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Occupational Safety Document for Operating an Air Compressor: The Most Detailed and Important Guide. Discover the necessary safety measures when working with an air compressor to ensure a safe work environment and minimize the risk of accidents. Read now to grasp the important regulations and guidelines.

Table of Contents

PART I: CURRENT STATE OF SAFETY FOR WORK RELATED TO AIR COMPRESSORS (COMPRESSOR)

I. General Situation

The Ministry of Labour, Invalids and Social Affairs informs sectors and localities of the occupational accident situation in the first 6 months of 2024 and outlines key solutions to proactively prevent incidents and accidents in the last 6 months of 2024. According to reports from 61 out of 63 centrally governed provinces and cities, in the first 6 months of 2024, there were a total of 3,201 occupational accidents nationwide (a decrease of 227 cases, equivalent to 7.09% compared to the same period in 2023), resulting in 3,065 victims (a decrease of 197 people, equivalent to 6.04% compared to the first 6 months of 2023), including both employees under labor contracts and those working without labor contracts. Specifically:

Number of fatal occupational accidents: 320 cases, a decrease of 25 cases (7.25%) compared to the first 6 months of 2023 (including 245 cases in areas with labor relations, a decrease of 28 cases or 10.3%; and 75 cases in areas without labor contracts, an increase of 3 cases or 4.2% compared to the first 6 months of 2023);
Number of deaths due to occupational accidents: 346 people, a decrease of 7 people or 1.98% compared to the same period in 2023 (including 268 in areas with labor relations, a decrease of 13 people or 4.63%; and 78 in areas without labor contracts, an increase of 6 people or 8.33%).
Number of people seriously injured: 810 people, an increase of 26 people or 3.32% compared to the first 6 months of 2023 (including 710 in areas with labor relations, a decrease of 5 people or 0.7%; and 100 in areas without labor contracts, an increase of 31 people or 44.92%).

Download the PDF file Occupational Accident Report – First 6 Months of 2024 issued by the Ministry of Labour, Invalids and Social Affairs.

The occupational accident situation in the first 6 months of 2024 in both sectors with and without labor relations saw a decrease in the number of deaths and fatal accidents compared to the same period in 2023.

II. Some occupational accidents when operating an air compressor (compressor)

Operating an air compressor, although an important part of many industrial and construction processes, also carries the risk of accidents for those working around it. Below are some common accidents when operating an air compressor:

Gas explosion: One of the most dangerous accidents when operating an air compressor is a gas explosion. The cause may be due to excessive pressure in the compressor or a short circuit due to contact with a flame or electromagnetism. Failure to properly maintain the compressor or using unsafe equipment can pose a significant risk of a gas explosion.
Infrastructure abuse: Some accidents occur due to infrastructure abuse, such as not thoroughly checking the electrical wiring system or gas pipes before operating the compressor. Infrastructure problems can lead to dangerous incidents, including short circuits, gas leaks, or fires.
Mechanical failure: An air compressor may experience mechanical failure due to wear and tear, damage, or other technical problems. If not regularly maintained and inspected, the compressor’s parts can cause unexpected incidents, which can injure employees or cause material loss.
Pressure-related risks: High compressed air pressure can pose a risk to workers if safety measures are not followed. Accidents can occur when the compressor’s parts are not carefully inspected, causing pressure leaks or incidents during operation.
Improper use of equipment: Operators must be trained and follow safety procedures when using an air compressor. Improper use of equipment can lead to unwanted accidents, including being caught between parts or getting stuck in surrounding structures.

To minimize the risk of accidents when operating an air compressor, it is necessary to implement safety measures such as employee training, regular maintenance and technical inspection of the compressor, and adherence to occupational safety regulations.

PART II: OCCUPATIONAL SAFETY AND HEALTH WHEN OPERATING AN AIR COMPRESSOR (COMPRESSOR)

I. Introduction

A. Overview of the importance of occupational safety when operating an air compressor (compressor)

Occupational safety is an undeniable factor in any work environment, especially when it comes to operating an air compressor. Maintaining a safe work environment not only protects the health and safety of employees but also helps to increase efficiency and reduce the risk of accidents.

