BRITISH STANDARD BS 6244:1982

ISO 5388-1981

Code of practice for

Stationary air
compressors —
[ISO title: Stationary air compressors —
Safety rules and code of practice]
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UDC 621.51.02-182.2
 BS 6244:1982

Cooperating organizations

The Mechanical Engineering Standards Committee, under whose direction

this British Standard was prepared, consists of representatives from the
following:
Associated Offices Technical
Committee
Association of Consulting Engineers
Association of Hydraulic Equipment
Manufacturers
Association of Mining Electrical and
Mechanical Engineers
British Compressed Air Society*
British Electrical and Allied
Manufacturers’ Association (BEAMA)*
British Gas Corporation*
British Gear Manufacturers’
Association
British Internal Combustion Engine
Manufacturers’ Association
British Pump Manufacturers’
Association
British Steel Corporation
British Steel Industry
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Department of Trade (Marine
Division)
Department of Transport
Electricity Supply Industry in
England Wales*
Energy Industries Council*
Engineering Equipment Users’
Association
Federation of Manufacturers of
Construction Equipment and Cranes
Health and Safety Executive*
Institution of Gas Engineers*
Institution of Mechanical Engineers*
Institution of Plant Engineers
Institution of Production Engineers
Lloyd’s Register of Shipping
London Transport Executive
Machine Tool Industry Research
Association

Chartered Institution of Building Ministry of Defence*

Services
Crown Agents for Oversea
Governments and Administrations
Department of Industry (Mechanical
Engineering)
Department of Industry (National
Engineering Laboratory)
Department of the Environment (PSA)
National Coal Board*
Oil Companies Materials Association
Process Plant Association
Society of Motor Manufacturers and
Traders Limited
Telecommunication Engineering and
Manufacturing Association (TEMA)
Water-tube Boilermakers’ Association

The organizations marked with an asterisk in the above list, together with the
following, were directly represented on the Technical Committee entrusted
with the preparation of this British Standard:

Contractors Plant Association Institution of Mining Engineers

Imperial College of Science and Technology South Wales Institute of Engineers
Institute of Marine Engineers Coopted member
Institution of Mining and Metallurgy

This British Standard, having

been prepared under the
direction of the Mechanical
Engineering Standards
Committee, was published
under the authority of the
Board of BSI and comes
into effect on Amendments issued since publication
31 March 1982

© BSI 02-1999 Amd. No. Date of issue Comments

The following BSI references

relate to the work on this
standard:
Committee reference MEE/39
Draft for comment 78/77428 DC

ISBN 0 580 12688 9

 BS 6244:1982

Contents

Page
Cooperating organizations Inside front cover
National foreword ii
Section 1. General
1 Scope and field of application 1
2 References 1
3 Unit system 1
4 Definitions 1
5 Compressor categories 2
6 Potential hazards 2
Section 2. Compressor design and construction
7 General 4
8 Guards 4
9 Pipework and pressure vessels 4
10 Vibrations and pressure pulsations 5
11 Electrical equipment 5
12 Overheating 5
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13 Materials 5
Section 3. Compressor installation and air distribution system
14 General 6
15 Compressor installation 6
16 Access platforms 7
17 Pressure gauges 7
18 Pipework 7
19 Design of pressure relief devices 8
20 Application of pressure relief devices 9
21 Installation of pressure relief devices 9
22 Noise 10
Section 4. Compressor operation and maintenance
23 Operation 11
24 Maintenance 11
Annex A Exposure to noise 13
Annex B Design principles for the pressure system of
oil-lubricated compressors 13
Annex C The mechanism of oil coke ignition and
the origin of oil explosions 14
Annex D The selection of lubricants for air compressors 15
Annex E Precautions against crankcase explosions 18
Table 1 — Maximum tolerable thickness of coke layer 12
Table 2 — General lubrication oil recommendations for air compressors 12
Publications referred to Inside back cover

© BSI 02-1999 i
 BS 6244:1982

National foreword

This British Standard, which has been prepared under the direction of the
Mechanical Engineering Standards Committee, is identical with ISO 5388-1981
“Stationary air compressors — Safety rules and code of practice” prepared by
Technical Committee ISO/TC 118, Compressors, pneumatic tools and pneumatic
machines, published by the International Organization for Standardization
(ISO).
Terminology and conventions. The text of the international standard has
been approved as suitable for publication as a British Standard without
deviation. Some terminology and certain conventions are not identical with those
used in British Standards; attention is especially drawn to the following.
Wherever the words “International Standard” appear, referring to this standard,
they should be read as “British Standard”.
The comma has been used throughout as a decimal marker. In British Standards
it is current practice to use a full point on the baseline as the decimal marker.
For the purposes of this code of practice, wherever the word “shall” has been used,
it should be read as “should”.
Cross-references
International standard Corresponding British Standard
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ISO 1000-1973 BS 5555:1976 SI units and recommendations for the use

of their multiples and of certain other units
(Identical)
ISO 2314-1973 BS 3135:1975 Gas turbines: acceptance tests
(Identical)
ISO 3046 BS 5514 Specification for reciprocating internal
combustion engines: Performance
(Identical)
ISO 3977-1978 BS 3863:1979 Guide for gas turbines procurement
(Identical)
The technical committee has reviewed the provisions of the following
International Standards, to which reference is made in clause 2, and has decided
that they are acceptable for use in conjunction with this standard. Related British
Standards are as follows.
International standard Corresponding British Standard
ISO 508 BS 1710:1975 Identification of pipelines
ISO 1996-1 BS 4142:1967 Method of rating industrial noise affecting
mixed residential and industrial areas
ISO 1999-1975 BS 5330:1976 Method of test for estimating the risk of
hearing handicap due to noise exposure
ISO 3448-1975 BS 4231:1975 Viscosity classification for industrial liquid
lubricants
ISO 3864a BS 5378 Safety signs and colours
IEC 34 BS 4296:1968 Methods of test for determining
synchronous machine quantities and BS 4999 General
requirements for rotating electrical machines
IEC 45:1970 BS 132:1965 Steam turbines
a In course of preparation.

ii © BSI 02-1999
 BS 6244:1982

The technical committee has also reviewed the provisions of ISO 2151 to which
reference is made in clause 2, and has decided that they are acceptable for use in
conjunction with this standard.
It is understood that ISO 2151 will be withdrawn on publication of ISO 3989 (also
referred to in clause 2). Consideration will then be given to publishing a
corresponding British Standard to ISO 3989.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.
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Summary of pages
This document comprises a front cover, an inside front cover, pages i to iv,
pages 1 to 18, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on
the inside front cover.

