1. Global Service Training
Compressed Air Safety
Training Module
Tristan Blanchard October 2007
Issue 2

2. Featuring….. MR T. (Guess Who !! )

3. Compressed Air Safety
The Following Presentation is a Guide to Your Safety !!
You are obliged by law to understand and adhere to national and local safety legislation and regulations.

4. Safety First !!!
CAUTION:
Work on a compressor unit must only be carried out by authorized service personnel who are fully trained and competent in:
The Compressor
The Compressed Air System
The Electrical System

5. Hot Surfaces Compressors can operate at temperatures
in excess of 200°C !!!
Beware of HOT Surfaces
Beware of HOT Oil
Beware of HOT Cooling Water

6. Compressed Air Safety Let’s look at each individually….
Pneumatic Safety
Electrical Safety
Safety Attire
Safe Working Practice
Site Safety Rules
General Safety
Read and Understand All Warning Labels
Chemical Safety
Let’s look at each individually….

7. 1 Pneumatic Safety Isolate Compressor From System
Depressurize Compressor and Pipe Work
Check Compressor Pressure Gauge

8. Pneumatic Safety
Isolate Compressor From System
It is advisable to use an Isolation Notice so people are aware that work is being carried out.

9. Pneumatic Safety
2. Depressurize Compressor and Pipe Work

10. 1 Pneumatic Safety
Check that compressor pressure gauge reads zero

11. 1 Pneumatic Safety Beware !!!
Air Exhausting to Atmosphere can be Dangerous….
Direct Discharge Air Away from the Unit & Operator
Clear Area of any Flying Hazards Before Discharge
Use Hearing Protection During Any Depressurization
Follow All Site / Local Regulations

12. 2 Electrical Safety

13. 2 Electrical Safety
Isolate From Main Supply
Remove Fuses
Lock Out
Test For Incoming Power
Only when absolutely necessary should any testing be performed with the power on. Use extreme care !
Never work on a powered or running unit alone!

14. 2 Electrical Safety
Isolate from Main Supply Isolate the compressor unit from the main power supply.

15. 2 Electrical Safety
Remove Fuses As an extra safety measure, remove fuses from the power supply to the compressor (and keep safely in your pocket).

16. 2 Electrical Safety
Lock Out…. Isolate the compressor’s power supply at the main board. Cover and lock the isolation box to prevent someone inadvertently switching supply back on whilst work is in progress or the unit is unsafe to use.
It is advisable to use an Isolation Notice so people are aware that work is being carried out.

17. 2 Electrical Safety
Test for Incoming Power…. Double check that the main supply terminals to the machine are not live before proceeding with any work. You may be 100% sure that supply has been isolated, but mistakes can occur from time to time. Get into the habit of double checking that the machine is safe to work on as high voltages can kill. It’s not worth the risk !!!

18. 3 Safety Attire Safety Footwear Gloves Hard Hat Ear Defenders
Safety Glasses
Coveralls
Reflective Vest / Jacket

19. 3 Safety Attire Protective Footwear
It is recommended that protective footwear is worn at all times to protect toes / feet from falling objects
Protective Footwear

20. Gloves Hand Protection
3 Safety Attire
It is recommended that protective gloves / latex gloves (where appropriate) are worn at all times to protect hands from injury / infections
Gloves Hand Protection

21. Hard Hats Head Protection
3 Safety Attire
Hard Hats Head Protection
It is recommended that hard hats / bump hats are worn at all times to protect the head from falling objects or low level hazards

22. Ear Defenders Hearing Protection
3 Safety Attire
Ear Defenders Hearing Protection
In noisy environments… it is recommended that ear defenders / ear plugs are worn at all times to protect your hearing

23. Safety Glasses Eye Protection
3 Safety Attire
Safety Glasses Eye Protection
It is recommended that safety glasses are worn at all times to protect your eyes

24. 3 Safety Attire Coveralls
While on any site, it is recommended that a coverall be worn
T.B
Coveralls

25. Reflective Jacket / Vest
3 Safety Attire
While on any site, it is recommended that a reflective item, such as a reflective jacket or vest, is worn
Reflective Jacket / Vest

26. 4 Safe Working Practices….
Use Correct Tools
Calibrated Equipment
Lifting Equipment

27. 4 Safe Working Practices….
Always use correct tools for the job Using incorrect tools can damage components and make further maintenance difficult and costly. e.g. Always use correctly sized spanners, never use grips or adjustable spanners.

28. 4 Safe Working Practices….
Always use equipment that has been correctly tested and calibrated. Using un-calibrated equipment may give false readings which could give rise to inaccurate fault diagnoses.

