
I
Compressor
Aftercooler
Figure 1 Illustration of a large compressor installation showing the position at which safeguards are
required or recommended
Page 10 of 50
Air receivers
Statutory requirements
(a) any reducing valve or other suitable appliance is provided in the single
supply pipe; and
(b) there is no means of isolating any interconnecting pipework.
33 The receiver should be fitted with a suitable safety valve complying with BS
6759, Part 2 or similar equivalent standard and adjusted so that air is allowed
to escape as soon as the safe working pressure has been exceeded. It is
essential that the valve is capable of discharging more air than the system
can supply to the receiver.
34 The receiver should be fitted with a correct pressure gauge complying with
BS 1780 or similar equivalent standard and which indicates pressure in bar,
lbf/sqin, or other suitable units.
35 There should be a suitable appliance, either manual or automatic, for draining
the receiver. It is recommended that manual drain valves should be full bore
and straight through, to minimise any build-up of debris which could prevent
tight shut off. Automatic drain valves should have adequate capacity for
liquid discharge, be designed to minimise debris build-up and have a manual
override to check performance. A strainer positioned immediately upstream
of the valve will help prevent debris build- up. Protection against freezing of
valves will be required in in low temperature conditions.
36
Page 11 of 50
Hazards
39 The main hazard is that the vessel may explode because its safe working
pressure has been exceeded or because its ability to withstand pressure has
been reduced through corrosion fatigue or internal coke fires for example.
Precautions
(a) the air temperature rising to the compressor lubricating oil flashpoint; or
(b) an explosion occurring below the designed working pressure because of
lost integrity owing to heat.
Page 12 of 50
Coolers
Hazards
46 Many aftercoolers are pressure vessels and the associated hazards are
similar to those of air receivers (see paragraph 39).
47 Cooling plays an important part in the supply of good quality compressed air.
Intercoolers and aftercoolers lower the temperature of the compressed air.
These coolers are usually water or atmospheric air cooled. With very small air
compressors the function of the aftercooler (ie the lowering of the dewpoint
of the compressed air) is performed by the air receiver. For other cases a
separate aftercooler will normally be necessary.
Precautions
48 Air-cooled coolers usually rely on a good circulation of external air over the
heat exchanger surface to ensure effective transfer of heat. There should be
adequate space available around these heat exchangers to allow effective
cleaning of all surfaces. The cooling air inlets and outlets should not be
obstructed by loose equipment, materials etc or by any subsequently erected
building. Where possible the air inlet should be sited on the north side of the
building.
49 It is recommended, particularly at medium and large compressors, that
aftercoolers are fitted to the discharge side immediately after the compressor.
These are frequently provided with separators to remove oil and moisture
from the air.
50 A condensate separator with an automatic drain valve should be provided
at a suitable drainage point at the coolers compressed air outlet. Protection
against freezing of the valve will be required in low temperature conditions.
51 Where a fluid is used as the cooling medium, a coolant drain valve should be
fitted and the cooling circuit protected against corrosion. There should be
some way of measuring the inlet and outlet temperatures of the compressed
air and of the coolant.
Page 13 of 50
Air dryers
Hazards
52 The hazards associated with the shells of large dryers designed on the
tube-in-shell principle are similar to those of an air receiver (for information
on hazards see paragraph 39). A secondary hazard, should an air dryer not
function properly, is that moisture-laden air can cause a safety system to fail.
53 Air dryers are sometimes desirable where pipe runs have to be routed outside
buildings or where the compressed air is used outside buildings eg for
operating valves. Where exceptionally dry air is needed, eg for purging double
glazing units, air dryers are essential. There are two main types: refrigerant
and desiccant. Further classification can be found in BS 6754 Specifications
and testing of compressed air dryers.
54
Refrigerant
Refrigerant air dryers can usually reduce the dewpoint of the compressed
air to 2 C. This prevents condensation from forming in the distribution pipes
where the ambient temperature exceeds 2C. This may be suitable even
where short runs of pipe are routed in the open air, provided they are properly
insulated.
Dessicant
55 Desiccant dryers can reduce the pressure dewpoint of the compressed air to
very low levels, exceptionally, as low as -100C but normally, between -20C
and -40 C. The reduction in the pressure dewpoint of compressed air should
be closely related to the requirements of the plant or equipment installed.
A desiccant dryer normally consists of two chambers that both contain
desiccant - one on stream, the other being regenerated. An automatic inlet
valve directs air from the compressor to each chamber in turn, thus ensuring
a constant supply of dry air.
56
Precautions
57 The chambers of air dryers are pressure vessels and should conform with
BS 5500 Specifications for unfired fusion- welded pressure vessels or to a
standard providing equal integrity. If means are provided for isolating the
dryer (and it is good practice to provide means of isolation for all equipment),
either the chambers should be constructed to withstand the maximum
pressure that can be generated by the compressor or a suitable pressure
reducing valve and a safety valve should be fitted to prevent the safe working
pressure of the chambers from being exceeded.
Page 14 of 50
58 Where there is no means of isolating the dryer from a suitable safety valve, eg
on the receiver, and where non-return valves are fitted to the dryer outlet (to
protect it from stored energy in the system), no safety valves are needed.
59 Some dryers regenerate the desiccant simply by passing a proportion of
the drier air through it. Others use heater coils embedded in the desiccant.