© BSI 02-1999 iii

Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI

iv
blank

Section 1. General
1 Scope and field of application
1.1 This International Standard establishes
standards for the safe design, construction,
installation and operation of stationary and
skid-mounted air compressors for general use. It
specifies requirements to help minimize compressor
accidents and defines general safety practices for
the field. Potential hazards associated with
compressors are listed and detailed under the
following headings in clause 6:
a) improper lubrication;
b) inadequate cooling;
c) mechanical failures;
d) personal injury;
e) exposure to noise;
f) fires and explosions in the pressure system;
g) crankcase explosions;
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h) incorrect installation, operation or
maintenance .
This International Standard does not cover the
prime movers, which are dealt with in other
International Standards.
1.2 This International Standard is based on the
requirement that the compressor components be
designed in accordance with recognized good
practice and applicable national standards.
1.3 This International Standard is intended to apply
to stationary and skid-mounted air compressors for
general use. However, the following types of
compressor are specifically excluded:
a) compressors with a shaft input less than 2 kW;
b) compressors with an effective discharge
pressure less than 0,5 bar (50 kPa);
c) compressors with an effective discharge
pressure exceeding 50 bar (5 MPa);
d) compressors specifically supplying air for
breathing, diving or surgery;
e) compressors used for air brake systems
f) ejectors.
2 References
ISO 508, Identification colours for pipes conveying
fluids in liquid or gaseous condition in land
installations and on board ships1).
ISO 1000, SI units and recommendations for the use
of their multiples and of certain other units.
1) At present at the stage of draft. (Revision of ISO/R 508-1966.)
2) At present at the stage of draft. (Revision of ISO/R 1996-1971.)
3) At present at the stage of draft. (Revision of ISO/R 408-1964 and ISO/R 557-1967.)
4) At present at the stage of draft.
© BSI 02-1999
BS 6244:1982
ISO 1996, Acoustics — Description and
measurement of environmental noise — Part 1: Basic
quantities and procedures2).
ISO 1999, Acoustics — Assessment of occupational
noise exposure for hearing conservation purposes.
ISO 2151, Measurement of airborne noise emitted by
compressor/primemover-units intended for outdoor
use.
ISO 2314, Gas turbines — Acceptance tests.
ISO 3046, Reciprocating internal combustion
engines: Performance.
ISO 3448, Industrial liquid lubricants — ISO
viscosity classification.
ISO 3864, Safety colours and safety signs3).
ISO 3977, Gas turbines — Procurement.
ISO 3989, Acoustics — Measurement of airborne
noise emitted by compressor units including
primemovers — Engineering method for
determination of sound power levels4).
IEC Publication 34, Rotating electrical machines.
IEC Publication 45, Specification for steam turbines.
3 Unit system
Throughout this International Standard, SI units
are used. (See ISO 1000.) However, in accordance
with accepted practice in the compressed air
industry, the bar is used as the unit of
pressure (1 bar = 105 Pa).
NOTE Unless otherwise stated, the term pressure means
effective (gauge) pressure.
4 Definitions
4.1
maximum allowable working pressure
the maximum operating air pressure which the
manufacturer specifies for any service condition
specified for the compressor or any part to which the
term is referred, such as an individual stage or
casing
4.2
relief valve or safety valve set pressure
the pressure on the inlet side of a relief valve or
safety valve when opening commences
4.3
maximum allowable working temperature
the maximum compressed air temperature which
the manufacturer specifies at any service condition
specified for the compressor or any part to which the
term is referred
1
 BS 6244:1982
4.4
maximum expected outlet temperature
the highest predicted outlet air temperature
resulting from any specified service condition
including part-load operation
4.5
maximum allowable compressor speed
the highest rotational frequency at which the
manufacturer’s design will permit operation,
assuming overspeed and governor mechanisms are
installed and operating
4.6
trip speed
the rotational frequency at which the primemover is
automatically tripped out
4.7
surge limit
the limiting flow below which stable operation of a
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turbocompressor is not possible
5 Compressor categories
Air compressors can be grouped into the following
three categories from a lubrication viewpoint:
a) “Oil-free” compressors in which the air does not
come into contact with the oil used to lubricate
the machine, for example dynamic compressors,
labyrinth compressors, diaphragm compressors
or compressors with unlubricated piston rings.
b) Oil-lubricated compressors in which the
moving parts in the compression chamber are
lubricated with oil which is either specially
injected for that purpose by a mechanical
lubricator or is carried over from other parts of
the machine, as in a single-acting trunk type of
reciprocating compressor without a crosshead.
Oil-lubricated compressors can be grouped into
any of the four main classes below:
1) Air-cooled reciprocating types with a power
input up to 20 kW, usually built as single- or
two-stage machines up to about 25 bar (2,5
MPa) and often for intermittent service.
2) Air-cooled reciprocating types with a power
input above 20 kW, usually built as
single-stage machines up to
about 3 bar (0,3 MPa), two-stage up to
about 25 bar (2,5 MPa) and more stages for
higher pressures.
3) Water-cooled reciprocating types, usually
built as single-stage machines up to
about 5 bar (0,5 MPa), two-stage up to
about 25 bar (2,5 MPa) and more stages for
higher pressures.
2 © BSI 02-1999
4) Water- or air-cooled rotary vane types,
usually built as single-stage machines up to
about 4 bar (0,4 MPa) to 7 bar (0,7 MPa) and
two-stage up to about 12 bar (1,2 MPa).
c) Oil-flooded rotary compressors in which
relatively large quantities of oil are injected into
the compression chamber not only to lubricate
the working parts but also to assist in sealing and
to absorb the heat of compression.
6 Potential hazards
The following sub-clauses do not attempt to identify
all the possible hazards associated with running
machinery but only those which are specific or
particularly applicable to stationary air
compressors. (See Annex A to Annex E.)
6.1 Improper lubrication
6.1.1 The more common causes of improper
lubrication are:
a) use of improper lubricant;
b) lack of oil;
c) poor maintenance leading to bearing wear with
increased clearances and too low oil pressure;
d) insufficient or excessive cooling;
e) overlubrication.
6.1.2 Malfunction of the lubrication system may
lead to a temperature increase which, with
continued operation, may introduce the risk of an oil
fire.
6.2 Improper cooling
The risks stemming from poor cooling are obvious.
However, overcooling is also to be avoided because it
gives rise to internal cylinder corrosion as the
condensate modifies the lubricant.
6.3 Mechanical failures
These usually emanate from one or more of the
following causes:
a) excessive pressure;
b) overspeed;
c) secondary phenomena caused by improper
lubrication;
d) secondary phenomena caused by improper
cooling;
e) poor maintenance;
f) excessive vibrations or external forces.
6.4 Personal injury
The more common potential causes of injury are:
a) contact with moving parts;
b) contact with hot parts;
c) falling from elevated positions;