When operating an air compressor, the risk of accidents can come from many different sources, including gas explosions, mechanical failures, pressure-related risks, and improper use of equipment. To minimize the risk, it is extremely important to apply safety measures such as employee training, regular maintenance and technical inspection of the compressor, and adherence to occupational safety regulations.

In addition, promoting a safety culture within the organization is indispensable. By creating a work environment where everyone is encouraged to participate in safety activities and report potential risks, the organization can create a positive work environment, enhance team spirit, and minimize the risk of accidents.

B. Important safety protocols and regulations when operating an air compressor (compressor)

Employee training: All employees involved in operating an air compressor should be trained on safety measures, how to use the equipment, and how to react in case of an incident. Ensuring that they are aware of the potential risks and know how to deal with them is an important part of minimizing accidents.
Regular inspection and maintenance: The air compressor should be regularly inspected and maintained to ensure that all parts are operating safely and effectively. This includes checking the pressure, checking the oil, and maintaining the mechanical parts.
Adherence to occupational safety regulations: Occupational safety regulations should be strictly followed, including the use of personal protective equipment such as safety glasses, masks, or gloves. At the same time, ensuring that no untrained individuals participate in the operation is also an important part of ensuring safety.
Monitoring and feedback: A continuous monitoring system should be established to track the compressor’s operation and detect any problems early. In addition, there must be a feedback process to handle emergency situations quickly and effectively.

II. Components and Functions of an Air Compressor (Compressor)

A. The different components of an air compressor (compressor)

Compressor unit: The compressor unit is the main part of the air compressor, where air is drawn in and compressed to a high pressure. Common types of compressor units include piston compressors, screw compressors, and scroll compressors.
Motor unit: The motor unit is the engine part of the compressor, providing the necessary power to operate the compressor unit. Common types of motors include electric motors and internal combustion engines.
Cooling unit: The cooling unit is used to cool the compressed air after compression to reduce the temperature and increase the machine’s durability. The cooling unit is usually integrated directly into the compressor or can be a separate part.
Filter and water separator: The filter and water separator are used to remove impurities and water from the compressed air, helping to protect the parts and ensure high operating efficiency.
Control unit and valves: The control unit and valves are used to regulate the air compression process and coordinate the flow of air into and out of the compressor.
Oil unit and lubrication system: The oil unit and lubrication system are used to lubricate and cool the moving parts in the compressor, helping to increase the machine’s lifespan and efficiency.

B. Structure and operating principle of an air compressor (compressor)

Compressor unit: The compressor unit is the main part of the air compressor, where air is drawn in and compressed to a high pressure. Common types of compressor units include piston compressors, screw compressors, and scroll compressors.
Motor unit: The motor unit is the engine part of the compressor, providing the necessary power to operate the compressor unit. The motor is usually connected directly or through a shaft to the compressor unit.
Cooling unit: The cooling unit is used to cool the compressed air after compression to reduce the temperature and increase the machine’s durability. The cooling unit is usually integrated directly into the compressor or can be a separate part.
Valve and control system: The valve and control system are used to regulate the air flow and pressure during the compression process. The valves are opened and closed to control the air flow and pressure as required.

C. Applications in the manufacturing industry of the air compressor (compressor)

Spray painting and coating: In the manufacturing industry, air compressors are used to supply compressed air to clean and compress paint or liquid coatings onto product surfaces. The high pressure of the compressed air helps to push the paint or coating through the spray gun at the necessary speed and pressure to create a uniform and high-quality coating.
Food and beverage production: In the food and beverage industry, air compressors are often used to supply compressed air for processes such as packaging, cleaning, and transportation. Equipment such as CO2 machines also need to use compressed air to operate.
Metal production and processing: In the metal production industry, air compressors are used in processes such as cleaning metal surfaces, supplying compressed air for plasma cutting or welding machines, and even cleaning dust and grease before painting or coating.
Pharmaceutical production: In the pharmaceutical industry, air compressors are often used to supply compressed air for equipment such as tablet presses, packaging machines, and separation and filtration processes.