This latter type should be equipped with a thermal protective device that
can detect any temperature rise above the thermostat setting. Excessive
temperature rises due to thermostat failures have been known to lead to oil
mist explosions.
Page 15 of 50
Installation of compressors
60
Precautions
61
Small compressors
Where possible the compressor unit should be mounted at ground level and/
or in an area big enough to allow for inspection and maintenance.
62
Any platform used for access or as a place of work should be big enough for
a person to stand safely on it, and have guard rails and toe boards.
63 The unit should not be mounted on a plant structure where there is excessive
vibration.
64 Small units used to supply workshops and similar installations should be sited
where they are accessible and physically protected against damage from
material, tools and equipment. Where the risk of damage is high they should,
where possible, be installed in separate rooms adjacent to the main building
(see paragraphs 60 and 67).
65
(a)
(b)
(c)
(d)
66
Noise
67
Page 16 of 50
(a)
(b)
(c)
(d)
(e)
HSE Guidance note PM 56 gives information and advice about nozzle design
to reduce noise.
Page 17 of 50
This section deals with the system of pipes, valves and fittings from the
source of the supply to the point of application or control.
Hazards
70
Inadequately sized and designed systems can lead to the operating units
being starved of air, causing machine malfunction. Repeated malfunctions
may tempt operators to adopt unsafe practices to overcome any problems.
Badly designed pipe runs and lack of isolation valves may expose
maintenance staff to unnecessary risks. Some grades of plastic pipework are
not recommended for use in compressed air installations and designers are
advised to consult manufacturers when selecting materials.
71
72
73
There are two main types of compressed air system; single line and ring
main. Figures 2 and 3 show typical layouts, with positions indicated for
various valves, drains, filters, air line lubricators and pressure gauges.
74
Users should keep a schematic drawing of the air system showing pipe
runs, intended direction of air flow, and the positions of fittings such as
valves, drains, etc. The drawings should be amended when modifications or
additions are made to the system. Any graphic symbols used should comply
with BS ISO 1219 Fluid power systems and components. Graphic symbols
and circuit diagrams.
Precautions
75
Pipe-runs
The route of the pipe run and the position of valves and operating points
should be safe and convenient for those who will use and maintain the
system.
Page 18 of 50
76
The pipe route itself should not present a hazard or obstruct access and
should be routed away from any areas where it may be vulnerable to
mechanical damage.
77
78
Pipe runs should have a slight fall in the direction of air flow, and drainage
valves should be fitted at the lowest point, in such a way that moisture and
air can be discharged safely. A drain valve should be fitted at the bottom of
vertical pipe runs. Sections of pipe and valves that may have water in them
and may be exposed to frost should be suitably insulated. Note: receiver
drains generally have a heavier duty than normal pipe run drains-see
paragraph 35.
79
Symbols
Description
Shut-off valve
Manual drain (water trap)
Automatic draining valve
Lubricator
Filter with manual control
Pipe fall in direction of air flow
Filter, pressure regulator
pressure gauge, lubricator
Control valve
Pressure gauge
Air cylinder(spring return)
Air
vent
Chute
operation
To
drain
Compressor
installation
Maintenance area
Air
grinder
To
drain
Air
point
To drain
Bin gate
operation
Page 19 of 50
KEY
Symbols
Description
Shut-off valve
Manual drain (water trap)
Automatic draining valve
Lubricator
Filter with manual control
Pipe fall in direction of air flow
Filter, pressure regulator
pressure gauge, lubricator
Control
point
Control valve
Pressure gauge
To
drain
Air
pump
B
Maintenance area
Air
point
Air
grinder
Chute
operation
Bin gate
Compressor
installation
Compressor
installation
80
81
All outlet points should, where practicable, be taken from the top of the
pipe run, and a stop valve or self-venting ball valve (where necessary
complete with handle) should be provided adjacent to the connection point.
The connection point at any outlet should be arranged horizontally or face
downwards; upward facing connection points invariably fill with dirt and
prompt the bad practice of blowing out before use. Outlet points should
be provided at convenient places for all routine activities which require
compressed air. They should be positioned so that hoses attached to them
will not cross or obstruct the normal access to the workplace, and can be
connected without the need for climbing.
82
Pipe runs should be identified by painting the pipe light blue (BS colour
reference 20.E.51) in accordance with BS 1710. Where applicable the risk of
coupling up to the wrong compressed gas supply can be further reduced by
the use of non-interchangeable connections (see also paragraph 100).
83
Page 20 of 50
84
For ring mains or systems with dual supply, stop valves must be provided
which enable each individual air supply to be isolated from the pipework
system. This arrangement of stop valves will allow safe operating procedures
to be adopted during maintenance of the system and ancillary equipment.
85
Where air cannot be vented from the system or any part of the system
through the normal outlets, valves should be fitted for this purpose. The
valves specified should be suitable for the application. In most cases threeport valves or self-venting ball valves are the most suitable type for isolating
and venting; these valves should be arranged so that when the supply is shut
off, the downstream part of the air system is vented through the exhaust port
of the valve and provision made to lock the valve in this position.
86
Where valves are grouped, or where the purpose or location of the valve
is not obvious, a notice should be provided indicating the position and/or
purpose of the valve.
