The Potential Dangers of Air Receivers

When comparing electricity or gas compressed air and air receiver systems, you’d be forgiven for thinking that compressed air presents very little danger. However, the reality is that compressed air brings its own set of serious issues to deal with.

Air receiver tanks, in particular, present a lot of potential danger when not regularly serviced. While receivers are classified as having non-hazardous gas content, they present serious risks due to the pressure built up as stored energy within the vessel. With regular servicing and inspections carried out on vessels and associated safety valves in compliance with Worksafe requirements, the likelihood that a problem will occur is greatly reduced, therefore reducing the risk to you and those working near a receiver.

Problem areas of air receivers

There are several common problems that air receivers may suffer from.

Vibration can create cracks in the welds attaching a compressor system to the air receiver or the welded base below the air receiver. Damage can also occur when rigid piping is connected to the air receiver without allowing for an amount of vibration. If your 2-tonne receiver breaks off and falls on someone close by, it could result in serious injury or even death.

External damage to the air receiver can also be caused by vehicles, objects or machinery coming into contact with the vessel. Without any proper barrier separating the unit from these external dangers, the chance of an accident is increased.

Internal corrosion is another problem area that can affect receivers. If condensate is allowed to collect, its volume decreases which can lead to increased cycling by your air compressor. The condensate can also potentially carry over to the air distribution lines, resulting in problems with air powered tools. The most detrimental effect of the condensate is internal corrosion of the air receiver. Since it’s internal, the corrosion is likely never seen by the owner and the effects are usually ignored.

Air Receiver Safety: What Can Go Wrong?

Air receivers are a familiar part of many compressed air systems, so it can be easy to overlook the pressure they contain.

An air receiver stores compressed air under pressure, helping your system manage fluctuations in demand and providing additional storage capacity. But that stored pressure also means the vessel needs to be properly maintained and inspected throughout its working life.

Problems such as corrosion, physical damage and deterioration of safety devices may not always be obvious during normal operation.

Regular air receiver inspections help identify these issues before they become more serious.

Why do air receivers need to be inspected?

An air receiver is a pressure vessel. While compressed air itself may seem relatively harmless, the energy stored inside a pressurised vessel can present a significant safety risk if the receiver fails.

The condition of the vessel can also change over time.

Age, operating conditions, moisture, vibration and physical damage can all affect an air receiver. Regular inspections allow the condition of the vessel and its associated safety equipment to be assessed.

Depending on its hazard level, an air receiver may also require registration with WorkSafe WA.

Internal corrosion

Moisture is a normal part of producing compressed air.

As compressed air cools, water vapour condenses and liquid water can collect within the system. This is one reason air receivers require effective condensate drainage.

If moisture remains inside the receiver, it can contribute to internal corrosion over time.

The difficulty is that you can’t necessarily see this deterioration from outside the vessel. Internal inspections allow the condition of the internal surfaces to be assessed and areas of concern identified.

External corrosion and physical damage

Not all air receiver damage happens internally.

The outside of the vessel should also be checked for corrosion, deterioration and physical damage.

Receiver location can play a part. Equipment installed in areas exposed to moisture, chemicals or other harsh conditions may require particular attention.

Air receivers can also be damaged by vehicles, forklifts or other equipment operating nearby. Suitable positioning and protection can help reduce the risk of accidental impact.

Vibration and connections

Air receivers and their associated pipework can also be affected by vibration.

Connections, supports, mounting points and surrounding pipework should be installed and maintained appropriately for the system.

During an inspection, signs of deterioration, damage or other conditions that could affect the safe operation of the receiver can be identified and assessed.

Pressure relief valves are an important safety device

The pressure relief valve, sometimes referred to as a PRV or PSV, is an important part of your air receiver installation.

Its role is to protect the vessel against excessive pressure by allowing compressed air to discharge if pressure exceeds its set limit.

Like other parts of a compressed air system, these valves require attention as part of the receiver’s ongoing inspection and maintenance requirements.

They shouldn’t be overlooked simply because the receiver itself appears to be in good condition.

Documentation is also important

Air receiver compliance isn’t only about the physical condition of the vessel.

Information such as the manufacturer’s data report (MDR), vessel identification and previous inspection records helps establish the history and specifications of the receiver.

Keeping this information available also makes future inspections easier, particularly when measurements need to be compared with previous results or the vessel’s original specifications.

Regular inspections help identify problems early

Air receivers can remain in service for many years when they are properly maintained, but their condition shouldn’t be assumed based on appearance alone.

Regular inspections provide an opportunity to identify corrosion, damage and other issues that may affect the vessel before they become more serious.

At Nessco Pressure Systems, our technicians carry out air receiver inspections for customers across Perth and regional WA. We can also assist with pressure relief valve replacement and WorkSafe WA registration requirements where applicable.

Not sure when your air receiver was last inspected? Check the inspection sticker on the vessel or call our service team on 1300 290 638 to arrange an inspection.