d) slipping (for example caused by oil spillage);
e) electrical hazards;
f) use of incorrect tools during maintenance;
g) bursting or explosion of an apparatus or
component under pressure;
h) production of smoke or toxic oil vapour arising
from accidental ignition of the oil.
6.5 Exposure to noise
Noise, even at reasonable levels, can cause irritation
and disturbance which over a long period of time
may cause severe injuries to the human nervous
system and can take forms such as lack of sleep,
irritation, etc. Noise at average sound pressure
levels exceeding 90 dB(A) is considered to damage
hearing. The effect depends on the level and the
duration of the exposure. Reference is made to
national regulations.
The noise from a compressor has three main
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components: intake noise, noise radiated from the
surfaces of the machine and noise from pipework.
The noise level in a room depends on the noise
emission from all noise sources in the room and the
acoustic properties of the room itself, i.e. the sound
absorption of walls, floors and ceiling. The noise
emission from the compressors is not always the
most important factor for the total noise level. The
noise from the prime movers must also be
considered. See also Annex A.
6.6 Fires and explosions in the pressure
system
6.6.1 Oil-lubricated compressors
It is generally accepted that the occurrence of fires
in oil-lubricated compressor systems is dependent
on the build-up of oil degradation (oilcoke) deposits.
When the pressure system is designed according to
the advice given in Annex B and the lubricating oil
is chosen according to the advice in Annex D, both
the compressor and the pressure system should
remain clean without any oil degradation, thereby
reducing the risk of fire. However, with pressure
systems that allow the build-up of oil degradation
deposits, the quality of the oil is still more
important, as is also a regular cleaning of the
pressure system (see Annex C).
Four factors that affect coke formation are listed
below.
a) Rate of oil feed
Excessive oil feed promotes deposit formation.
b) Air filtration
Solids ingested with the suction air thicken the
oil and delay its passage through the hot part of
the delivery system, increase the time it is
subject to oxidation, and hence increase the rate
of deposit formation.
© BSI 02-1999
BS 6244:1982
c) Temperature
The temperature at which significant oxidation
starts is related to the grade and type of oil used.
In the case of compressors with water-cooled
cylinders, it is recommended that treated or
demineralised water be used to prevent the
formation and deposit of scale inside the
pipework. A failure of cooling water can result in
a sharp rise in temperature above the level
appropriate to that particular machine, and is a
well-recognized cause of fire initiation when the
coke layer in the hot zone is thick enough.
Failure of valves can similarly raise the
temperature and cause dangerous conditions.
NOTE In compressors with a very high stage pressure ratio,
“dieseling” can occur when the cooling is poor and the
lubrication is rich. Such a cylinder”explosion” can, under
special circumstances, propagate along the delivery pipe as a
detonation.
d) Catalysts present, for example iron oxides.
6.6.2 Oil-flooded rotary compressors (special
precautions)
Experience shows that oil-flooded rotary air
compressors of good design, correctly lubricated and
maintained, are free from fire hazards. Abnormal
temperature rise in the oil filter pads can, however,
accelerate the oil oxidation with consequent fire
risk.
Laboratory tests and experience from the field
indicate that three factors are important to prevent
the risk of such oil fires occurring. These are:
a) the design;
b) the choice of oil;
c) the operation and maintenance of the
compressor; the following points are of particular
importance:
1) keeping the oil consumption low;
2) regular oil changes;
3) ensuring that the oil cooling arrangements
are working satisfactorily.
6.7 Crankcase explosions
Explosions can and have occurred in the crankcases
or gear cases of compressors (see Annex E).
6.8 Incorrect installation, operation or
maintenance
Besides the types of potential hazard described
above, hazards also exist if the installation,
operation and maintenance work are not carried out
in the correct way. (See also section 4 and
Annex B.)
3
 BS 6244:1982
Section 2. Compressor design and construction
Implementation of and compliance with the
requirements of this section will normally be the
responsibility of the compressor supplier.
7 General
Compressors shall be designed and built to
withstand safely all specified pressures,
temperatures and other service conditions. The
design shall facilitate the convenient operation and
maintenance of the compressor unit, whilst
minimizing the risk of physical injury.
7.1 Every compressor shall have a permanently
attached and clearly visible nameplate of durable
material and carrying the following minimum
information:
— manufacturer;
— model designation and serial number;
— maximum allowable working pressure;
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— maximum allowable continuous shaft speed.
NOTE On compressors above 20 kW, information about
capacity, shaft input and coolant flow, etc. is often included.
7.2 The function of all instruments shall be clearly
indicated, and in the case of a remote capacity
control the actual capacity load must be displayed in
the compressor room.
7.3 Compressor parts which cannot be lifted by one
man without danger shall be fitted with suitable
devices for attaching them to lifting gear unless the
shape of the part is such as to make this
unnecessary.
7.4 Reciprocating compressor valve and valve port
design shall be such that no inlet valve can be fitted
instead of a discharge valve and that no discharge
valve can be wrongly fitted in such a way as to
prevent the proper discharge of air.
7.5 To provide safe conditions during removal of the
piston rod from the piston, provision should be made
in the design to ensure that dangerous quantities of
compressed air cannot remain trapped in the piston.
7.6 When considered necessary for large
compressors, crankcase explosion-relief devices
should be fitted. (See Annex E.)
8 Guards
8.1 Guards shall be provided on all rotating and
reciprocating parts which may be hazardous to
personnel. Guards shall also be provided for
flywheels. An opening shall be provided in flywheel
guards, when required, for barring over the machine
and to provide access to timing marks, wheel centre
and any other part which may require attention.
5)
1,5 kN ≈ 150 kgf
4 © BSI 02-1999
8.2 The guards shall be easy to remove and to
re-install, and shall have sufficient rigidity to
withstand deflection and prevent rubbing as a
result of bodily contact.
8.3 Belt- and chain-drive guards for outdoor
installations shall be weatherproof.
8.4 Pipework or other hot parts shall be adequately
guarded or insulated (see 14.2).
8.5 Pipework runs in a horizontal plane or which
might otherwise be accessible for personnel should
either be guarded or be robust enough, when
supported, to carry a vertical load of 1,5 kN5)
without unacceptable deflection or damage.
9 Pipework and pressure vessels
9.1 All pipework and auxiliaries integral to a unit
shall be supported in such a way that the possibility
of damage due to vibration, thermal expansion and
own mass is eliminated.
9.2 Unguarded pipework (other than local gauge,
cylinder lubrication, instrument and control air and
similar pipework) shall have a wall thickness great
enough to resist damage by accidental impact.
9.3 Delivery pipework, up to the aftercooler or
receiver, for oil-lubricated compressors should,
where possible, be run so that gravity assists the
flow of oil through the hot zone. Interstage pipework
and coolers like other vessels, where fitted, should
be similarly arranged. (See Annex B.)
9.4 Pipework and compressor accessories such as
water jackets, coolers, pulsation dampers and air
receivers shall be provided with drainage facilities
at low points to prevent damage from freezing
during idle periods.
9.5 The coolant outlet from cylinder jackets and
compressor casings shall be open or so arranged
that excessive pressures cannot occur.
9.6 All auxiliaries which come within the scope of
pressure vessel codes (for example air coolers,
silencers, separators and traps) shall be designed in
accordance with applicable codes.
9.7 The compressed air side of the compression
space shall be hydrostatically tested at a pressure of
not less than 1,3 times the maximum allowable
stage working pressure. However, sample testing is
sufficient for batch-produced compressors for
effective working pressures below 15 bar (1,5 MPa).
NOTE Valves and fittings shall be properly vented before the
hydrostatic test in order to prevent the formation of air pockets.
 BS 6244:1982