87
Lever operated stop valves can be inadvertently moved to the open position.
During maintenance they should be either locked in the closed position or the
lever handle should be removed.
88
89
Page 21 of 50
90
Pressure regulators
Where it is necessary to protect equipment from overpressurisation,
pressure regulators should be provided and set to maintain a constant safe
downstream pressure. An air pressure gauge should be provided on the
outlet side. Depending on the level of risk created by overpressurisation all
adjustable controls should have some form of tamper-resistant protection.
Where the risk is low, a simple snap action lock should suffice. As the risk
increases, greater security against unauthorised adjustment is needed.
Consideration should be given to using models incorporating positive internal
stops or positive means of locking. For very high risks, non-adjustable models
may be the best answer; alternatively the adjustable items may be sited in
lockable enclosures with the key kept by a responsible person.
91
Page 22 of 50
Statutory requirements
92
93
94
Under the Management of Health and Safety Regulations 1992 and the
Health and Safety at Work Act 1974 employers have a responsibility to train
their staff. Further advice on training is given in paragraphs 171 to 173.
Hazards
95
Both blow guns and hand held tools are usually connected to a length of
flexible hose which during the course of its life will be subject to mechanical
damage and considerable flexing. This damage and/or flexing particularly at
connection points can cause the hose to rupture. This can lead to sudden
discharges of compressed air and may cause unsupported lengths of hose to
whip and snake dangerously.
96
The practice of using blow guns for removing swarf, powdered materials etc
from components and from machinery is widespread throughout industry.
There are a number of hazards connected with the use of blow guns
including:
(a)
(b)
(c)
(d)
(e)
97
By following the advice in the previous sections a clean, dry air supply should
be safely generated and distributed to all outlet points. The type of equipment
to be connected to the outlet point will determine what extra precautions, if
any, will be required. The most common range of devices will be air or blow
guns, portable tools or pneumatic powered machinery. Each has its own
particular requirements.
eye injuries - at air line pressures the air causes swarf or other particles
to move at high velocity creating a serious hazard to the eyes of the
operator or anyone nearby;
other injuries - injuries have been caused by discharging guns with the
nozzle held close to the skin. Very serious injuries, sometimes fatal, have
occurred when the nozzle of the gun has been pointed towards the
anus, even at some distance from it. Many of the injuries occur when
clothing is dusted down and because of this compressed air should
never be used for cleaning clothing; instead vacuum cleaners with brush
type heads are recommended. Others are the result of horseplay (see
also paragraphs 172 and 173);
dust explosions - there has been at least one serious explosion of a dust
cloud when a blow gun was used to remove flammable dust;
toxic hazards - the use of compressed air for cleaning toxic material can
result in the dispersal of the material into the air;
noise - blow guns frequently produce high noise levels.
Page 23 of 50
98
Precautions
99
Heavy, medium and light grades of hose are available. Where hoses are used
for semi-permanent distribution of compressed air, for example in quarries,
construction sites, shipyards, farmyards, garage forecourts etc, heavy grades
should be used. Medium and light grades are used for general purposes such
as fixed pneumatic machinery and pneumatic cylinders, small power tools
and portable equipment. Hoses used with hand-held power tools should be
light and flexible (but suitable for the duty).
Flexible hoses
When selecting a flexible hose, users should take into account the site
conditions, including temperatures, oils and pressures to which it will be
subjected. Where lubricating oil is present in pipelines, a grade of hose
resistant to that particular oil must be used. A synthetic based grade of hose
should be used for mineral oils and a natural based grade for vegetable oil.
Where fire and explosion risks may be present, the use of fire-resistant antistatic (FRAS) hoses should be considered. The manufacturers advice should
always be followed.
100 Tubes and hoses used to connect cylinders to their control valves are
available in a variety of colours to make fault finding and maintenance easier
(see paragraph 143). They should be neatly run and adequately secured.
If the failure of a flexible hose would be hazardous it should be further
restrained or shielded.
101 Coupling a portable tool to the outlet point is usually achieved by use of a
quick-acting connector. The connector should be designed so that when
disconnected it automatically seals the air pressure on the upstream side and
slowly vents the air pressure on the downstream side. For all hoses above 10
mm bore, more than 10 m long or subject to a pressure exceeding 7 bar, the
connector should have a self-venting socket which releases the downstream
pressure before disconnection is possible. Alternatively, a plug with a
controlled venting action should be used. These safety features prevent
inadvertent tool operation and uncontrolled whipping of the hose when its
inlet end is uncoupled from the socket. Another way of reducing whipping or
snaking is to fit emergency shut-off valves, hose rupture valves or air fuses
as close as practicable to the connector. The valves will close or reduce flow
to a very low level in the event of excessive air-flow conditions caused by a
failure of the hose (see also paragraph 83 about fitting of isolation valves). The
same requirement could be necessary when using plastic tubing.
102 Similar requirements for quick-acting connectors apply to most percussive
and vibrating air tools, which may be fixed or hand held. If a quick-acting
coupling socket is fitted at the hose end adjacent to the tool, the plug should
not be screwed directly into the inlet port but should be fitted onto a short
isolation hose (0.5 to 1.5 m long), thus isolating the plug and socket from the
tool vibrations.
