COMPRESSED AIR ATLAS COPCO
Why contingency planning isn’t just hot air By Sean Clemens, UK Sales & Business Development Manager, Atlas Copco
It’s often inevitable that unexpected emergencies will take place within your manufacturing plant. However, there are steps that can be taken so that you can minimise the disruption, as the old adage rings true: failure to plan is planning to fail.
A
ppreciating that there may be instances of unavoidable disruption, a contingency plan is there to ensure operations continue
safely and effi ciently, with minimal interruption. As one of the biggest threats, when operations rely on compressed air, is downtime. Therefore, preparation makes all the difference when unforeseen challenges arise. With a contingency plan in place teams don’t need to scramble to react. They can focus on executing a well-thought-out plan to keep production running smoothly
For a quick response and a unifi ed approach to
emergency outages, it’s a priority for manufacturers to include their compressed air contingency plan into their overall emergency response plan or disaster recovery plan. Included in the plan should be defi ned roles, responsibilities, communication protocols, timeframes, and details of a chain of command for decision-making. And make sure your plan is communicated to relevant teams! So, whilst requirements for a backup compressed air system will vary, depending on a manufacturer’s needs and the importance of compressed air to their operations, the following points are key elements every organisation should consider when contingency planning for compressed air systems.
ASSESS YOUR REQUIREMENTS The fi rst step in establishing a contingency plan for compressed air should be conducting relevant assessments, notably calculating risk and criticality. Here you should include an analysis of potential failure points in your compressed air system, the likelihood and impact of failures, and importantly the processes and equipment that rely on compressed air. The output of these assessments will help you determine priorities for your compressed air contingency plan.
DETAIL SYSTEM OBLIGATIONS Once you’ve identifi ed your risks and the important functions of the system, your attention can turn to determining the requirements for the backup, as not all compressors are built the same and you want to ensure any replacement is fi t for purpose. Here, you’ll be making a note of pressure range,
fl ow range, air quality and reference temperature. It is also important to consider any additional specifi cations your air compressor must meet for
example, energy effi ciency, emission levels and even noise levels. Further consideration should be given to
any additional features required such as remote monitoring, the connection conditions and potential limitations. Which could include any restriction for the footprint of the system (think here about size and weight) and restrictions on accessing the site. You don’t want any replacement sat on the back of a wagon whilst you navigate access. Furthermore, consider available power sources, for example do you require modular power generators to keep your compressed air system running during power outages. Lastly, especially if you’re looking to have a backup contingency in the form of a rental, you should account for any ancillaries or accessories that are required for the operation of the backup system. For example, distribution lines, hoses, air dryers, boosters, fi lters, and fuel. Having a clear outline of your system requirements will also help you to determine the most appropriate contingency solution for your compressed air systems, whether you opt to purchase and store a backup compressor onsite or opt for a temporary rental compressor. For example, onsite backup systems require a large storage space whereas rental solutions can be provided as and when needed. DETERMINE TIMINGS
10 September/October 2025 Irish Manufacturing
Calculated into your contingency plan should be the time it takes to commission the backup system and reach the necessary pressure levels to align with your operational needs. For instance, there are many logistical factors which can impact the time to connect such as how quickly can your team mobilise any onsite solution and do they have the skillset to do so? And with a rental solution, does your supplier have a logistics team that can coordinate the transport? Are they available 24/7? An ideal solution here may be a ‘plug and play’ compressed air confi guration pre-fi tted with dryers, all packed on one trailer – especially if you require ancillaries and accessories.
COMPLY WITH REGULATIONS Whether you opt for a rental or an onsite back up system, it is typically the user’s responsibility to ensure regulatory compliance. Namely, in accordance with the Pressure Systems Safety Regulations (PSSR) 2000, it is a legal requirement that a Written Scheme of Examination (WSE) is in place on most pressure systems before the equipment is put into operation. Other industry regulations and internal guidelines
may have further stipulations on safety, operation, and environmental impact that you need to cover within your contingency plan. What’s really important here is that you’re ahead of the curve and aren’t trying to scramble a compliant plan, when
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