10 Vibrations and pressure pulsations 12.2 Oil-flooded compressors shall have an

10.1 Vibration and shaft axial movement alarms
and shut-downs may be utilized to prevent
destructive failures.
10.2 Pressure pulsations are inherent in
reciprocating compressor installations owing to the
pulsating flow of air into and out of the cylinders. If
the frequency of the pulsations is in resonance with
the natural frequency of pipework or the
foundations, fatigue failure of pipework, nipples,
anchor bolts and other parts may result. With air
compressors it is often possible to calculate the
resonance frequency and to arrange the pipework
system to obtain satisfactory damping.
(See Annex B, clause B.7.) When this is not possible,
properly designed pulsation dampers with draining
devices should be installed adjacent to the
compressor cylinders or incorporated into the
cylinder construction to minimize the pressure
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automatic shut-down device to prevent the
temperature of the compressor oil from exceeding
the safe limit. The tripping temperature shall not
exceed 120 °C.
NOTE Higher temperatures are permissible when special oils
are used.
12.3 When electric immersion heaters are used for
heating the lubricant, they should have a maximum
energy dissipation of 25 kW/m2 (2,5 W/cm2). If
overheating or ignition of the oil occurs, the oil shall
be systematically replaced.
12.4 Oil-choking sometimes occurs in gear
transmissions with high pitchline velocities. This
has in some instances resulted in overheating of the
oil and subsequent fires. Sufficient free volume
inside the gear casing and adequate draining
facilities must be provided.
13 Materials

pulses and their effect on other parts of the system.

When pulsation dampers are used with lubricated 13.1 In each compressor, all seals or gaskets shall be
compressors, they should be designed to prevent the made from materials which are capable of
build-up of oil degradation deposits (see also 9.3). withstanding any pressure and temperature likely
to be encountered in service.
11 Electrical equipment 13.2 Materials used shall be compatible with the
11.1 All electrical equipment shall comply with the lubricants.
applicable international or national regulations and 13.3 It is recommended that cast iron valves and
directives. fittings be avoided in pipework subjected to shocks
or vibrations.
12 Overheating
12.1 The design of single-stage, oil-flooded
compressors should be such that the maximum
temperature at the delivery flange of the
compressor before the oil separator does not
exceed 110 °C at an ambient temperature of 30 °C.
NOTE Higher temperatures are permissible when special oils
are used.

