Air compressor and accessory setup design
When Compressed Air Controls designs an air compressor setup we ensure there is:
- ease of access for servicing
- adequate ventilation
- correct piping design
- condensation waste is draining efficiently
- pressure vessels/receivers are correctly installed and meet safety requirements
Compressed Air Controls design the setup of your air compressor and accessories to mitigate potential issues
When Stevenson Structural Engineers needed to replace their air compressor, Compressed Air Controls’ Manawatu Territory Manager Steven Carran conducted a site visit which helped him see why the last air compressor had prematurely died.
The previous air compressor, which was supplied and installed by a different company, had sucked in contaminants from the blast booth beside it, which destroyed its bearings in a Chernobyl-like fashion.
So instead of installing an air compressor in the same place, Steve designed a portable shed on a skid so the air compressors didn't have to be near the blast booth.
“It was rather an ingenious idea as we can move the air compressors around as we need them and it gives us space if we expand the business in the future,” Stevenson Structural Engineers’ Purchasing Manager Tony Twist said.
Compressed Air Controls always follows industry best practice
As well as ensuring no further meltdowns, this new air compressor plant room setup also follows industry best practice by ensuring the air compressors are protected from the elements
We also impressed Norwood when we designed their air compressors set up and supplied and installed an ELGi air compressor, AIRCOM air piping, and ELGi air dryer, and pre-filter
Grant Lister, Norwood’s Construction Equipment Sales Representative, was impressed by Compressed Air Controls’ Palmerston North Territory Manager Steve Carran clearly explaining why Compressed Air Controls follow best practice by using couplings instead of bending their AIRCOM aluminium piping.
The straight pipe is connected with AIRCOM elbow couplings to go around corners. The other compressed air company that Grant was potentially looking at working with said they would bend their piping. Steve said bending aluminium air piping would compromise the air piping’s coating and integrity and may cause it to fail. Bending aluminium pipe is not best practice or industry standard.
Compressed Air can design the air receiver setup, supply the air receiver and install and maintain it.
When we are planning the installation of an air receiver we will take into account the layout of your plant from a health and safety and production perspective. Poor location of an air receiver can affect the ongoing health and safety of operators, maintenance personnel and people in the surrounding area, as well as the integrity of the pressure vessel.
The following matters will be considered:
• locating the compressor and air receiver to minimise the effects of heat and noise, and where:
– it cannot be struck by mobile plant
– it can be fully accessed for inspection and maintenance (eg work platforms)
– safety devices can be monitored
– other plant does not affect its operation (eg drawing in exhaust fumes from combustion engines)
• the direction that a blowdown/pressure relief valve discharges
• avoiding burns through contact with hot piping
• the location of shut-off valves and isolation points
• the location of dangerous goods (in relation to the air receiver to avoid the possibility of fire
Before buying an air receiver from us, consult your staff to ascertain:
• the intended use
• operational parameters
• frequency of use (eg 24 hours a day continuously or sporadically)
• physical constraints of the workplace
• required distances from other plant
• required distances from flammable liquids
• required distances from people
• impact caused by the weather.
You should also consider safety within the workplace after the air receiver is purchased, for example:
•what new risks will be introduced to the workplace?
•what engineering controls will need to be introduced (eg piping that is pressure rated)?
•what new safe systems of work will need to be developed?
•what specific information, instruction, training and supervision will be required for the new plant?
A formalised safe work method statement and a risk assessment should also be completed.
Compressed Air Controls can then supply you with the right air receiver for your requirements as some are not designed to supply respiratory air.
We supply ELGi Equipment Ltd AirMate Air Receivers and air compressors which emit low levels of noise. We would nevertheless position the air compressor and air receiver to minimise risks associated with noise.
When we install the air receiver we would ensure that it can be locked out and tagged out when:
- not in use (to prevent unauthorised use)
- being worked on (to ensure the safety of maintenance staff or operators)
- deemed unfit for use (either following an incident, during an inspection or before commissioning).
We would also supply safety devices which we would inspect, maintain and repair during services.
- Pressure relief valves – designed to prevent pressure from building up beyond the design pressure of the air receiver.
- Blowdown valves – used to drain contaminants from the air receiver. There are automated systems available. These need to be tested to ensure that they are working regularly.
- Shut off valves – used to shut the air off from the air line or hose. They need to be easily accessible from locations along the line in case of rupture or other issues when immediate access is required.
- Isolation point – will be located so that the air compressor can be shut down safely in an emergency. The isolation point will not discharge the energy or compressed air from the system.
We would also ensure:
- That the air receiver was installed and anchored on proper foundations to prevent tipping over.
- The supports are protected against corrosion.
- The air receiver is level with the blowdown valve at the lowest point on the vessel.
- The blowdown valve is accessible for performing the regular blowdown and maintenance activities.
We would then commission it to specific performance parameters before it was used for the first time or before restarting after maintenance or repair,
We advise you on what is required to keep your records to the appropriate standard
As part of the servicing, Compressed Air would inspect the air receiver to ensure it stays in a safe condition. This would include an external inspection; checking fittings, safety devices, protective coatings, anchoring, supports and identification markings. These inspections are used to detect anomalies or defects, such as corrosion, leaks, bulging, signs of excessive temperatures or signs of cracking. We will also inspect it internally and the pressure relief valve will be tested at the same time.
If your air receiver does get damaged, we will advise whether it is more cost-effective to repair or replace it. If the defect makes it unsafe then we will decommission it and lock it out before replacing it. We will also explain what the damage is and how to decrease your chances of that reoccurring.
Compressed Air Controls would conduct a recommissioning inspection following repairs, changes to use, relocation and when returning to service after a period of non-use.
Have you had an air compressor setup designed and installed by us? Leave us a review.