103 Where hoses are used to suspend tools, the load strength of hose and
couplings should be at least five times the suspended load.
Blow guns
104 Blow guns consisting simply of a reduced orifice in direct line with the supply
hose can be extremely dangerous, unless preceeded by a pre-set tamperproof pressure regulator set at a reduced pressure from the normal 80 psi
airline supply. Models are available commercially which incorporate an air
curtain designed to provide a protective shroud around the nozzle. Although
Compressed air safety
Page 24 of 50
not completely safe, these designs significantly reduce the risk of eye injury
and the dangers from close skin contact. If designed correctly such nozzles
can often help to prevent the operator from being subjected to excessive
noise. Because air is vented directly into the atmosphere, clean dry air
is essential and lubricators should not be used. Blow guns can exhaust
significant quantities of air and place extra loading on the compressor
system. In view of this and the attendant risk arising from use of blow guns,
their use should be considered carefully with a view to using alternative
means for cleaning down machinery or components.
Portable tools
105 Pressure regulators should be used to reduce the pressure to the optimum
value for the safe and efficient use of the equipment. This value should be
clearly marked on the tool. Filters and lubricators should be fitted in the
supply pipe as shown at A in Figure 3. To prevent over-speeding, tools
with air motors should incorporate a governor or throttle. There should be
available an easily accessible means of isolating the air supply from the tool.
European Standard pr EN 792 Hand-held non electric power tools-Safety
covers design of drills, grinders, nibblers, polishers etc. It is poor practice to
pull portable tools using the hose or use it as a means of access by climbing
on to suspended hose . Old damaged hose should not be used to make up
fresh hose assemblies.
Page 25 of 50
Hazards
106 The hazards normally associated with powered machinery are equally
applicable to pneumatic powered machinery and suitable safeguards are
necessary as described in BS EN 982 Safety requirements for fluid power
systems and their components-Pneumatics and BS 5304 Code of Practice
Safety of machinery.
107 Unlike liquid fluid power media, compressed air is elastic (compressible),
and because of this, additional hazards can arise from stored energy and
actuators under load (see paragraphs 138 to 141). This hazard requires
particular consideration when the machinery is fitted with interlocking guards.
Interlocking systems are covered in paragraphs 129 to 137 of this booklet.
Precautions
110 To a large extent the design features needed will depend on how the
machine will be used. However, paragraphs 111 to 141 outline some basic
requirements for machine and circuit design.
111 All components used in the machine design, including connecting hoses,
should be able to withstand safely the maximum possible air main pressure.
The maximum safe working pressure of the machine should be clearly,
prominently and permanently marked on the machine.
Page 26 of 50
Page 27 of 50
Actuators
Hazards
117 Where linear actuators are used, special attention should be given to stroke
length, loading and the methods of mounting the cylinder to avoid buckling
of the piston rod and excessive side loading which could lead to piston rod
bearing and seal wear. Where shear forces on fixing screws are likely to
be excessive, the cylinder mounting should also be keyed or dowelled in
position. Alternatively, fitted bolts may be used.
118 Repeated shockloads on cylinder endcaps can eventually cause either the
cylinder or the piston rod assembly to fail, which could lead to serious injury.
Most cylinder manufacturers can supply cylinders with built-in cushioning
designed to reduce speed at stroke extremities, thus bringing the machine
component to a shockless stop. Equally hazardous is the potential for piston
and rod to separate. Cylinder manufacturers should ensure that pistons are
positively locked to the piston rod.
119 The function of the actuator determines the precautions necessary for a
safe design. If the purpose is to impart motion to a load which is otherwise
supported, the problem will be different from those for an actuator designed
to lift or lower a load. Cylinders designed to clamp pose yet another problem.
Precautions
120 For any actuators imparting motion, smooth action is preferable and
cushioning is desirable. If the cylinders are double-acting there may be
occasions, eg at start-up or following an emergency, when the cylinder is
pre-exhausted, causing the actuator to accelerate rapidly when air is first
introduced to the cylinder. Where this is likely to cause a hazard a soft start
arrangement should be introduced in the supply line to the machine. This will
initially restrict the flow rate until a certain predetermined pressure has been
reached.
121 Linear actuators with magnetic pistons and integral mounted reed switches
or proximity switches for signalling control valves are now popular. This
is largely due to the comparative cheapness of using electric or microelectronic control together with cost and space savings from not needing to
install independent mechanically actuated trips. Safeguarding pneumatically
powered machines where the control circuit is electrical requires extra caution
to ensure that the risk of injury is minimised if either the electric or pneumatic
power supply fails. Reed switches may malfunction in areas subjected to high
vibration levels or electromagnetic fields.
122 Actuators designed for lifting or supporting loads may collapse dangerously
if the supply fails. The machine should have spring-applied mechanical
scotches to support the load whenever movement is not required. In certain
instances mechanical scotches may be impracticable. As a safety back up
a normally closed, air to open, spring return valve in the cylinder supply line
could be used.
Page 28 of 50
123 Supply failure to clamping cylinders can lead to a hazard by releasing the
component prematurely. This can be overcome by using single acting
cylinders where the return spring applies the clamping force (see paragraph
127), or the use of two control valves will temporarily keep the cylinder
pressurised (see figures 4 and 5). But care should be taken in using this
design as even a small leak could affect the integrity of the system.