© BSI 02-1999 5
 BS 6244:1982
Section 3. Compressor installation and air
distribution system
Implementation of and compliance with the
requirements of this section may be the
responsibility of the compressor supplier, the plant
contractor or the purchaser, depending on the scope
of supply as defined in the relevant contracts.
14 General
For compressor package units and compressors
together with their auxiliaries, as well as for
components forming part of an air distribution
system, clause 7 applies. If special requirements
exist for noise emission or/and vibration magnitude,
this shall be clearly stated in the contract.
14.1 All pipework, vessels and other items shall be
designed in accordance with applicable national
regulations or international codes.
14.2 Pipework or other parts with an external
surface temperature in excess of 80 °C and which
may be accidentally contacted by personnel in
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normal operation shall be guarded or insulated.
Other high-temperature pipework should be clearly
marked in accordance with ISO 3864 and ISO 508.
14.3 Check valve(s) to prevent rotation reversal
shall be installed on the discharge side of
compressors which do not have built-in non-return
valves, when the design of the system would permit
reverse flow of air through the compressor. Such
compressors operating in parallel shall require
check valves without exception.
14.4 An anti-surge device shall be utilized on
turbo-compressors if system requirements indicate
that the compressor may operate near the surge
limit for extended periods. Such a device shall vent
or recycle air from the compressor discharge in
order to maintain a flow into the compressor which
exceeds the surge flow. Recycled air shall be cooled
to avoid excessive temperatures.
14.5 Vibration and shaft axial movement alarms
and shut-downs may be utilized to prevent
destructive failures.
14.6 For manual shut-down of electric motors, a stop
button shall be provided at a readily accessible
location to interrupt power to the motor.
14.7 Emergency stop buttons shall be red.
14.8 In some installations, the air is reheated after
compression in order to increase its volume or to
reduce the relative humidity. Direct fired reheaters
shall not be used when the compressed air contains
traces of oil.
14.9 When the prime mover is potentially capable of
developing power significantly in excess of that
required by the compressor, adequate protection
shall be provided to avoid mechanical overload
(for example an overcurrent trip device in the case
of an electric motor).
6 © BSI 02-1999
14.10 When the prime mover is of a variable-speed
type, the compressor shall be protected from
unacceptably high speeds by either a speed governor
or an overspeed trip device unless it can be shown
that dangerous overspeeding is not a practical
possibility.
14.11 The speed governor or overspeed trip device
shall be set to operate at a level which will not allow
the transient speed to exceed the maximum safe
limit of the shaft under any sudden loss of load.
Reference is made to the following publications:
— ISO 2314;
— ISO 3046;
— ISO 3977;
— IEC Publication 34;
— IEC Publication 45.
14.12 Reciprocating compressors having
oil-lubricated cylinders and a shaft input power
greater than 200 kW should be fitted with an easily
readable thermometer to indicate the delivery
temperature at the last stage.
15 Compressor installation
15.1 If possible, each compressor should be placed in
position where the ambient air is cool and clean.
However, should it be necessary to place a
compressor in hot or dusty surroundings, the inlet
air should be drawn through a suction duct from an
area as cool and free from dust as possible. Care
shall be taken to minimize the entry of moisture
with the inlet air.
15.2 The aspirated air shall be free from flammable
fumes or vapours, such as those from paint solvents,
which could lead to internal fires or explosions.
15.3 Air-cooled compressors shall be installed in
such a way that an adequate flow of cooling air is
available.
15.4 Sufficient space shall be allowed around each
compressor unit for inspection, necessary attention,
and dismantling when required.
15.5 To enable maintenance work and subsequent
testing to be carried out safely, it shall be possible to
start and stop any compressor independently of
others.
15.6 Remotely controlled compressors shall have
provisions for stopping at site.

