U.S. Department of Energy - Energy Efficiency and Renewable Energy

Federal Energy Management Program – Operations and Maintenance

Air Compressor Safety Issues

All components of compressed air systems should be inspected regularly by qualified and trained employees. Maintenance superintendents should check with state and/or insurance companies to determine if they require their own inspection of this equipment. Operators need to be aware of the following general safety requirements for compressed air.

Air Recievers
  • The maximum allowable working pressures of air receivers should never be exceeded, except when being tested. Only hydrostatically tested and approved tanks shall be used as air receivers.
  • Each air receiver shall be equipped with at least one pressure gauge and an American Society of Mechanical Engineers (ASME) safety valve of the proper design.
  • A safety (spring loaded) release valve shall be installed to prevent the receiver from exceeding the maximum allowable working pressure.

Air Distribution Lines
  • Air lines should be made of high quality materials and fitted with secure connections.
  • Hoses should be checked to make sure they are properly connected to pipe outlets before use.
  • Air lines should be inspected frequently for defects. Any defective equipment should be repaired or replaced immediately.
  • Compressed air lines should be identified as to maximum working pressures (psi) by tagging or marking pipeline outlets.

Pressure Regulation Devices
  • Valves, gauges, and other regulating devices should be installed on compressor equipment in such a way that they cannot be made inoperative.
  • Air tank safety valves should be set no less than 15 psi or 10% (whichever is greater) above the operating pressure of the compressor. They should never be set higher than the maximum allowable working pressure of the air receiver.

Air Compressor Operation
  • Air compressor equipment should be operated only by authorized and trained personnel.
  • The air intake should be from a clean, outside, fresh air source. Screens or filters can be used to clean the air.
  • Air compressors should never be operated at speeds faster than the manufacturer's recommendations.
  • Moving parts, such as compressor flywheels, pulleys, and belts that could be hazardous should be effectively guarded.