Is it safe to install the air compressor in the workshop?

The safety of the installation of air compressors in the workshop requires a comprehensive assessment of equipment characteristics, environmental conditions and management measures, and its safety depends on the following key elements:

1. Potential Risk Analysis

1. high temperature risk
   • during the operation of the air compressor, the surface temperature can reach 80-120 ℃. If there are combustibles (such as oil, cloth, solvent) within 1 m around the equipment, it may cause a fire risk.
   • A machinery factory once caused the melting and deformation of the surrounding plastic pipes due to poor heat dissipation of the air compressor, causing the production line to stop.
2. Noise pollution
   • the noise level of the air compressor without noise reduction measures can reach 85-95 decibels. Long-term exposure can cause hearing damage and interfere with workshop communication.
   • An electronic factory was required to install a soundproof cover due to excessive noise from an air compressor, and the noise dropped below 75 decibels.
3. Risk of gas leakage
   • if there are problems such as pipeline corrosion and loose joints in the compressed air system, high-pressure gas leakage may occur. In confined spaces, leaking gas may cause a risk of suffocation.
   • Due to the aging of air compressor pipes in a food factory, compressed air was ejected to crush lighting fixtures, causing minor injuries to personnel.
4. Electrical safety hazards
   • if the air compressor control cabinet is not dustproof and waterproof, it may cause short circuit and electric shock accidents in humid environment.
   • An auto parts factory due to air compressor motor junction box water, resulting in the motor burned and caused a small fire.

Specification for safe installation of 2.

1. Location selection
   • keep away from the storage area of inflammable and explosive materials, keep a distance of at least 0.8 meters from the wall and equipment, and ensure smooth heat dissipation channel.
   • Give priority to the edge area of the workshop, avoid crowded areas, and set up warning signs.
2. Ventilation and heat dissipation
   • install forced air exhaust device to ensure that the inlet temperature of the equipment is ≤ 40 ℃. For water-cooled models, it is necessary to ensure that the cooling water circulation flow is ≥ 90% of the design value.
   • By installing axial flow fan in a chemical plant, the operating temperature of air compressor is reduced by 15 ℃, and the failure rate is reduced by 40%.
3. noise reduction measures
   • adopt soundproof cover, silencer and damping base to control the noise below 80 decibels.
   • A precision manufacturing enterprise through the construction of independent sound insulation room, the air compressor noise down to 65 decibels, in line with occupational health standards.
4. Pipeline system protection
   • the main pipe is made of stainless steel or galvanized steel pipe, and the pressure level shall be 1.5 times higher than the design pressure.
   • Pressure gauge and safety valve shall be installed on key joints, and overpressure automatic relief device (operating pressure ≤ 1.1 times rated pressure) shall be set.
5. Electrical safety
   • the control cabinet shall reach IP54 protection level and be equipped with leakage protection device (action current ≤ 30mA).
   • The grounding resistance of the motor shall be ≤ 4Ω, and the insulation performance shall be checked regularly.

3. operation and maintenance management requirements

1. daily inspection
   • daily check the oil level, temperature, pressure and other parameters, record equipment operation data.
   • Clean the dust on the surface of the heat sink every week to ensure the ventilation efficiency.
2. Regular maintenance
   • replace the lubricating oil and oil filter every 2000 hours, and check the bearing clearance of the main engine every 4000 hours.
   • Entrust a third-party testing agency to carry out pressure vessel inspection every year to ensure that the safety valve and pressure gauge are qualified.
3. Emergency plan
   • formulate emergency treatment process for air compressor failure, and provide fire extinguishers, first aid kits and other emergency materials.
   • Carry out annual emergency drills to improve employees' ability to deal with emergencies such as gas leakage and fire.

4. compliance verification

1. safety distance verification
   • use an infrared thermometer to detect the surface temperature of the equipment to ensure that the distance from combustibles meets fire protection specifications.
   • Measure the noise in each area of the workshop with sound level meters to ensure compliance with GBZ 2.2-2007 Occupational Exposure Limits for Hazardous Factors in the Workplace.
2. Pressure system detection
   • the special equipment inspection agency shall conduct annual pressure pipeline inspection and issue inspection report.
   • Conduct on-line calibration of safety valve to ensure accurate take-off pressure.
3. Electrical safety testing
   • use an insulation resistance tester to test the insulation performance of the motor, and the resistance value shall be ≥ 1MΩ.
   • Verify the reliability of the earth leakage protection device and ensure that the power supply is cut off within 0.1 seconds under 30mA current.

Through strict implementation of installation specifications, implementation of operation and maintenance management measures, and regular compliance verification, the safe operation of the air compressor in the workshop can be ensured. It is recommended that enterprises establish equipment safety files to record the life cycle data of installation, commissioning and maintenance, so as to provide data support for safety management.