Cylinder
Stop
valve
(b) Control
valves
Guard
(a) Interlocking
valves
Figure 4 Single control system interlocking with piston arrest and hold (guard open)
Note: Figures 4 - 19 illustrate principles only, and they are not intended to provide all the
information needed to construct a safe working system.
Page 29 of 50
Cylinder
Stop
valve
(b) Control
valves
Guard
(a) Interlocking
valves
Figure 5 Single control system interlocking with piston arrest and hold (guard closed)
Page 30 of 50
125 The method used for interlocking should be commensurate with the risk. The
higher the risk the higher the integrity of the interlocking system should be.
126 Principles for design and selection of interlocking devices associated with
guards are given in EN 1088 and BS 5304. General principles for application
are given in BS EN 983 Safety of Machinery- Safety requirements for fluid
power systems and their components-Pneumatics.
127 On pneumatic machinery, because the power medium is compressible
and normally exhausted to atmosphere, the safety circuit design is not
straightforward as for other power media. However, the basic aims for
interlocking remain the same and, where possible, the power supply should
be interrupted by the guard operated interlocking device and any residual
system pressure exhausted to atmosphere. In this condition any cylinders
will be pre-exhausted and alternative arrangements in the system design will
be necessary where any cylinders are required to be under constant load
(see paragraph 122). In addition, particular precautions may be necessary
when reinstating the supply to pre-exhausted cylinders if rapid acceleration
is undesirable. To avoid the need to maintain supply pressure to cylinders
required to be under constant load, such as those operating clamps or
supports, alternative features should be considered, such as single-acting
cylinders, or spring applied mechanical scotches. Cylinders fitted with rod
locks, the locking action of which is triggered by loss of air supply, may also
be used to prevent uncontrolled movement.
128 Signal air lines should be kept to a minimum length to facilitate rapid exhaust
pressure decay. Where this is not practicable and pilot signals exhausting
to the atmosphere retain sufficient pressure levels to operate main control
valves (even after a guard has been opened), additional interlocking devices
should be provided which prevent opening of the guard until it is safe to do
so. When 3-position valves are used in safety circuits, where practicable the
centre position should provide a supply-sealed-only condition (outlets vented)
because an all-ports-sealed centre position can result in stored energy in the
actuator, leading to unintended movement if piping is disconnected.
Interlocking systems
Single control system interlocking
129 The basic elements of single control system interlocking (see Figures 4 and 5)
are:
(a)
(b)
(c)
Page 31 of 50
130 Any of these elements, or the piping or wiring interconnecting them, can
fail and cause danger, so they should be chosen to provide the maximum
degree of reliability. The greater the number of devices incorporated in the
system, the lower its inherent reliability, so interposing devices should be
avoided if possible.
131 The basic elements are similar to those employed in single control system
interlocking. Where the possibility of common mode failure needs to be
minimised different control power media should be used and kept separate
except for necessary interconnections for cross monitoring (where provided),
and connection to the supply.
132 Such systems can be entirely pneumatic (see Figures 15 and 16), or hybrid
for example one system, pneumatic and one system, electric (see Figures
17 and 18). This latter arrangement may be particularly appropriate where
cylinders with magnetic pistons and integral reed switches or proximity
switches are used. In both systems the output of the power controlling
devices should be connected so that either can stop hazardous movement
of the machinery, irrespective of the condition of the other. Where the circuit
is such that a single failure is not self-revealing eg the actuator continues to
operate, the integrity of the dual control system can be improved by cross
monitoring (shown also in Figures 17 and 18).
Cylinder
Guard
Note:
Manual reprositioning of the
cylinder is possible with this
type of control valve.
(a) Interlocking
valves
(b) Control
valves
Figure 6 Single control system interlocking with piston arrest (guard open)
Page 32 of 50
Cylinder
Guard
(a) Interlocking
valves
(b) Control
valves
Figure 7 Single control system interlocking with piston arrest and hold (guard closed)
Cylinder
Guard
(a) Interlocking
valves
(b) Equalising
valve
Page 33 of 50
Cylinder
Guard
(a) Interlocking
valves
(b) Equalising
valve
Cylinder
Guard
Equalising valve
(with power interlocking)
Control valve
(Air operated)
Figure 10 Use of an equalising valve - power locking (guard open)
Page 34 of 50
Cylinder
Guard
Equalising valve
(with power interlocking)
Control valve
(air operated)
Figure 11 Use of an equalising valve - power locking (guard closed)
Guard
Cylinder
Note
Cylinder returns
to instroke
position whenever
guard is open
Interposed
control
valves
Power
interlocking
valves
Reservoir
Page 35 of 50
Guard
Cylinder
Interposed
control
valves
Power
interlocking
valves
Reservoir
Page 36 of 50
Guard
To
close
Spring
return
Sequence
Closed guard
A+
B+
C+ D+
AC- DBOpen guard
To ports
marked
Page 37 of 50
Cylinder
(b) Interposed
control valves
Guard open
(a) Interlocking
valves
Figure 15 Dual control system interlocking without cross-monitoring, both channels pneumatic
(guard open)
Cylinder
(b) Interposed
control valves
Guard closed
(a) Interlocking
valves
Figure 16 Dual control system interlocking without cross-monitoring, both channels pneumatic
(guard closed)
Page 38 of 50
Guard open
Cylinder
Monitor
Control
valves
Interlocking
valve
(Pneumatic)
Power
control
valve
Interlocking
switch
(electric)
Sol A
Monitor C
2nd channel
interposed power
control valve
Figure 17 Dual control interlocking, one control channel pneumatic and one electric, with electric cross
monitoring (guard open)
Guard closed
Cylinder
Monitors
Control
valves
Interlocking
valve
(Pneumatic)
Power
control
valve
Monitor C
Interlocking
switch
(electric)
Sol A
2nd channel
interposed power
control valve
Figure 18 Dual control interlocking, one control channel pneumatic and one electric, with electric cross
monitoring (guard closed)
Page 39 of 50
Drill
A3
Scotch
A4
B11
Clamp
A1
Clamp
A2
C1
B22
Drill
A5
B21
B31
C3
C2
Guard
lock A7
Feed
A61
B52
B51
B62
A62
B61
C6
C5
B72
C7
B72
B52
B62
B11
B21
B31
B22
Run
V1
Single
cycle
V2
V3
B61
B51
Guard
Interlocking
valve
To
close
A7
Close guard
Scotch withdraws (A4 - )
Operate V2
Guard locks(A7+)
A1+
A2+
A3+
A5+
A2 - A3 - A5.
