Breathing Air Quality Matters: Ensuring Safety in Compressed Air Systems

Understanding Breathing Air

Breathing air is compressed air that has been purified to be safe for human inhalation. Our customers use the air compressor for their workers to breathe. Whether they're doing painting, chemical application, or pharmaceutical work, they hook it up to a helmet or mask to breathe clean, process-approved air.

You've probably seen it in common situations like firefighting, where compressed air is purified and used in breathing apparatuses, or in diving, where similar processes are used in industrial applications but on a larger scale.

Common Uses of Breathing Air 

Breathing air is vital in several everyday scenarios, including:

• Firefighting: Firefighters use compressed air in their breathing apparatus to navigate hazardous environments.
• Diving: Divers use purified compressed air stored in tanks to breathe underwater.
• Industrial Applications: In factories, breathable air systems are scaled to meet the demands of multiple operators, with systems customized based on the number of users and their specific tasks.

In facilities around the world, workers in chemical, pharmaceutical, and construction industries, especially in confined spaces, use compressed air. It's crucial for applications like automotive painting where clean air ensures worker safety.

A couple of important specifications you need to consider are how many people are going to be breathing the air and what they're wearing. Breathing air reaches the person through a mask or a full suit, and each type of mask or suit requires different air volumes and pressures. The amount of air needed depends on how closely the mask fits, the person, and the task they're performing. A close-fitting masks use 4 to 6 cubic feet per minute (CFM), while loose-fitting masks use 6 to 8 CFM. The amount of air used for a full suits depend on the size of the suit.

Components of a Breathing Air System

A typical breathable air system includes several key components to ensure safety:

• Desiccant Dryers: These remove moisture from the air, ensuring it is dry before being breathed in.
• Catalytic Converters: These convert harmful carbon monoxide (CO) into carbon dioxide (CO₂).
• Filters: Multiple stages of filters remove particulates, oil, and other contaminants.
• Carbon Monoxide Monitors: Continuous monitoring of CO levels in the air stream to alert workers if levels become unsafe.

Regulatory Standards and Compliance

The safety of breathable compressed air is governed by strict standards, such as the CSA Z180. This standard outlines the requirements for air purity, including the permissible levels of carbon monoxide, hydrocarbons, water vapour, and particulates. Compliance with these standards ensures that the air workers breathe is free from harmful contaminants.

CSA Z180 Standards

The governing body, CSA, has a Z180 brochure that covers all rules and regulations for breathable compressed air. It includes everything from the type of dryer to use, filtration, pipework, and even the style of quick connects.

Testing and Certification

There's a checklist of levels for carbon monoxide, hydrocarbons, water vapor, and particulates. You can capture an air sample, send it to a third-party lab, and get a certificate if it meets CSA Z180 standards. This certificate must be posted on the wall, indicating compliance and safety.

Common Pitfalls and How to Avoid Them

One of the major risks in using compressed air for breathing is carbon monoxide contamination, which is odourless and highly dangerous. Ensuring that the air intake for compressors is located away from potential contaminants like vehicle exhaust is crucial.

Sometimes, business owners cut corners by installing low-cost filtration that fails to remove moisture and carbon monoxide effectively. This puts workers at risk. It's essential to have a dedicated breathing air dryer that filters, dries, and purifies the air.

On the other hand, sometimes owners may install adequate systems but workers bypass safety measures.

Avoiding Common Pitfalls

• Proper Filtration: Use high-quality filters to remove contaminants effectively.
• Regular Maintenance: Schedule maintenance and filter replacements based on system usage and testing results.
• Monitoring: Implement continuous monitoring for CO and other contaminants to ensure immediate detection of unsafe conditions.
• Ensure worker compliance: Make sure your workers comply with the safety measures. It’s for their own health and safety!

Real-World Examples and Best Practices

Case Study: Automotive Painting Facility

In an automotive painting facility, workers use breathable air systems to avoid inhaling paint fumes. The facility installed a desiccant dryer, catalytic converter, and multiple filters to ensure the air meets CSA Z180 standards. Regular testing and certification help maintain compliance and worker safety.

Case Study: Chemical Processing Plant

A chemical processing plant faced issues with CO contamination. After relocating the air intake away from the loading dock and installing additional filtration, the plant significantly improved air quality. Continuous monitoring and bi-annual testing ensure ongoing safety and compliance.

Actionable Advice for Maintenance Managers

For maintenance managers, ensuring the reliability of a breathable air system involves several steps:

1. Assess Compliance: Regularly review your system to ensure it meets CSA Z180 standards.
2. Schedule Testing: Conduct air quality tests every six months and display the certification for transparency.
3. Invest in Quality: Use high-quality filters and components to avoid cutting corners that could endanger workers.
4. Monitor Continuously: Implement both audio and visual alerts for CO levels to ensure immediate action can be taken if needed.
5. Educate Staff: Ensure all operators are trained in the use of breathable air systems and understand the importance of maintaining these systems.

At the end of the day, we all want everyone going home safely after their shift. There are short-term and long-term effects of inhaling bad air, so compliance and proper maintenance are crucial. By following these guidelines, you can ensure that your compressed air system provides safe, breathable air, protecting your workers' health and maintaining regulatory compliance.

Conclusion

Ensuring the safety of breathable compressed air in industrial applications is not just about compliance; it’s about safeguarding your most valuable asset – your people. By investing in quality components, regular maintenance, and continuous monitoring, you can provide a safe working environment that meets industry standards and protects your workforce.