Air compressor explosion is a very serious hazard that everyone who uses these machines should be aware of. These powerful devices can put you at risk if you don’t know how to use and maintain them.
In a 2013 study, researchers found that compressed air blasts can lead to severe injuries, such as intracranial emphysema (40% of air compressor explosion cases). This condition describes the presence of air between the skull and the brain, and it can be deadly!
So, are air compressors safe? Generally, yes, air compressors are safe to use when the proper measures are implemented. However, failing to follow safety guidelines and regular maintenance can lead to dangerous situations, such as exploding air compressors. Understanding the causes of air compressor explosions can help prevent them.
In this article, we will detail all the causes that may lead to an air compressor exploding and provide you with valuable information on how to prevent these incidents.
What causes an air compressor to explode?
Excessive Pressure
A major cause of compressor failure is excessive pressure. When an air compressor operates beyond its recommended pressure, the unit could explode. The pressure relief valves are designed to prevent this. Unfortunately, they might malfunction or fail, precipitating an air compressor explosion.
Poor Maintenance
The oversight of regular maintenance and inspection of air compressors is another major cause of compressor failure. While uncommon, it can still cause air compressor explosion, especially if some components start to malfunction. Therefore, regular maintenance ensures that all parts are working properly and reduces the risk of sudden failures and explosions.
Overheating
Can an air compressor explode in heat? Yes.
An overheating (i.e., high temperature) air compressor can blow up. A common reason for this issue is not shutting down the compressor for too long or operating it in extremely hot conditions.
Make sure to take adequate cooling measures and rest intervals to prevent overheating.
Incorrect Installation
If an air compressor is installed incorrectly, it can cause the compressor to operate under excessive pressure, leading to an air compressor explosion.
Oil Contamination
In situations where oil in the air compressor becomes highly pressurized and there’s a spark or source of ignition, the air compressor can explode. To prevent this, make sure to inspect for oil leaks and maintain proper cleanliness.
Faulty Parts
Defective parts in the compressor can also cause an air compressor to blow up. For example, a pressure switch that doesn’t shut off the motor when the tank reaches its preset maximum pressure can lead to over-pressurization and explosion.
Deterioration due to Age
A very old air compressor might be susceptible to explosion. As the air compressor ages, its components can become rusty and unable to deal with the operating conditions.
Air Contamination
This cause of air compressor explosion is relatively rare; however, this is a comprehensive guide, so I saw fit to include it. If the compressed air is contaminated with volatile substances, such as flammable dust, gases, or vapors, the air compressor might explode.
Inadequate Ventilation
Using an air compressor in an area with poor ventilation can cause the unit to overheat. The heat produced by the compressor can’t dissipate efficiently without adequate ventilation, which can cause the compressor to overheat and potentially explode.
Puncture
This one is a no-brainer. A puncture in the air compressor tank will sometimes cause an explosion. The weakened structure might not withstand the pressure during operation, causing the air compressor to blow up.
Lubrication Problems
Insufficient lubrication increases friction in the motor and compressor pump, which often increases the temperature of the compressor. Add an ignition of flammable substances to the equation, and the air compressor might explode.
How big is an air compressor explosion
The severity of an air compressor explosion varies significantly depending on a range of factors, such as:
- Size of the air compressor
- The type of gas being compressed
- Operating pressure
- The level of containments in the air
- The presence of any combustible materials nearby
With that said, an air compressor explosion can be extremely dangerous. The compressor stores air under high pressure. If the tank fails, the stored energy will dissipate in an explosive manner. Unfortunately, this can prove fatal.
For example, on July 23, 2005, an 80-gallon air tank exploded at an automated car wash, killing an employee, who was on site completing upgrade work. The explosion resulted in fatal injuries to the employee’s abdomen and pelvic region.
Other documented instances where the failure of an air compressor tank caused an explosion powerful enough to launch the compressor up to several meters away. What’s worse, the explosion can propel pieces of the tank and other debris at high speeds, virtually turning them into deadly bullets.
Can an Air Compressor Explode From Excessive Heat?
Before we discuss the relationship between heat and air compressors, we must consider two primary factors. First, ambient heat, which refers to the surrounding temperature where the compressor is located. The second factor is the operational heat, which is the temperature that follows the compressor during operation.
Ambient heat doesn’t typically cause any safety concerns. However, if the compressor is situated in a particularly hot climate, this is a different story. In these conditions, you need to ensure the appropriate lubrication of the compressor’s parts. This is because your compressor will function at high temperatures compared to those in cooler climates. An optimal operating temperature range for most air compressors falls between 10 to 32.2 degrees Celsius (50 and 90 degrees Fahrenheit).