Guard unlocks (A7 -)
A61 & A62 Machine stops
Open guard
Scotch engages (A4+)
To lock
Figure 19 Guard operated power interlocking with scotch to prevent drill falling under gravity. Also fitted
with guard lock to prevent inadvertent opening
Power interlocking
133 Power interlocking is achieved by direct mechanical action of a valve in the
main air supply in series with the actuator. The mechanical action may be
direct from guard movement (see Figures 10 and 11) via a linkage, by a
captive key or a trapped key.
134 Interlocking by means of air isolation and exhaust may cause difficulties on
machinery which relies on the air supply to keep heavy articles suspended
or components clamped in position. Similarly, where complex machinery
is designed to perform a series of functions in sequence automatically (see
Figure 14), air isolation and exhaust interlocking could lead to the need
for potentially dangerous, extensive manual re-setting of actuators and
sequencing valves. For these reasons, power system methods of interlocking
are not normally practicable for complex air operated machinery and hence
control system interlocking of the pilot signals has to be used.
135 Where practicable, however, power system interlocking of complex systems
is better than single control system interlocking, provided the power
interlocking valve and the arrangements between the guard and valve are of
similar or higher integrity than the control system interlocking. In addition, any
machinery parts which are supported by compressed air and which would fall
under gravity when the air is isolated and exhausted should be automatically
scotched while the guard is open.
136 Such precautions are shown in Figure 19, the layout of which is in line with
BS ISO 1219-2 recommendations. Hazards arise from actuators Al, A2,
A3 and A5, which need safeguarding. Also, A3 operates vertically and will
Page 40 of 50
fall under gravity when air supply, through the guard operated interlocking
valve, is exhausted. The circuit has thus been arranged so that, with the
guard open, A3 is scotched using a single acting cylinder. Once the guard is
closed the scotch withdraws and the guard is locked so that the sequence
cannot be broken by inadvertently opening the guard. The complete single
cycle sequence is indicated in Figure 19, where it can be seen that the guard
unlocks to allow manual feeding if necessary. Continuous cycling can be
effected by operating the valve labelled run. If, during use, a malfunction
occurs requiring the guard to be opened, this can only be achieved by
shutting the stop valve in the main air supply line.
137 All these problems highlight the need for the machine designer to
consider carefully the overall system design to ensure that the interlocking
arrangements are effective. Although in many cases interlocking the pilot
signals rather than the power supply may be the only practical solution (see
Figure 14), this should be a last resort only.
Circuit design
Piston arrest
138 Where it is necessary just to arrest the movement of a piston when a guard
is open, this can be achieved by using either two three-port, two-position
valves (see Figures 6 and 7) or an equalising valve (see Figures 8 to 11). If an
equalising valve is used the piston may not stop immediately, but it will seek
an equilibrium position whereby forces on both sides of the piston are equal.
The circuit in Figure 6 will allow manual repositioning of the piston without
disconnecting pipes (depending on the friction in the system). Neither of these
techniques is suitable for clamping or supporting applications.
Piston arrest and hold
139 Where, for safety reasons, the piston must be arrested and held in position,
two two-port control valves can be used (see Figures 4 and 5). The piston will
seek an equilibrium position before coming to rest. However, a hazard could
arise if connections to the cylinder are broken to subsequently override the
locked position. Air exhausting through the broken connection could allow air
under pressure on the opposite side of the piston to expand, thereby causing
movement which could lead to injury.
Overriding locked position
140 Where the locked condition must be overridden while the guard is open, a
two-port stop valve can be added to the circuit (see Figures 4 and 5). This
would normally have blocked ports but by depressing the stop valve both
sides of the cylinder are opened to atmosphere, enabling the piston to be
moved manually.
Predetermined position
141 It may be necessary to ensure that pistons adopt a predetermined safe
position in the event of power supply failing. Again the use of single acting
cylinders may be possible but an alternative is to use a reservoir and
nonreturn valve arrangement (see Figures 12 and 13). It is important to
ensure that where reservoirs are used they are of sufficient capacity to ensure
that the piston does not stall in an unsafe position.
