Compressed Air System Safety

Compressed air systems store and distribute air under pressure for tools, controls, and process equipment.
Air receivers and pipework are pressure vessels that must comply with the Pressure Systems Safety Regulations 2000.
A written scheme of examination must be in place and examinations completed by a competent person.
Compressed air hose failure under pressure causes violent whipping that can cause fatal impact injuries.
Air at even low pressures can penetrate skin and enter the bloodstream, causing fatal air embolism.
Noise levels from compressed air venting and pneumatic tools regularly exceed 85 dB.
Condensate in compressed air systems must be drained regularly to prevent corrosion and equipment damage.
Pressure relief valves must be tested and maintained to prevent over-pressurisation of receivers.
Flexible hose connections must be secured with whip checks to prevent hose separation under pressure.
Isolation and depressurisation are essential before any maintenance on compressed air components.

Pressure hazards	Catastrophic failure of pressurised components can cause fatal blast injuries and high-velocity fragment impact.
Air injection	Compressed air entering the body through even a small puncture can cause fatal air embolism within seconds.
Legal requirement	The Pressure Systems Safety Regulations 2000 require written schemes and periodic examination of air receivers.

Do

Don't

Ensure a written scheme of examination is in place for all pressure vessels
Complete examinations by a competent person at the intervals specified in the scheme
Install whip checks on all flexible hose connections to prevent separation
Drain condensate from air receivers and moisture traps on a regular schedule
Test pressure relief valves to confirm they operate at the correct set pressure
Isolate and fully depressurise the system before carrying out any maintenance
Wear hearing protection when working near compressed air venting or pneumatic tools
Inspect hoses, fittings, and couplings for wear and damage before each use
Label all air receivers with their safe working pressure and examination due date
Store compressed air hoses coiled neatly when not in use to prevent trip hazards

DON'T direct compressed air at yourself or another person for any reason
DON'T use compressed air to clean dust from clothing or skin — it causes injury
DON'T exceed the maximum working pressure marked on the air receiver
DON'T operate a compressed air system without a valid written scheme of examination
DON'T use hoses without whip checks — a separated hose under pressure is lethal
DON'T bypass, block, or tamper with pressure relief valves on air receivers
DON'T carry out maintenance on pressurised components without full depressurisation
DON'T ignore leaking fittings or damaged hoses — repair or replace them immediately
DON'T allow unskilled personnel to modify compressed air system pipework
DON'T neglect condensate draining — water causes internal corrosion and failure

See also: Pressure Testing Safety | Compressor and Pneumatic Tools

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