When assessing mechanical integrity in industrial facilities, large air receivers are often overlooked. These components store compressed air to maintain consistent system pressure, and their integrity is vital for safe and efficient operations. Recently, IFO Group consultants have encountered numerous cases where air receivers have been neglected, leading to significant safety and compliance risks.
Air receivers under pressure pose a significant safety risk when neglected. Over-pressurization or structural failure can lead to dangerous explosions, jeopardizing worker safety and causing costly damage to equipment and facilities. Ignoring inspections and maintenance also puts facilities at risk of regulatory violations, leading to fines, operational disruptions, and reputational damage. Including air receivers in your mechanical integrity program isn’t just about compliance—it’s about ensuring the safety and efficiency of your operations.
Common Issues with Air Receivers
Air receivers are frequently excluded from mechanical integrity programs, often because they are not considered critical assets or due to incomplete equipment inventories. This oversight means they are not being monitored, maintained, or inspected, leaving their condition unknown. Without proper oversight, minor issues like corrosion or pressure valve wear can escalate into major safety hazards.
Many facilities also fail to conduct inspections in accordance with ASME (American Society of Mechanical Engineers) standards. These standards set clear guidelines for the safe operation and inspection of pressure vessels, including air receivers. Without ASME-compliant inspections, there is no way to verify the structural integrity of air receivers. Undetected issues, such as thinning walls, cracks, or weld defects, can lead to catastrophic failures under pressure.
Pressure relief valves (PRVs) are another area of concern. PRVs are designed to release excess pressure and prevent catastrophic failure. However, many air receivers are equipped with improperly sized PRVs or lack them entirely. This exposes the equipment to over-pressurization, significantly increasing the risk of explosion.
In addition to technical issues, many facilities fail to meet state or local licensing requirements for air receivers. These requirements exist to ensure that air receivers are operated and maintained safely. Operating unregistered or unlicensed air receivers not only violates regulations but also suggests that the equipment may not have undergone necessary safety evaluations.
Finally, neglected air receivers often exhibit significant wear and tear, including corrosion, weakened welds, leaking seals, or damaged fittings. Poor condition not only compromises the reliability and efficiency of air receivers but also increases the risk of sudden failure. Corrosion can weaken the walls of the pressure vessel, making it more prone to ruptures under normal operating pressures.
To ensure the safety and compliance of air receivers, facilities should:
- Include Air Receivers in Your Mechanical Integrity Program: Regularly assess and document air receivers as part of your overall program to ensure they receive appropriate attention.
- Conduct Inspections in Line with ASME Standards: Work with qualified professionals to inspect air receivers and assess their integrity, pressure ratings, and overall condition.
- Verify and Maintain Pressure Relief Valves: Ensure every air receiver is equipped with a properly sized and functioning pressure relief valve, installed according to ASME guidelines.
- Comply with Licensing Requirements: Register and license air receivers in accordance with state and local regulations, keeping documentation up to date.
- Address Repairs and Maintenance Promptly: If deficiencies are identified, take immediate corrective action to mitigate risks and ensure safe operation.
At IFO Group, we specialize in identifying and addressing gaps in mechanical integrity programs, including overlooked air receivers. Our team of experts conducts thorough inspections and provides actionable recommendations to help facilities maintain safety, compliance, and operational efficiency.
Contact us today at 832-403-21356 or at info@ifogroup.com to learn more about how we can support your mechanical integrity program.
