How To Use A Compressor Safely

Although compressed air is commonly used to deliver power at construction sites, manufacturing facilities, and automotive garages, it should be treated with the same caution as other energy sources. It’s vital that compressed air system operators have proper training, read all instruction manuals thoroughly, and understand how to mitigate safety risks and potential damage.

It is important to remember that air compressors can be hazardous as the output is under such pressure that even brief contact with protected skin can cause abrasions, cuts, or other injuries. In rare cases, impact from compressed air has been known to cause traumatic organ damage.

This guide will discuss the basics of air compressor safety, areas to check before u

se, what to monitor, and how to keep operators and the workspace safe to minimize damage.

Common Air Compressor Hazards

Operators and workers

can mitigate the common dangers by following proper safety measures and air compressor precautions.

• Electrical dangers: If an outlet isn’t grounded correctly, it can result in electrical shocks for your operators or irreparable damage to the machine. Be sure to follow the instructions in the owner’s manual for extension cord use.
• Fumes: Gas-powered and diesel-powered compressors produce dangerous fumes, so it is important that you only use them outside.
• Flying particles and debris: Highly pressurized air and pneumatic tools can cause flying debris. If the debris strikes an operator, the pieces can cause bodily injury or become lodged in the machine and cause machinery damage.
• High pressures: If high-pressure air is injected into the body, dangerous conditions and injuries such as air embolism, ruptured eardrums, and ruptured organs can result.
• Noise: Noise from a compressor can cause hearing loss.

Equipment and Workspace Setup Safety Tips

Every operator needs to undergo proper training and learn the relevant safety standards before using an air compressor. It is also important to check air compressor safety regulations from the Occupational Safety and Health Administration (OSHA) to ensure you comply with any regulations that apply to your machines. The way your workspace is laid out can have a significant impact on safety. Here are some tips to keep in mind:

• Component pressure ratings: Make sure that all components, including hoses, pipes, and fittings, are rated for the maximum pressure of the
• air compressor.
• Relief valves: Relief valves automatically release air if the pressure in tanks gets too high. The relief valves are important safety features, so they should never be adjusted, bypassed, or removed.
• Drain valves: Electric drain valves need to be placed at least a foot and a half above the ground. Electric drain valves must be kept away from moisture.
• Shutoff valves: The shutoff valves should always be visible and within reach when working with compressed air.
• Guard for moving parts: Ensure that all moving parts such as flywheels, belts, and pulleys are effectively guarded.
• Workspace air circulation: Intake air contains pollutants and carbon monoxide that can be hazardous to your health. It’s essential to keep your workspace continuously circulated with clean air.
• Workspace humidity: The humidity level in your workspace must be maintained to prevent it from getting too high. To decrease the moisture in the air, try increasing air circulation in the workspace, operating your compressor longer, using a peripheral crankcase heater, or adding a dryer to your compressor.

Pre-Operation Checks

Before using a compressor, check the critical components to ensure your machine is working correctly. Create an air compressor safety checklist to keep track of all the various elements to look out for, as each of these is significant to maintain a healthy machine and operate it safely.

• Oil level: It’s essential to make sure the machine has an appropriate amount of oil. Using a compressor without an adequate amount of oil can lead to costly repairs or replacements. If your compressor needs more oil, add oil to the reservoir but be careful not to overfill it.
• Lubrication: Properly apply lubricants to every pneumatic tool to increase operational efficiency. Be sure to verify that the lubricants are not flammable before using them.
• Fuel level: To run an air compressor, you need enough fuel. Do not refuel your compressor when it is on or has been shut off for only a short amount of time. You should only conduct refuels and oil changes when the machine is fully cooled.
• Air filter: Always check the air filters before use. If the filter appears dirty or clogged, it should be removed, washed, or replaced.
• Air connection: Before turning on your compressor, ensure it is securely connected to the air source. If the connection is weak or loose, the compressor may not perform as expected, or parts could disconnect. These could potentially lead to injury.
• Outlets: Ensure your air compressor is only used with outlets that have proper grounding. If you plug an air compressor into an incorrectly grounded outlet, it could damage the machine’s electrical circuitry and potentially cause a fire.
• Tools: Make sure that any tools you have hooked to the air compressors don’t have pulled triggers before you power up the machine.

There are also air compressor safety tips and procedures for specific parts of a compressor. Three components include pressure regulation devices, air receivers, and distribution lines. Each is significant to maintain a healthy machine and operation.

Pressure Regulation Devices

• Valves: Ensure the safety valves on your air tank are set to at least 10% or 15 psi above the operating compressor pressure but never higher than the air receiver’s working pressure limit.
• Air intake: The compressor should only intake air from clean or outdoor sources. This can be accomplished by placing a filter or screen at the valve to keep the intake air clean.
• Speed: Check your compressor manual for the maximum recommended speed to ensure that the compressor never exceeds the maximum speed.

Air Receivers

• Draining: Make sure your air compressor can drain the air receiver regularly so the liquid does not build inside of it.
• Gauges and valves: Check the pressure gauges and safety valves to make sure they meet the American Society of Mechanical Engineers (ASME) standards.
• Release: Air receivers should include a spring-loaded release valve to prevent working pressure from exceeding the recommending maximum.

Distribution Lines

• Air hoses: Check distribution lines regularly for flaws, damage, or imperfections. Replace any defective airlines immediately.
• Fittings: Only use secure standard fittings on airlines.
• Tags: Place tags on each airline that indicate its maximum working pressure to help operators avoid exceeding those limits.

General Operator Safety

Operators should take precautions while operating air compressors, making sure to always remain in control of compressor units. Standing at surface level at a safe distance from the unit is crucial as well as keeping your hands, clothes, and hair away from the air nozzle and tools.

Be sure to wear the proper safety gear for the job. Personal protective equipment to consider while operating machines include goggles, face masks, rubber or leather gloves, steel-toed shoes, and leather or PVC aprons. Cover any part of the body that is at risk of encountering compressed air or flying particles.

To prevent any safety issues, keep an eye out for potential hazards while using an air compressor. Once you start your operation, check the following items consistently:

• Surroundings: As an operator, you must manage the safety of yourself and the other workers by keeping the surrounding area safe. Make sure all hoses, cables, and wires are tucked away where no one can trip.
• Voltage: Pay attention to your air compressor voltage. If repairs are needed, power down the machine and lock or tag out all power sources to release pressure from the compressor. Indoor compressors need to be kept inside as outdoor conditions can cause electrical problems.
• Air source: Be sure to check the air source regularly to ensure optimal performance and efficiency. The air should be clean and dry.
• Air inlet: At an air inlet, the air that goes in should be clean and free of moisture. It should not exceed the maximum recommended pressure. If the maximum pressure is surpassed, it could cause various dangers such as cracks, undue velocity, faulty pressure, or output torque.

FS-Curtis offers an array of machines and parts for a variety of industries, with each top-of-the-line product able to handle any operation safely with the utmost ease at maximum efficiency. Everyone who shops with us receives support from authorized partners and industry-leading warranties on select compressor products.

For more information, contact your local channel partner today!