15.7 Remotely controlled and automatically
controlled compressors shall have a sign6) in the
appropriate language of the user’s country reading:
DANGER
THIS COMPRESSOR IS REMOTELY
CONTROLLED
AND MAY START WITHOUT WARNING
As a further safeguard, persons switching on
remotely controlled compressors shall take
adequate precautions to ensure that no one is at, or
working on, the compressors. To this end, a suitably
worded notice shall be placed at the starting switch.
15.8 The compressor air intake shall be so arranged
that loose clothing cannot be sucked in and cause
personal injury.
15.9 No compressor shall be installed unless it is
provided with an inlet air filter or screen designed
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
and constructed in such a manner that all the air
entering the compressor passes through the filter
system.
15.10 A water manometer or other pressure-drop
indicating device should be fitted to each inlet air
filter of compressors having a shaft input power
exceeding 100 kW, when the filter is of such a type
that accumulation of dust or other objects could lead
to a significant increase in pressure drop over the
filter.
15.11 Whenever a metallic or concrete suction line,
of such length that it cannot be properly cleaned, is
used, screens or filters shall be installed before the
compressor suction flange during initial start-up
and running-in as protection against damage from
foreign materials (for example welding beads,
concrete dust). Such temporary screens or filters
shall be removed when the intake pipework is clean.
16 Access platforms
16.1 When platforms, stairs and railings are
required for the daily maintenance, they shall be
positioned so that access is given to all areas where
routine maintenance or operator inspection is
necessary. Their positioning, however, shall not
interfere with maintenance of any parts with
respect to accessibility or lifting.
16.2 Elevated platforms and floors shall be of grid or
plate construction. All open sides shall be guarded
with safety rails, set at about 1 050 mm
and 600 mm above the platform, and a toeboard
about 100 mm high or in accordance with national
regulations. Stairs or ladders of more than four
steps shall have a safety rail on one side as a
minimum.
6) See ISO 3864.
© BSI 02-1999
BS 6244:1982
16.3 Access to elevated platforms should, wherever
possible, be by stairways with a slope not greater
than 50°.
16.4 Stairs and platforms shall be protected from
corrosion. Sheet metal floors shall incorporate a
non-slip surface.
17 Pressure gauges
17.1 A suitable pressure gauge shall be fitted to:
a) each air receiver;
b) each final stage of piston-, screw- or
vane-compressors with an effective working
pressure exceeding 1 bar (100 kPa);
c) each stage of diaphragm compressors with an
effective working pressure
exceeding 3 bar (300 kPa);
d) each stage of compressors with a shaft input
exceeding 20 kW;
e) the delivery side of each turbo-compressor
casing.
NOTE It is recommended that there should be a red field on the
discharge pressure gauge scale to indicate the maximum
allowable working pressure. A line should indicate the normal
working pressure.
17.2 The operating pressure of the gauge shall be
within the middle of the full scale reading.
17.3 The final stage air pressure gauge dial shall be
graduated from zero to not less than one-and-a-half
times (but not more than twice) the maximum
allowable working pressure of the air receiver. The
scale must be graduated in the same units as the
“set-pressure” marking on the associated safety
valve.
17.4 A pressure gauge shall be fitted on all
compressors with an input power exceeding 75 kW
to indicate the lubricant pressure in any force-feed
system.
17.5 For effective working pressures
above 10 bar (1 MPa) and for pressure gauges with
a casing diameter exceeding 63 mm, safety type
gauges having an unbreakable window and an
unloading opening shall be used.
17.6 Where pressure gauges are subject to
pulsations, precautions shall be taken to protect
them from damage and to ensure adequate
readability.
18 Pipework
18.1 Any blanking flanges or plates, as well as
desiccant bags, shall be removed before connecting
the pipes.
7
 BS 6244:1982
18.2 Delivery and cooler pipework should, where
possible, be run so that gravity assists the flow of oil
through the hot zone. The air velocity shall not
normally fall below 8 m/s.
18.3 Pipework and compressor accessories such as
water jackets, coolers, pulsation dampers and air
receivers shall be provided with drainage facilities
at low points to prevent damage from freezing
during idle periods.
18.4 The coolant outlet from cylinder jackets and
compressor casings shall be open or so arranged
that pressures exceeding design pressure cannot
occur.
18.5 All pipework and auxiliaries integral to a unit
shall be supported in such a way that the possibility
of damage due to vibration, thermal expansion and
own mass is minimized.
18.6 Pipework runs in a horizontal plane or which
might otherwise be used by personnel for support
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
should either be guarded or be robust enough, when
supported, to carry a vertical load of 1,5 kN7)
without unacceptable deflection or damage.
18.7 The discharge pipe from the compressor to the
aftercooler or air receiver should be free to expand
under heat and should not be in contact with wood
or any other flammable material. If such material is
in close proximity to the pipework, steps shall be
taken to preclude ignition.
18.8 In multiple-unit compressor systems, valves
shall be provided for isolating each compressor.
Check valves shall not be relied upon for isolating
compressors.
18.9 Unguarded pipework (other than local gauge,
instrument and control air and similar facilities)
shall have a wall thickness great enough to resist
damage by an accidental impact.
19 Design of pressure relief devices
19.1 Pressure relief devices for normal compressed
air systems should preferably be spring-loaded
valves. Bursting discs may be used in lieu of, or in
conjunction with, relief valves provided that they
are properly designed and installed.
19.2 Bursting discs may have application for very
high capacity compressors where required relief
capacity is in excess of that which can be handled by
a reasonable number of relief valves. When bursting
discs are used, the maximum allowable working
pressure of the protected equipment shall be
sufficiently above the intended operating pressure
to prevent premature failure of the disc due to creep
or fatigue.
7) 1,5 kN ≈ 150 kgf
8 © BSI 02-1999
19.3 When a bursting disc is used, it shall have a
specified bursting pressure at a specified
temperature and be stamped with identifying serial
letters and numbers unless the size of the disc is
insufficient for this purpose. In the latter case, the
disc shall be contained in a sealed envelope prior to
its installation. The envelope shall be clearly
marked so as to identify the disc with its intended
service.
19.4 The design of pressure relief devices shall allow
for the possible effect of differential expansion and
contraction and of gumming or deposits.
19.5 The materials used in the construction of
pressure relief devices shall be suitable for the
pressure, temperature and corrosion conditions as
well as other relevant conditions,
for example erosion. Non-metallic inserts of
suitable material, properly secured and reinforced,
may be used in the valve discs of relief valves.
Fibrous or other materials which may become
distorted under operating conditions shall not be
used. The use of membrane valves shall be
considered for corrosive conditions.
19.6 Relief valves shall be so designed that the
moving parts are efficiently guided and have
adequate clearance under all conditions of service.
The spindle shall not be fitted with a packed gland
(stuffing box).
19.7 Relief valves shall be so designed that breakage
of any part or failure of any device will not obstruct
free and full discharge through the valve.
19.8 Relief valves shall be so designed that they
cannot inadvertently be reset beyond the set
pressure marked thereon.
19.9 Relief valves for compressed air shall be
provided with lifting gear, arranged so that the
valves can be lifted positively off their seats when
under working pressure. The lifting gear shall be
such that it cannot lock or hold the valve off its seat
when the external lifting force is released.
19.10 When the relief valve load is applied by a coil
spring, the spring shall be so made that all coils still
have a clear space of half the wire diameter or
at least 2 mm at the necessary lift at full discharge.
19.11 Every relief valve shall incorporate
permanent markings as follows:
a) manufacturer’s identification;
b) direction of flow;
c) set pressure;
d) coefficient of discharge and related net flow
area or flow capacity of valve.

