How to check for safety hazards in air compressors?

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Air compressors have a wide range of uses, and I believe those working on safety in factories must have seen them before. Where compressed air is used, there is generally an air compressor, or processes that involve a \"spraying\" action, such as sprayers, sandblasters, paint sprayers, etc.; the air compressor provides the power needed for these devices to function. There are many types of air compressors, and we need not delve into the specific working principles of each one, as it is not possible to disassemble the air compressors during safety inspections. But we need to find out whether the air compressors in our own factory use lubricant, as well as pay attention to some important parameters. Such as the operating temperature, pressure, speed, as well as the pressure value of the internal safety valve. Image: What are the risks associated with air compressors? Xiao Zhou experienced a fire involving a small air compressor; the reason was a lack of oil inside the equipment, which led to a continuous rise in operating temperature. Inside the air compressor, there are components that move in a manner similar to pistons or through other types of motion; these components require lubricating oil to keep their bearings lubricated. Just like in motors, a lack of oil or the use of oil of poor quality supplied by the supplier can lead to an increase in operating temperature, thereby creating a risk of fire. Another risk is that air compressors are usually installed in air compressor rooms, and those who have been to such rooms know that the noise level there is quite high. Another reason is overload of critical parameters, such as excessive operating pressure or too high internal rotation speed, which leads to equipment failures. Although there are cases of air compressor explosions online, I have not seen one with my own eyes yet. Xiao Zhou doesn’t like to go into too much detail or discuss all the internal components, as that’s pointless – after all, we can’t see that many things during regular safety inspections. Image 1: Checking the pipelines and air storage tank. Modern air compressors usually have few exposed components; at least the air compressors in our factory are equipped with integral protection, with the motor and pipelines all located within this protection structure. If there are pipes that are not covered by protection, the safety engineer can request that impact warning signs be added on site. Furthermore, an air compressor is usually equipped with a gas storage tank, which is generally a simple pressure vessel; of course, there are also pressure vessels that qualify as special equipment. Both such pressure vessels and the safety accessories attached to them (such as safety valves) need to be regularly inspected by a specialized inspection agency. II. Checking alarms: There are many alarms on the air compressor; the most common one is the emergency stop button. This can be listed as a routine inspection item. On the control panel of the air compressor, there are usually also vibration alarms, exhaust temperature alarms, oil temperature alarms, and operating pressure alarms. The vibration alarm is triggered when excessive internal load or improper installation causes excessive vibration and displacement of the air compressor, which can easily lead to serious mechanical damage ； Exhausting gas is usually done to remove excess gas, and if the temperature of this exhaust gas is too high, it is often due to an excessively high oil temperature inside; in such cases, it is necessary to be vigilant and consider replacing the oil system components ； Oil temperature alarms are associated with various faults, such as poor quality of lubricating oil, failure to replace it regularly, excessive load, and so on ； Excessive pressure may be caused by an inappropriate load pressure set on the panel, among other things. Therefore, as a safety engineer, one can ask the on-site operators to retrieve the alarm records to check whether any related alarms have occurred recently and whether those alarms were addressed. III. Check the environment: Compressors are usually installed indoors, in a place free from direct sunlight, and at least at a normal room temperature, to prevent the compressor from overheating. Furthermore, multiple compressors are usually installed in one room, and sufficient spacing should be maintained between them to facilitate maintenance and daily panel operations. There are also compressors that are connected to the interlock control in the control room, eliminating the need to operate them on-site; in such cases, start/stop buttons should be available next to the compressor to allow for immediate activation or shutdown in case of an emergency or interlock failure. Additionally, our factory has built a mobile maintenance platform vehicle, which is similar to a steel ladder that allows people to stand on it. Since our compressors are quite large, it is necessary to stand at a higher height during maintenance or cleaning tasks; therefore, a fence has also been welded around the platform where people stand.