Page 41 of 50
Statutory requirements
Hazards
144 The efficient safe running of a compressed air system relies on cleanliness,
filtration, cooling and lubrication. The best way of achieving these four
conditions is to operate the plant in accordance with the operators manual
and to draw up and follow a written schedule of maintenance work which can
be revised in the light of experience. This is a form of safe system of work.
The written schedule should identify areas for attention, how often attention
should be given and the responsibilities of those who carry out and supervise
the work (see paragraphs 146 and 147).
145 The frequency of inspection depends very largely on the circumstances and
environment in which the plant is used. The frequency stated in this Booklet
should therefore be taken as a guide only and adjusted to suit particular
installations in the light of operational experience.
Supervision and procedures
146 Small compressor units are easily overlooked, especially if sited in a separate
enclosure outside the working area. Particular care is needed to see that
regular maintenance, inspection and testing is carried out. Procedures should
be laid down and records kept.
147 The user should nominate a responsible person to supervise the proper
operation and maintenance of the compressor plant in line with the
manufacturers instructions.
148 This person should regularly check that all instructions regarding operation
and maintenance are properly followed and that the compressor, its
accessories and safety devices are kept in good working order. The
responsible person should also make sure that maintenance work is carried
out only by adequately trained staff.
Page 42 of 50
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
Weekly
152 Each week the safety valves (where design allows) should be checked by
easing them by hand.
600 hours
153 After each 600 hours of running:
(a)
(b)
the quality of oil in the crank case should be checked and, according to
the manufacturers recommendations, replaced if necessary; and
the condition of the inlet air filters should be checked and thoroughly
cleaned or replaced. The interval between successive replacements
will be determined by local circumstances but is, to a certain extent,
controlled by the capacity of the filter and the cleanliness of the
atmosphere in the vicinity. Where oil wetted viscous filters are used,
spare units should be provided and excess oil should be drained
from the filter units for at least four to eight hours before the units are
replaced, except where the manufacturer advises otherwise.
Six-monthly
154 Where oil coke deposits are liable to occur, the explosion risk can be reduced
by carrying out six-monthly inspections of the delivery ports and pipework
and cleaning as required. The period between inspections can be modified in
the light of experience gained from operating a particular installation.
Page 43 of 50
2000 hrs or annually
155 After each 2000 hours of running or annually (whichever is the sooner):
(a) in the case of oil lubricated compressors, the delivery valves, ports and
all the pipework, vessels and fittings between the delivery port and that
point in the system
at which the air temperature can be confidently expected to be below
80C, should be inspected. Any carbonaceous deposit should be
effectively removed;
(b) fusible pellets or complete plugs should be replaced;
(c) the condition of protective devices should be checked and tested to
determine that they operate correctly;
(d) the intercooler and aftercooler sections should be cleaned;
(e) the radiator should be drained and washed out;
(f) the output control gear should be cleaned and inspected; and
(g) the air receiver should be thoroughly cleaned and examined internally.
Precautions
156 All maintenance work, other than routine checks to filters designed for
cleaning in-service, should be undertaken only when the compressor has
been stopped, disconnected and locked off from the power supply and all
internal pressure dissipated. Other precautions may also be necessary: for
example, the compressor may have to be scotched to prevent movement of
the mechanism.
157 Under no circumstances should flammable liquids by used for cleaning.
Appropriate safety precautions should be taken against any toxic vapours
liberated during usage of any cleaning or degreasing liquids.
158 An open flame should never be used for inspecting the interior of a
compressor, pressure vessel or pipework.
159 Dirty and wet air and worn components are among the most common
causes of hazards associated with air powered equipment.
Supervision and procedures
160 The user should nominate a responsible person to supervise the regular
inspection and maintenance of the equipment. Where the equipment is
extensive, some form of written system of planned maintenance should be
used and records of tests, repairs and modifications kept.
161 In addition to any maintenance required by statutory requirements, the
following maintenance procedures are recommended.
Daily
162 The system should be checked for leaks and repairs carried out as
necessary.
163 At the end of each day any accumulation of water should be drained from the
drain points. The drain valves should be inspected to make sure that they are
not choked with sediment.
Page 44 of 50
Weekly
164 At the end of each week, air line lubricators should be topped up as
necessary with the correct grade of oil and checked to ensure that they are
providing adequate but not excessive lubrication. Filters should be checked
and those that are clogged or causing unacceptable flow restrictions should
be replaced.
165 Similarly, on machines which require pressure regulation below mains
pressure, the pressure regulator should be checked to make sure that it has
not been tampered with and that the correct pressure is maintained.
Monthly
166 All hoses which are subject to flexing and/or mechanical damage should be
inspected for signs of cracking or deterioration and replaced as necessary.
Particular attention should be paid to areas adjacent to couplings.
Three monthly
167 Every three months machines with interlocking guards should be checked
to make sure that all interlocking valves are firmly secured and operated
positively by their cams. Check that wear in any linkages or valve operating
mechanisms is not so excessive that the valve is in danger of malfunctioning.