20 Application of pressure relief
devices
20.1 Every pressure vessel, compressor, and
auxiliary used to contain air above atmospheric
pressure shall be protected by a pressure-relieving
device or devices as required to prevent the pressure
in any element of the system from exceeding its
maximum allowable working pressure by more
than 10 %. Each compartment of a subdivided
vessel shall be treated as a separate vessel and
suitably connected to a pressure-relieving device.
20.2 Positive displacement compressors shall
always be protected with pressure-relieving devices
between compressor discharge and the first shut-off
valve.
20.3 Pressure-relieving devices may not be required
in systems using centrifugal or axial compressors
where the maximum pressure that may occur in any
element cannot exceed its maximum allowable
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
working pressure by more than 10 %. To determine
whether relief facilities may be omitted, the
maximum pressure which may occur within the
system should be evaluated for the various
combinations of inlet pressure, inlet temperature,
flow and speed, which could occur simultaneously.
20.4 In cases when sub-atmospheric pressures may
occur and the vessel is incapable of withstanding
such conditions, a vacuum break device shall be
fitted.
20.5 The system shall be analysed to determine
what circumstances, or combinations thereof, will
result in the pressure on any compressor element
exceeding its maximum allowable working pressure
by more than 10 %. The flow at this pressure for the
most severe conditions shall govern the capacity of
relief facilities.
NOTE 1 The most frequent causes of excessive compressor
pressure are:
a) blocked outlets or other restrictions to flow;
b) failure of automatic controls combined with low air
consumption;
c) increase in inlet pressure;
d) excessive speed;
e) inlet air or intercooler temperatures lower than the design
values of turbocompressors.
NOTE 2 Excessive pressure on equipment resulting from
various combinations of the causes above shall not be considered
as controlling if such an occurrence is only possible in the event
of two or more unrelated causes occurring simultaneously.
20.6 To eliminate leakage from the relief device, the
set pressure at which it starts to open shall
preferably be a minimum of 10 % or 1 bar (100 kPa),
whichever is the greater, above the intended
operating pressure at the valve inlet.
NOTE 1 To prevent unnecessary lifting of the relief valves, it is
desirable to have a margin between the pressure at which the
compressor delivers air and the lowest pressure at which any of
the relief valves is set to lift.
© BSI 02-1999
BS 6244:1982
NOTE 2 Too frequent blowing of a relief valve endangers its
proper function. However, when such conditions cannot be
avoided, two relief valves with different settings, each of
sufficient capacity, shall be used.
20.7 Vessels which are to operate completely filled
with liquid shall be equipped with a relief valve
capable of releasing any vapour generated, unless
they are otherwise protected against over-pressure.
20.8 When a vessel is fitted with a heating coil or
other element, malfunctioning of which might
increase the normal pressure of the fluid in the
vessel, the designed relieving capacity of the
protective device shall be adequate to limit this
increase to no more than 10 % of the maximum
allowable working pressure, allowing for any
vapour which may be generated.
20.9 Vessels connected together by a system of
pipework of adequate flow area, which does not
contain any valve that can isolate any vessel, may
be considered as a system of vessels for the
application of pressure relief devices.
21 Installation of pressure relief
devices
Pressure relief devices shall be installed as close as
practical to the system being protected. Under no
circumstances shall it be possible to shut off a relief
device with a valve unless duplicate or multiple
relief devices are provided with isolation valves so
interlocked that adequate relieving capacity is
always ensured. Total blow-off capacity shall be
sufficient to prevent the pressure from exceeding
the maximum allowable working pressure by more
than 10 % at maximum continuous air delivery into
the system.
21.1 For most compressor installations, excessive
pressure protection for the compressor and its
auxiliaries requires a pressure-relieving device only
on the discharge of each compressor stage. Such an
arrangement will usually suffice, provided that the
system pressure gradient under relieving conditions
is such that the pressure on the weakest element
will not exceed its maximum allowable working
pressure by more than 10 %.
21.2 The inlet line to a relief device, including all
valves and fittings, shall have an effective flow area
at least equal to that of the inlet to the relief device.
21.3 The maximum pressure drop through inlet
lines to pressure relief devices shall not exceed 3 %
of the set pressure under conditions of maximum
flow.
21.4 Where feasible, direct relief to the ambient
atmosphere is recommended. Atmospheric
discharge or discharge pipes shall terminate at a
location which will not create a hazard to personnel.
9
 BS 6244:1982
21.5 Any discharge pipe used shall be of such size
that the pressure that may exist or develop therein
will not reduce the relieving capacity.
21.6 The size of a discharge line serving two or more
pressure-relieving devices which may reasonably be
expected to discharge simultaneously shall be based
on the sum of their outlet areas with due allowance
for pressure drop in the downstream sections.
21.7 Discharge lines, together with their supports
and anchorages, shall be so designed and
constructed that reactions are resisted without
excessive forces being transmitted to the
pressure-relieving devices.
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
10
21.8 Relief valve discharge lines shall be so designed
and constructed as to preclude the collection of
liquid at any point in the system.
22 Noise
It is often good practice to have a separate
compressor room in order to screen off the
compressor noise from the general working area.
Depending on the number of compressors and their
noise emission, the noise in the compressor room
can be considerable. Intake noise can, however, be
reduced to a satisfactory level by the use of suction
silencers. (See Annex A.)
© BSI 02-1999