D. Risks associated with operating an air compressor (compressor)

Explosion risk: High pressure in an air compressor can create an explosion risk, especially when not regularly maintained or inspected. A short circuit or the creation of explosive conditions, such as the generation of electromagnetism or contact with a flame, can pose an explosion risk if not carefully managed.
Mechanical accidents: Moving parts in an air compressor can create an accident risk for employees, such as the fan, compressor unit, or other parts. If safety measures are not followed or personal protective equipment is not used, there is a risk of a mechanical accident.
Pressure leaks: Pressure leaks in the compressed air system can create a safety risk for employees working around. Leaks can lead to incidents such as loss of pressure, short circuits, or even explosions when encountering a flame or electromagnetism.
Improper use of equipment: Using equipment improperly or not following safety regulations can lead to dangerous situations. Operators need to be trained and follow safety procedures when operating an air compressor to minimize the risk of accidents.

III. Safety Inspection and Maintenance Before Operating an Air Compressor (Compressor)

A. Safety check before operating an air compressor (compressor)

Before operating an air compressor, it is extremely important to perform safety checks to ensure a safe work environment and to minimize the risk of accidents. Below are some safety checks to be performed before operating an air compressor:

Check periodic maintenance: Ensure that the air compressor has been periodically maintained and technically inspected to ensure all parts are operating safely and effectively.
Check pressure: Check the pressure of the air compressor to ensure that it does not exceed the safe limit and is correct for the specific application’s requirements.
Check valves and controls: Ensure that the valves and controls on the air compressor are operating correctly and there are no incidents.
Check the lubrication system: Ensure that the air compressor’s lubrication system is working properly and has enough lubricating oil to keep the moving parts working smoothly.
Check the filter and water separator: Check and clean the filter and water separator to ensure that there are no impurities or water in the compressed air, which helps to protect the parts and ensure high operating performance.

Performing these safety checks before operating an air compressor will help to ensure that the machine operates safely and effectively, minimizing the risk of accidents and protecting the health of employees.

B. Guide to periodic maintenance of an air compressor (compressor)

Change lubricating oil: Change the lubricating oil periodically according to the manufacturer’s instructions or a determined schedule. Changing the oil correctly and periodically will help to protect the moving parts and increase the machine’s lifespan.
Check and clean the filter and water separator: Check and clean the filter and water separator periodically to remove impurities and water from the compressed air. This helps to protect the parts and ensure the compressed air is clean and dry.
Check valves and seals: Check and replace the valves and seals if necessary to ensure the compressed air does not leak and the pressure is maintained stably.
Check the cooling system: Check the cooling system and clean any dirt that may reduce cooling efficiency. Ensure that the compressor is not overheating and is operating in a safe condition.
Perform an overall maintenance check: Perform a periodic overall maintenance check to inspect all parts of the air compressor, including the compressor unit, motor, and control system.

IV. Safe Operating Procedure for an Air Compressor (Compressor)

A. Step-by-step guide on the safe operating procedure for an air compressor (compressor)

Pre-operation check: Before starting to operate the air compressor, carefully check all parts, including the valves, compressor unit, cooling system, and other parts to ensure that they are working correctly and there are no incidents.
Ensure personal safety: Before approaching the air compressor, ensure that you are wearing full personal protective equipment, including a helmet, safety glasses, gloves, and a heat-resistant jacket if necessary.
Start the air compressor safely: Start the air compressor according to the manufacturer’s instructions and ensure that there are no people or objects near the machine’s work area.
Monitor operation: Monitor the operation of the air compressor while it is running to detect any unusual signs early, such as loud noises, vibrations, or gas leaks.
Turn off the machine safely: When the job is finished, turn off the air compressor safely by following the specified procedures. Ensure that the machine has completely stopped before performing any maintenance work.

B. Emergency response measures and incident response mechanisms when operating an air compressor (compressor)

Stop the machine immediately: In the event of an incident, stop the air compressor immediately to prevent the risk of an accident and to protect the equipment from serious damage or loss.
Check and resolve the incident: After stopping the machine, proceed to check and determine the cause of the incident. Take the necessary repair measures or replace the damaged part to resolve the incident.
Report the incident: Report the incident to the manager or the company’s safety department so they can take preventive measures and improve the work process.
Train employees: Ensure that all employees are trained on safety measures and emergency response procedures in the event of an incident.
Perform periodic maintenance: Perform periodic maintenance and technical inspections to minimize the risk of incidents and to ensure the safe operation of the air compressor.