Six monthly
168 Every six months all stop valves should be checked. Check that access to
the valve has been maintained, that the handle is in position, that it will shut
off the air supply and that it will open fully and operate freely.
Precautions
169 Before any pressurised components are dismantled they should be effectively
isolated from all pressure sources and completely vented to atmosphere.
Precautions should also be taken to guard against the possibility of injury
through sudden release of trapped springs.
170 When components, especially valves, are found to be worn and service kits
of seals are used to rebuild them, care should be taken to check thoroughly
the function of the rebuilt valve before placing it in the equipment. For
convenience, manufacturers of service kits often include enough seals to
service a range or family of valves, although not all the seals in the kit are
required for each valve. Incorrect seal replacement can completely alter the
valves function and if replaced in the equipment could present a serious
hazard. Manufacturers should supply clear instructions on how to use such
service kits properly and supervisors should ensure that this information is
passed on to the person carrying out the maintenance.
Page 45 of 50
Training
Statutory requirements
171 Section 2(2)(c) of the HSW Act and Management Regulations and
Regulations 8 & 9 of the Provision and Use of Work Equipment Regulations
(PUWER) requires every employer to provide such information, instruction,
training and supervision as is necessary to ensure, so far as is reasonably
practicable, the health and safety at work of their employees. Sections 7 and
8 of the HSW Act place responsibilities on employees to take reasonable care
to co-operate with employers and not to interfere with or misuse anything
provided for their safety.
Hazards
172 All those who, in the course of their work, need to use compressed air
must be properly trained. Many accidents would be avoided if adequate
training was provided. It is probably because compressed air supplies are
so commonplace, being found at most garage forecourts, for example, that
employers falsely believe that training in their use is unnecessary.
Precautions
(a)
(b)
(c)
(d)
(e)
(f)
Further information
The following five publications are produced by the European Committee on
Manufacturers of Compressors, Vacuum Pumps and Pneumatic Tools (PNEUROP):
Safety recommendations for the use and operation of portable air compressors
London
Safety recommendations for the use and operation of stationary air compressors
London
Pneumatic tools - safety in operation London
Page 46 of 50
Safety recommendations for the use and operation of portable pneumatic tools
London
Recommendations for the proper use of hand held and hand operated pneumatic
tools London 1986
British Compressed Air Society (BCAS) produces: Guide to the selection and the
installation of compressed air services London, 4th edition ISBN 0 905608 02X and
A guide to compressor noise reduction London, under revision
European Oil Hydraulic and Pneumatics Committee (CETOP) Hydraulic and
pneumatic systems circuit diagrams London
(PNEUROP, BCAS and CETOP publications are available from the British
Compressed Air Society, 33/34 Devonshire Street, LONDON W1N 1RF)
Royal Society for the Prevention of Accidents (ROSPA) Beware compressed
air Birmingham, (IS 303) (available from: ROSPA, Cannon House, The Priory,
Queensway, BIRMINGHAM B4 6BF)
British Aggregate Construction Materials Industry Compressed Air Safety London
(available from: British Aggregate Construction Materials Industry, 25 Lower
Belgrave Street, LONDON SW1 OLS)
British Coal Reciprocal air compressors (surface and underground) (NCB codes and
rules series) Doncaster (available from: British Coal, HQ Mining Department, The
Lodge, South Parade, Doncaster DN1 2DX)
Page 47 of 50
Page 48 of 50
Legal requirements
Supply of Machinery (Safety) Regulations 1992 (as amended 1994)
ISBNS 0-11-025719-7 & 0-11-045063-9
Provision and Use of Work Equipment Regulations1992 (as amended 1997)
Management of Health and Safety at Work Regulations 1992
Mines and Quarries Act 1954, HMSO, ISBN 0 10 850389 5
Personal Protective Equipment Regulations 1992
Health and Safety at Work etc Act 1974, chapter 37, HMSO, ISBN 0 10 543774 3
Electricity at Work Regulations 1989
The Pressure Systems and Transportable Gas Containers Regulations 1989 (SI
1989 No 2169), HMSO, ISBN 0 11 098169 3
The future availability and accuracy of the references listed in this
publication cannot be guaranteed.
Page 49 of 50
Further information
For information about health and safety ring HSEs Infoline Tel: 0845 345 0055
Fax: 0845 408 9566 Textphone: 0845 408 9577 e-mail: hse.infoline@natbrit.com or
write to HSE Information Services, Caerphilly Business Park, Caerphilly CF83 3GG.
HSE priced and free publications can be viewed online or ordered from
www.hse.gov.uk or contact HSE Books, PO Box 1999, Sudbury, Suffolk
CO10 2WA Tel: 01787 881165 Fax: 01787 313995. HSE priced publications
are also available from bookshops.
British Standards can be obtained in PDF or hard copy formats from the BSI online
shop: www.bsigroup.com/Shop or by contacting BSI Customer Services for hard
copies only Tel: 020 8996 9001 e-mail: cservices@bsigroup.com.
The Stationery Office publications are available from The Stationery Office,
PO Box 29, Norwich NR3 1GN Tel: 0870 600 5522 Fax: 0870 600 5533
e-mail: customer.services@tso.co.uk Website: www.tso.co.uk (They are also
available from bookshops.) Statutory Instruments can be viewed free of charge
at www.opsi.gov.uk.
Page 50 of 50