On the other hand, the overheating of an air compressor is what really poses an immediate danger. As we mentioned before, high temperatures can directly lead to air compressor explosion. Once again, a key factor that contributes to overheating is poor lubrication. Not using the right oil will increase friction. In Physics 101, excessive friction boosts temperature, eventually exploding the air compressor.
Additionally, poor lubrication could force oil into the compressor’s valves. If this occurs, there’s a risk that the high heat generated by the compressor could put the oil on fire. Such ignition could cause an explosion or rupture within the compressor.
How do you keep your air compressor from exploding
To prevent air compressor explosion, you should maintain your compressor’s operation within safe parameters. The following steps focus on crucial areas, such as drainage, lubrication, ventilation, adherence to manufacturer guidelines, and a regular check of all components.
Drain the Tank Regularly
After using the compressor, drain the tank to prevent the accumulation of moisture. The latter is responsible for internal corrosion. The drain valve location varies with each compressor model. Once you’ve completed your task with the air compressor, ensure to switch off the device and thoroughly drain the tank.
Aside from draining the tank, it’s also important to empty the air out of any attached hoses. You can do this by turning off the compressor and triggering the wand until you hear the air escape. This practice can significantly increase the lifespan of your hoses and attachments.
Maintain Proper Lubrication
While oil-free compressors require less maintenance than their oiled counterparts, it’s vital to frequently check the lubrication status. Oil-free machines use synthetic gel lubricants on certain parts, with some manufacturers claiming them to be maintenance-free. However, dirt accumulation can lead to premature wear, a primary reason behind the typically shorter lifespan of oil-less compressors.
Ensure Adequate Ventilation
If your compressor is operating indoors, sufficient ventilation is indispensable. A constant airflow is necessary for effective compressor operation. Be vigilant about any equipment or supplies obstructing the compressor’s air intake, which could lead to overheating and malfunction. For example, a misplaced dirty rag over the compressor could be a potential hazard.
Adhere to Manufacturer’s Guidelines
Ensure that you are adhering to the manufacturer’s guidelines during the installation and operation of your air compressor. If your device isn’t rated for pressures above 120 psi, it’s unwise and unsafe to push the compressor beyond this limit. Overpressurization can lead to tank rupture, exploding the air compressor.
Inspect All Components for Damage
Regularly examine valves, hoses, connections, and the tank for any signs of damage. Replace any cracked parts promptly.
Air Compressor Explosions – Frequently Asked Questions (FAQs)
1. Can an air compressor catch fire?
Yes, an air compressor can catch fire. Luckily, it is not common and typically occurs due to the misuse or failure to follow safety guidelines. Overheating due to prolonged use, poor ventilation, and inadequate cooling can lead to fires.
Regular maintenance and inspections, proper ventilation, and operating within manufacturer recommendations are key to preventing fires.
2. Is compressed air an explosive?
Compressed air itself isn’t explosive; however, it contains potential energy due to the high pressure. If a compressor fails or the air is suddenly released, it will mimic an explosive-like event, ejecting debris at high speed and potentially causing injury or even death.
Furthermore, if the compressed air in the tank contains flammable contaminants, it could lead to an actual explosion.
3. What kills a compressor?
Several issues can cause an air compressor to fail or “die”:
Insufficient Lubrication – Compressor pumps need proper lubrication. Insufficient lubrication can cause excessive friction, leading to wear and eventually killing the compressor.
Read about oil-free air compressors by clicking here.
Excessive Pressure or Overheating – As previously mentioned, both excessive pressure and overheating can cause significant damage and lead to compressor failure.
Age and Wear – Over time, all compressors experience natural wear and tear. If left unchecked, it can eventually lead to failure.
Electrical Issues – Faulty wiring, power surges, and running the compressor on improper voltage can cause electrical failures.
4. What is a common problem with air compressors?
A common issue with air compressors is that they can start having difficulty building up pressure or maintaining their output.
This could be due to several reasons, such as:
- A leak in the air hose or tank
- A worn-out valve or pump
- An engine issue in gas-powered compressors
- A malfunctioning pressure switch
Pre-emptive inspections can help identify and correct these issues before they cause serious problems.
Takeaway message
Air compressor explosion is a relatively uncommon but serious incident that could be deadly for the operator. Learning more about the causes and preventive measures for this incident is crucial to protect yourself and your surroundings.
I hope that this article helped you understand the causes of air compressor explosions and how to address them.
If you have any questions about this topic, feel free to express your thoughts in the comment section below.