V. Risk Assessment and Hazard Management When Operating an Air Compressor (Compressor)

A. Identifying potential risks and hazards in operating an air compressor (compressor)

Explosion and fire risk: High pressure in an air compressor can create an explosion risk when encountering flammable conditions, such as an electrical fault or contact with a flame. The combination of compressed air and air quality increases the risk of an explosion.
Mechanical accidents: Moving parts in an air compressor can pose an accident risk if not properly maintained or used. Accidents can occur due to collisions, wear and tear, or part failures.
Pressure leaks: Pressure leaks in the compressed air system can pose an accident risk to employees working around. Leaks can also reduce the operating efficiency of the air compressor and lead to a loss of pressure.
High temperature: The air compression process can generate high temperatures, increasing the risk of an explosion and causing damage to the air compressor’s parts.

B. Effective hazard prevention strategies when operating an air compressor (compressor)

1. Regular inspection and maintenance of the air compressor (compressor) for safe operation

Check pressure: Check the pressure of the air compressor to ensure that it does not exceed the safe limit and is correct for the specific application’s requirements.
Check lubricating oil: Check the lubricating oil level and perform periodic oil changes to protect the moving parts and increase the machine’s lifespan.
Check valves and seals: Check and replace the valves and seals if necessary to ensure the compressed air does not leak and the pressure is maintained stably.
Check the cooling system: Check the cooling system and clean any dirt that may reduce cooling efficiency. Ensure that the compressor is not overheating and is operating in a safe condition.
Check the filter and water separator: Check and clean the filter and water separator to remove impurities and water from the compressed air, which helps to protect the parts and ensure high operating performance.

2. Adhere to occupational safety regulations for the safe operation of an air compressor (compressor)

Train employees: Ensure that all employees are trained on how to use and operate an air compressor safely. Training includes familiarizing them with the risks and accident prevention measures.
Use personal protective equipment (PPE): Ensure that all employees are fully equipped with personal protective equipment, including a helmet, safety glasses, gloves, and a heat-resistant jacket if necessary.
Perform a pre-operation safety check: Before starting to operate an air compressor, perform a safety check to ensure that the machine and the work environment are in a safe condition.
Perform periodic maintenance: Perform periodic maintenance measures according to the established schedule to ensure that the air compressor is always operating stably and safely.
Report incidents: Immediately report any incidents that occur during the operation of an air compressor so that the manager or the safety department can take corrective and preventive measures.
Perform supervision: Continuously monitor the operation of the air compressor to detect any unusual signs early and to prevent the risk of an incident.

3. Identify and mark a safe zone when operating an air compressor (compressor)

Identifying and marking a safe zone during the operation of an air compressor is very important to minimize the risk of accidents and to protect the health of employees. Here are the steps to be taken to identify and mark a safe zone:

Identify hazardous areas: First, it is necessary to identify the high-risk areas when operating an air compressor, including places with high pressure, moving parts, and areas of direct contact with the machine.
Determine a safe distance: Determine a safe distance from the hazardous areas by using the instructions from the air compressor manufacturer or occupational safety regulations.
Mark the safe zone: After determining a safe distance, mark the safe zone by using signs, lines, or other measures to highlight and guide employees away from the hazardous area.
Train employees: Ensure that all employees are trained on how to identify and adhere to the safe zones when operating an air compressor, and that they understand the importance of following this safety regulation.

By accurately identifying and marking a safe zone, you can help to minimize the risk of accidents and create a safe work environment for employees when operating an air compressor.

4. Use personal protective equipment when operating an air compressor (compressor)

Helmet: A helmet helps to protect the head from the risk of impact from falling objects, collisions with machine parts, or other materials.
Safety glasses: Safety glasses help to protect the eyes from dust, impurities, and small particles that may be thrown out during the operation of an air compressor, while also reducing the risk of injury in the event of an incident.
Gloves: Use protective gloves to protect your hands from impact, cuts, abrasions, or damage when in contact with air compressor parts or during maintenance work.
Heat-resistant jacket: In case of working near high-temperature parts, use a heat-resistant jacket to protect your body from the risk of an explosion or burns.
Safety shoes: Choose safety shoes that are suitable for the work environment to protect your feet from impact, slipping, or heavy materials falling on them.