29. 4 Safe Working Practices….
Where required always use suitable lifting equipment Make sure that:- Items being lifted are well secured The lifting equipment and tackle is in good order and capable of lifting the item. Nobody, including yourself, stands too close or beneath items that are lifted.

30. 5 Site Safety Rules
Observe All Posted Signs and Notices

31. 6 General Safety…. If testing is required with unit running:-
Ensure all guards are in place.
Be aware of any items that may come in contact with moving parts.
Don’t wear long hanging cloths, neck ties
Do not play with compressed air
Do not point air hoses at anyone
Do not use compressed air to blow dirt from clothing

32. 6 General Safety…. Check Security and Condition of Air Hoses
Check Security and Condition of Electrical Cables
Protect yourself from Noise and Vibration from Air Tools
Remove ‘SLIP HAZARDS’: Clean Up………
Oil Spills / Oil Leaks / Water Leaks / Condensate
Tie back long hair
Beware of Loose Clothing e.g.… Tie !!
Walk Don’t Run !!
Beware of Trip Hazards
Beware of Low Level Bump Hazards
Beware of Heavy Lifting

33. 7 Read and Understand All Warning Labels
The following slides give brief descriptions of some of the most commonly used safety signs on CompAir compressors.

34. 7 Read and Understand All Warning Labels
Attention:
Only lubricate the system while the motor is running. For further details, see the operating instructions

35. 7 Read and Understand All Warning Labels
Don’t attempt any servicing / maintenance without reading the manual first.

36. 7 Read and Understand All Warning Labels
Attention:
Replace oil filter cartridge after approximately operating hours. For further details, see the operating instructions.

37. 7 Read and Understand All Warning Labels
Caution:
Hot Surfaces, Do Not Touch

38. 7 Read and Understand All Warning Labels
Caution:
Hot and dangerous exhaust fumes

39. 7 Read and Understand All Warning Labels
Check and, if required, re-tighten connection terminals. For further details, see the operating instructions.

40. 7 Read and Understand All Warning Labels
Earthing Point

41. 7 Read and Understand All Warning Labels
Warning Pressurized part or system

42. 7 Read and Understand All Warning Labels
Risk of electric shock

43. 7 Read and Understand All Warning Labels
The system continues to run for 30 seconds after pressing the ‘O’-Key

44. 7 Read and Understand All Warning Labels
This system can start up by means of a remote control or automatically after a power failure.

45. 7 Read and Understand All Warning Labels
Caution:
Pressure Vessel

46. 7 Read and Understand All Warning Labels
General Warning

47. 7 Read and Understand All Warning Labels
Rotating Machinery

48. 7 Read and Understand All Warning Labels
Do not re-engage starter until all moving parts are stationary

49. 7 Read and Understand All Warning Labels
Never attempt to operate the machine without the safety device mounted.

50. 7 Read and Understand All Warning Labels
Carefully read the operating manual before commissioning or servicing this compressor.

51. 7 Read and Understand All Warning Labels
Never operate the unit with open doors or loose access panels

52. 7 Read and Understand All Warning Labels
Never breathe in compressed air from this system

53. 7 Read and Understand All Warning Labels
Caution:
Vessel is pressurized

54. 7 Read and Understand All Warning Labels
Caution:
Do not start machine until……
Usually accompanied with another graphic

55. 7 Read and Understand All Warning Labels
Wait at least half an hour before proceeding

56. 7 Read and Understand All Warning Labels
Condensate drain from after-cooler or from after-cooler with subsequent filtering.

57. 7 Read and Understand All Warning Labels
Sound levels:- (needs checking )
There are two action levels for continuous noise:-
Ear protection should be provided if requested when noise levels are between dB(A)
Ear protection must be provided and their use enforced for anyone exposed to noise levels above 85dB(A)

58. 7 Read and Understand All Warning Labels
Safety relief valve setting

59. 7 Read and Understand All Warning Labels
Tie down point

60. 7 Read and Understand All Warning Labels
Lifting point

61. 7 Read and Understand All Warning Labels
Fork Lift points

62. 7 Read and Understand All Warning Labels
Protect the generator from moisture.
Do not clean with a Water / Vapor jet

63. 7 Read and Understand All Warning Labels
Bleed water from the pressure vessel after every 24 operating hours or if the water ratio is too high.

64. 8 Chemical Safety
When required to handle chemicals and oils, refer to the manufacturers material safety data information (MSDS)

65. PLEASE REMEMBER TO BE SAFETY CONSCIENTIOUS AT ALL TIMES….
Mr T. Says … Be careful out there
T.B.

66. Global Service Training
Compressed Air Safety
Training Module
Tristan Blanchard October 2007
T.B.