How to Ensure the Safety of Air Receivers?

As special equipment for storing high-pressure air, the core of air receiver safety lies in “preventing overpressure, corrosion, leakage, and irregular operations”. By implementing “unremitting daily inspections, non-overdue regular inspections, regular maintenance of key components, and compliance with operating standards”, the risk can be reduced to nearly zero. Below is a specific and actionable safety guarantee plan:

I. Daily Inspection: 5 Minutes a Day to Identify Obvious Hidden Dangers

1. Pressure and Temperature Monitoring: After starting the machine, check the pressure gauge to ensure the pressure is always lower than the air receiver’s design pressure (marked on the nameplate, usually 0.8-1.0MPa). Overpressure operation is strictly prohibited. Observe the thermometer; the surface temperature of the tank should be ≤60°C. If it is abnormally hot, shut down the machine for inspection immediately.
2. Visual Appearance Inspection: Visually check the tank for bulges, deformation, or corrosion (focus on the bottom and welds). If rust peeling or weld cracks are found, stop using the machine immediately. Check pipeline joints and valves for “hissing” air leakage. Apply soapy water to the joints—bubbles indicate leakage points, which need to be tightened or have seals replaced in a timely manner.
3. Drainage Operation: Open the blowdown valve at the bottom of the tank before starting or after shutting down the machine every day to drain condensed water (until clear air flows out). This prevents water accumulation inside the tank from causing internal wall corrosion. If the blowdown valve is blocked, blow it through in reverse with compressed air; do not strike the valve body with hard objects.
4. Status of Safety Accessories: Check if the safety valve’s exhaust port is unobstructed, free of oil contamination or debris blockage, and if the sealing surface is leaking. Inspect the pressure gauge pointer for flexibility and the dial for damage. If the pointer is stuck or the dial is damaged, replace it immediately.

II. Regular Inspection: Mandatory Legal Requirements, Cannot Be Ignored

1. Inspection Cycle:
   • Initial Inspection: A comprehensive initial inspection must be completed within 3 years of commissioning (conducted by a qualified third-party organization).
   • Subsequent Inspections: Under normal operating conditions, inspections should be conducted every 3-6 years (shortened to every 1-2 years for scenarios with severe corrosion or harsh working conditions).
   • Hydrostatic Test: A hydrostatic test must be performed every 6 years to test the tank’s pressure-bearing capacity and ensure no leakage or deformation.
2. Inspection Content: Professional organizations will test the tank wall thickness (whether corrosion has reduced the wall thickness), weld quality (whether there are hidden cracks), and the sensitivity of safety accessories (safety valve opening pressure, pressure gauge accuracy). A “Inspection Report” will be issued after passing the inspection, which must be filed for future reference.
3. Scrapping Standards: If the inspection finds that the tank wall thickness is lower than the minimum design value, welds have irreparable cracks, or the tank is severely deformed, the tank must be scrapped in accordance with regulations. Refurbishment and reuse are prohibited.

III. Maintenance of Key Components: Guard the Core Line of Safety

1. Safety Valve (Core of Overpressure Protection):
   • Regular Calibration: Send to a qualified organization for calibration at least once a year. After passing calibration, attach a label indicating the next calibration date.
   • Daily Testing: Manually pull the safety valve handle once a month (with moderate force) to check if it exhausts smoothly and seats tightly without leakage after releasing.
   • Prohibited Operations: Do not block the exhaust port with iron wire or bolts, and do not disassemble or adjust the opening pressure without authorization (the adjusting screw is sealed with lead; unauthorized modification is illegal).
2. Pressure Gauge (Key for Pressure Monitoring):
   • Regular Calibration: Calibrate every 6-12 months to ensure the accuracy error is ≤±0.05MPa.
   • Replacement Standards: If the pressure gauge pointer is stationary, the dial is broken, or it is overdue for calibration, immediately replace it with a pressure gauge of the same range and accuracy (the range should be 1.5-2 times the working pressure).
3. Blowdown Valve and Pipes:
   • Regular Cleaning: Disassemble the blowdown valve every 3 months to clean internal sludge and impurities, avoiding valve core jamming.
   • Pipeline Maintenance: Check connecting pipes for corrosion and aging, and flange joints for looseness. If the pipe wall is thinned or aged, replace it in a timely manner.

IV. Standardized Operation: Avoid Human Safety Risks

1. Strictly Prohibit Overpressure Operation: Do not arbitrarily increase the air compressor’s pressure setting. Ensure the air receiver’s working pressure is always lower than the design pressure. If adjustment is necessary, it must be calculated by professionals first.
2. Prohibit Unauthorized Modification: Do not arbitrarily increase the tank volume, alter the tank structure (such as welding or cutting), or use the air receiver to store flammable, explosive, or toxic gases (only compressed air is allowed).
3. Operator Requirements: Operators must receive safety training, be familiar with the air receiver’s working principle and emergency handling methods, and operate without a license is strictly prohibited. Confirm that safety accessories are normal before starting the machine, and relieve pressure and exhaust after shutting down.
4. Environmental Requirements: The air receiver should be installed in a well-ventilated area away from heat sources (such as boilers, main units) and flammable and explosive materials. A safety distance of ≥1 meter should be reserved around the tank; storing debris is prohibited.

V. Emergency Handling: How to Respond to Emergencies

1. Overpressure Without Pressure Relief: If the internal pressure continues to rise and the safety valve does not actuate, immediately shut down the machine and cut off power, then open the manual pressure relief valve to exhaust. If pressure relief is still not possible, evacuate personnel to a safe area and contact professionals for handling; do not approach the tank.
2. Leakage or Rupture: If severe leakage of the tank or pipelines is found, or the tank bulges and deforms, immediately shut down the machine to relieve pressure, cut off the air source, evacuate surrounding personnel, set up a warning zone, and contact after-sales or professional organizations for maintenance. Self-repair is prohibited.
3. Fire or Explosion Risk: If a fire breaks out nearby, immediately close the air receiver’s inlet and outlet valves and move it to a safe area. If the tank explodes, immediately activate the emergency plan, organize personnel evacuation, and call 119 and 120.

Summary