5. Emergency procedures and response in case of an incident when operating an air compressor (compressor)

Personal protection: As soon as an incident is detected, employees should ensure their own safety by using personal protective equipment such as a helmet, safety glasses, and gloves.
Stop the air compressor: Stop the air compressor immediately to prevent the situation from worsening and to avoid the risk of a widespread accident.
Assess the situation: Assess the situation of the incident quickly and accurately to determine the cause and the level of danger.
Take firefighting measures: In the event of an incident related to a fire risk, take timely firefighting measures by using a fire extinguisher or the nearest fire suppression system.
Call a professional: Call a responsible person or a technical team to come and check and resolve the incident, while also notifying the manager and the safety department.
Report the incident: Report the incident in detail and accurately to the management levels and the safety department so they can take preventive measures and improve the work process.

6. Participate in occupational safety courses when operating an air compressor (compressor)

Occupational safety and health training is not only a legal requirement but also a commitment to the safety and health of workers. It helps employees recognize and deal with risks and hazardous situations, thereby reducing accidents, injuries, or fatalities in daily work.

The risk of accidents is always present and can happen at any time in the work environment due to the possibility of human error and the inability to anticipate every situation. This emphasizes the need for continuous Occupational Safety Training and vigilance.

When participating in occupational safety training at Nam Viet Safety Training Center, workers will be thoroughly trained from theory to practical risk scenarios. Accordingly, there will be measures to identify and prevent occupational accident risks that may occur during work. After the training course, trainees will take occupational safety tests to obtain an occupational safety certificate. From there, workers will have a clear understanding of safety knowledge as well as a valid certification for work.

VI. Factors Affecting Occupational Safety When Operating an Air Compressor (Compressor)

A. How do weather conditions affect the operation of an air compressor (compressor)?

Temperature: High temperatures can cause the air compressor to overheat, reducing work efficiency and increasing the risk of an incident. Low temperatures can also affect the lubricating oil and reduce its viscosity.
Humidity: High humidity can increase the risk of water forming in the compressed air system, causing leaks and damage. At the same time, humidity can also reduce the work efficiency of the air compressor.
Environmental conditions: External work environments such as rain, snow, or dust can affect the cooling system and reduce the work efficiency of the air compressor.
Altitude: Altitude can affect the air pressure, reducing the efficiency of the air compressor. At high altitudes, the air compressor needs to be adjusted to ensure stable operation.

B. How does the work environment affect the operation of an air compressor (compressor)?

Temperature and humidity: The temperature and humidity of the work environment can affect the work efficiency of the air compressor. High temperature and high humidity can cause the machine to overheat, reducing efficiency and increasing the risk of an incident.
Dust and impurities: A work environment contaminated with dust and impurities can reduce the work efficiency of the air compressor and cause incidents such as leaks.
Vibration and noise: A work environment with high vibration and noise levels can increase wear and tear and reduce the lifespan of the air compressor.
Workspace: A narrow and poorly ventilated workspace can increase the temperature and humidity, posing a risk of an incident and reducing the machine’s work efficiency.
Air pressure: A work environment at a high altitude can affect the air pressure and, therefore, the work efficiency of the air compressor.

C. How does the technical condition of an air compressor (compressor) affect its operation?

Maintenance condition: The air compressor needs to be regularly maintained to ensure the parts are operating stably and safely. If the maintenance is not done correctly, it can cause incidents and reduce the machine’s work efficiency.
Lifespan and wear and tear: The lifespan and wear and tear of the parts in the air compressor can affect the machine’s work efficiency and reliability. Worn parts may need to be replaced periodically to ensure stable operation.
Pressure and flow rate: The technical condition of the air compressor also affects the pressure and flow rate of the compressed air produced. If the machine cannot produce the necessary pressure and flow rate, it will affect the efficiency of the equipment and the processes that use compressed air.
Technical incidents: Technical incidents such as leaks, part failures, or errors in the control system can reduce the efficiency and safety of the air compressor. Timely diagnosis and resolution of technical incidents are very important to ensure the machine’s stable operation.

D. How do the safety knowledge and skills of the worker affect the operation of an air compressor (compressor)?

Knowledge of the air compressor: Workers need to have a basic knowledge of how an air compressor works, its important parts, and how to operate it safely and effectively.
Knowledge of occupational safety: An understanding of the principles and regulations of occupational safety is very important for workers to be able to identify and avoid risks and dangers during the operation of the machine.
Operating skills: Possessing the skills to operate an air compressor professionally is a decisive factor in efficiency and safety. This includes knowing how to start, adjust the pressure, and react in case of an incident.
Skills in recording and reporting incidents: The ability to record and report incidents promptly helps workers to deal with unexpected situations and to ensure that the incident is resolved quickly and safely.

