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FEATURE COMPRESSED AIR


SPECIFYING FOR SAFETY: Compressed air piping installations


Often referred to as the fourth utility, compressed air is a vital component in modern manufacturing and therefore needs to be specified appropriately to ensure safe and efficient operation. Compressed air piping in particular should be designed and installed correctly with proper procedures followed during commissioning to ensure the integrity of all of its connections


I


n this article, BCAS, the UK’s trade association for compressors, air treatment and vacuum products, advises operators on the steps to take during specification and commissioning.


SUPPLIER SELECTION The first area to consider is the selection of a suitable and competent supplier. Under Regulation 6, The Pressure Systems Safety Regulations 2000 Approved Code of Practice, the owner or user of the system must ensure that those carrying out the installation have the required training, skills and experience. While the Regulations do not specify


piping types or specific installation procedures, it is important that the user selects a supplier that can demonstrate competence through experience and evidenced training in pipe installation and jointing, including an understanding of safety issues and demonstration of safe working practices.


To demonstrate compliance with the


law, users (and their contractors) should follow ‘good industry practice’ during installation, such as trade bodies’ codes of practice, for example the ‘BCAS installation Guide’ and the ‘BCAS Pressure & Leak Testing Best Practice Guide (BPG 103)’. These publications cover the selection of equipment, correct installation and commissioning prior to use.


INSTALLATION GUIDELINES The next area to focus on is the actual installation itself to ensure compliance and safety. The air mains can be sited at any level from under-floor ducting to overhead. For ease of servicing and draining and for access when connecting to service points, the overhead main is often used. Here are some general installation guidelines: • Pipes must not be allowed to sag or


hog, especially at threaded or flanged joints, since the bending stress could


result in leakage and possible pipe fracture. Follow manufacturer’s instructions for support spacing. • The air main should be supported throughout its length, so that the correct fall to the drain points is maintained and condensate cannot collect in the pipe. • Allowance must be made for thermal expansion and contraction. This allowance will vary with the material used. • Compressed air piping should not be attached to (or hung from) other utilities such as gas mains. • In jointing, it is important to read the


instructions – many new modular piping systems may be similar in appearance, but the jointing procedure can be quite different. If not correctly carried out this presents a real risk of failure and consequent injury to personnel. Over- tightening can be as dangerous as fittings that are too loose and will subsequently fail.


SAFETY IN COMMISSIONING Once the installation has been carried out to the appropriate recommendations, the air pipe systems should then be tested before use to establish the leak rate for energy efficiency and reliability, and to verify the integrity of the pipe/fittings joints to ensure personnel safety. This means that two distinct tests must be completed: the leakage test and the pressure (integrity) test. Before carrying these out, a risk assessment procedure and method statement should be drawn up to establish which areas would be dangerous to personnel should there be a major leak or system failure – and the appropriate precautions taken. Where there is an extension to an existing system, then only the new part of the system should be tested. The existing system should not be pressure tested and should be isolated before pressure testing commences. Subjecting an old system to a pressure test of up to 1.5 times operating pressure could over- stress it and lead to its premature failure. In conclusion, appointing suitably


qualified personnel that can install, extend or modify a compressed air system to ensure it is safe and efficient will always pay dividends – ensuring safety, compliance and best performance.


www.bcas.org.uk T: o207 935 2464 16 DECEMBER/JANUARY 2018 | FACTORY EQUIPMENT / FACTORYEQUIPMENT


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