VII. Occupational Safety Training on Skills for Safe Operation of an Air Compressor (Compressor)

A. Why do operators of air compressors (compressors) need to be trained in occupational safety?

Occupational safety training is an indispensable part for operators of air compressors because it brings many important benefits:

Reduces the risk of accidents: Occupational safety training helps operators to recognize and avoid the potential risks and dangers in operating an air compressor. This helps to reduce the risk of accidents and injuries.
Increases work efficiency: A person trained in occupational safety usually has a clear understanding of the work process and how to operate an air compressor more safely and effectively. This can lead to increased work efficiency and reduced downtime due to incidents.
Protects health: Occupational safety training not only helps to protect workers from the risk of accidents but also helps them to recognize and avoid health risks such as dust, noise, or toxic chemicals that may be present in the work environment.
Complies with the law: Occupational safety training helps operators to understand and comply with the legal regulations and requirements on occupational safety, minimizing the risk of violations and avoiding legal consequences.
Creates a positive work environment: A work environment where safety is trained creates confidence and support among employees, helping to enhance team spirit and organizational work efficiency.

B. Where to get occupational safety training for operating an air compressor (compressor)?

An Toan Nam Viet is a reputable and high-quality occupational safety training center in Vietnam today. With occupational safety training sessions held continuously at production workshops, factories, or construction sites across the country (63 provinces in Vietnam).

To ensure the effectiveness of the training, An Toan Nam Viet prepares carefully and meticulously, down to the smallest detail. From preparing tools, equipment, teaching aids to curriculum, materials, sound, and lighting.

The occupational safety training instructors at An Toan Nam Viet are experts with many years of experience in the field. They even have research projects identifying hazards in all industries and how to prevent them.

The instructor’s lectures are drawn from practice and conveyed in the most vivid and easy-to-understand way to the workers. These factors help workers feel comfortable during the learning process and absorb the teaching knowledge well. Of course, the knowledge conveyed always adheres to Decree 44/2016/ND-CP. From there, they will grasp many measures to prevent hazards and how to protect themselves. At the same time, they will also apply it most appropriately in their actual work.

VIII. The Significance of Occupational Safety in Operating an Air Compressor (Compressor)

A. The importance of maintaining occupational safety in the operation of an air compressor (compressor)

Protecting workers: Occupational safety is a top priority, and maintaining safety in the operation of an air compressor helps to protect the health and lives of workers on a safe and healthy work platform.
Reduces the risk of incidents: Implementing occupational safety measures helps to minimize the risk of incidents, occupational accidents, and machinery breakdowns, helping the business to maintain stable and effective operations.
Increases efficiency and production: A safe and healthy work environment creates favorable conditions for workers to work more effectively and with greater concentration, thereby increasing work efficiency and the business’s production.
Minimizes costs: Maintaining occupational safety helps to minimize the costs associated with occupational accidents, downtime, and repairs, while also helping to reduce legal and insurance risks for the business.
Creates a positive image: A business with a strong policy on occupational safety not only creates a positive work environment but also helps to create a positive image with the community and customers.

B. Important safety measures to know before operating an air compressor (compressor)

Regular inspection and maintenance: Ensure that the air compressor has been regularly inspected and maintained to ensure the parts are operating stably and safely.
Use personal protective equipment (PPE): Ensure the full and correct use of personal protective equipment such as a helmet, gloves, safety glasses, and non-slip shoes to protect your health during operation.
Knowledge of emergency procedures: The operator needs to be trained and knowledgeable about emergency procedures and responses to incident situations such as gas leaks, pressure measurements, and shutting down the air compressor safely.
Identify and mark a safe zone: Identify and clearly mark the safe zones around the air compressor, ensuring no objects or people are near the hazardous work area.
Adhere to occupational safety regulations: Always adhere to the business’s occupational safety regulations and rules and the relevant legal regulations to ensure the safety of yourself and those around you.

Participate in an occupational safety course: Complete the occupational safety training course to be issued an occupational safety card by the occupational safety training center to properly supplement your work records.