Section 4. Compressor operation and maintenance
Implementation of and compliance with the
requirements of this section is the responsibility of
the owner or user of the plant of which the
compressed air system forms part.
23 Operation
23.1 A foreman or other adequately qualified person
should be designated as supervisor for the
compressor and be responsible for its proper
operation and maintenance.
23.2 The supervisor shall ensure that the operators
are adequately instructed about all safety measures
necessary to prevent accidents or personal injuries.
23.3 Compressors should only be operated by
appointed and properly instructed operators.
23.4 The start-up, shut-down and emergency
procedures for all operations involving compressors
shall be periodically reviewed with the operators.
23.5 A clear operating instruction shall be provided
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
in the form of a plate or a book.
23.6 Only oils of a grade and type recommended or
agreed to by the manufacturer shall be used.
(See Annex D.)
23.7 Overcooling of compressor cylinders shall be
avoided as this can lead to internal corrosion. Rust
acts as a catalyst for building up oil-carbon deposits
on the pressure side. The use of a thermostatic
water valve is recommended for water-cooled
compressors.
23.8 Records shall be kept of oil consumption and all
major inspections, examinations, repairs, pressure
tests, etc., carried out on all compressors with a
shaft input power exceeding 100 kW.
NOTE Lack of oil is a common cause of compressor breakdowns.
A compressor failure is often preceeded by an increase in oil
consumption. A regular follow-up of the oil consumption will
therefore help the operator to spot the trouble in time.
23.9 In the case of “oil-free” compressors, it should
be checked that the oil consumption is not
abnormal. This will indicate if excessive quantities
of oil are leaking into the air stream and creating a
potentially hazardous situation.
23.10 Inlet pipework to compressors and prime
movers, condensate traps and cylinders shall be
drained prior to start-up.
23.11 On starting-up the compressor initially, and
after any alteration to the electrical connection(s) or
switch-gear, the direction of rotation of all electric
motors shall be checked to ensure that they rotate in
the correct direction.
23.12 When oil-wetted or oil-bath type filters are
used, the oil should be chosen so that the fire risk is
not increased. It is important that only oils
recommended or agreed for this purpose by the
compressor and air filter manufacturer be used.
© BSI 02-1999
BS 6224:1982
23.13 Care shall be exercised to avoid damage to
pressure relief devices. Care shall also be exercised
to avoid plugging by paint or dirt accumulation that
could interfere with the functioning of the device.
23.14 Operators and maintenance personnel should
use ear protectors when staying in compressor
rooms with a sound pressure level exceeding the
value set by local regulations.
23.15 The cooling system of oil-flooded compressors
shall be kept clean, inside and outside, to ensure
that overheating of the circulating oil or the
separating filter does not occur.
NOTE 1 When the compressor operates in a dusty atmosphere,
the cooler shall be cleaned externally daily or weekly, as
required.
NOTE 2 When the compressor works at an elevated ambient
temperature, care shall be taken to ensure that the internal oil
circulation in the cooler is not restricted by sludge formation.
NOTE 3 The over-temperature shut-down device shall be
checked regularly.
NOTE 4 The oil shall be replaced at regular intervals as
specified by the manufacturer. It is recommended that these
intervals be reduced when the compressor operates at an
elevated ambient temperature.
23.16 In large reciprocating compressors, with a
power exceeding 200 kW, the user should consider
measuring the temperature of the cooling water, the
delivered air and the crankcase oil.
24 Maintenance
24.1 The supervisor (23.1) shall check annually, at
least, that all instructions regarding compressor
operation and maintenance are properly followed
and that the compressor with all accessories and
safety devices are in good working order.
24.2 Maintenance work shall be carried out only by
adequately trained personnel.
24.3 All maintenance work other than routine
attention to filters designed for cleaning in service
shall be undertaken only when the compressor is
stopped.
24.4 Before dismantling any pressurized
component, the compressor shall be effectively
isolated from all sources of pressure and completely
vented to the atmosphere.
24.5 The compressor unit shall be kept as clean and
free from oil and dust deposits as possible.
24.6 When maintenance is carried out on
electrically driven compressors, the electrical switch
shall be locked in “open” position, or other positive
means of current interruption shall be employed,
for example taking out the fuses.
11
 BS 6244:1982

24.7 All safety devices should be maintained to Table 1 — Maximum tolerable thickness of
ensure that they always function properly. They coke layer
shall not be put out of operation and shall be Effective operating pressure Maximum tolerable
replaced only by devices giving at least the same thickness of coke layer
security. Pressure and temperature gauges shall be bar mm
checked regularly with regard to their accuracy.
They shall be replaced whenever they are outside < 10 3
accepted tolerances. > 10 < 30 2
24.8 A check of the safety devices on compressor > 30 < 50 1
equipment shall be included as part of the regularly
scheduled maintenance. 24.14 Whenever there is any reason to suspect that
24.9 All relief valves shall be tested according to a bearing or other internal part may be
advice from the manufacturer and at regular over-heating, after stopping the machine no
intervals to determine whether they are in good crankcase door or other inspection cover should be
operation condition. opened until sufficient cooling time has elapsed
(at least 15 min) for the temperature of the
24.10 When compressors are being repaired, steps overheated part to have fallen below the minimum
shall be taken to prevent inadvertent starting, and spontaneous ignition temperature (for air/oil vapour
the control power shall be disconnected. In addition, or mist mixtures, approximately 275 °C) to avoid
a warning sign bearing a legend (in the appropriate the risk of a crankcase explosion. (See Annex E.)
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI

language of the user’s country) such as:

24.15 An open flame must never be used for
inspecting the interior of a compressor or pressure
WORK IN PROGRESS —
vessel.
DO NOT START 24.16 If the operating conditions of a relief valve are
shall be attached to the starting equipment. changed so as to require setting for a pressure
outside the pressure range recommended by the
24.11 Prior to stripping or undertaking major manufacturer for the particular spring, the spring
overhaul on a reciprocating compressor, all movable shall be changed and the valve re-adjusted
parts with a mass exceeding 15 kg shall be accordingly and re-marked.
prevented from roll-over or movement. After such
work has been completed, the compressor shall be 24.17 Bursting discs should be inspected regularly
barred over at least one revolution to ensure that for any sign of fatigue cracking, corrosion or other
there are no mechanical interferences within the deterioration.
compressor or its prime mover. 24.18 To prevent an increase in air delivery
24.12 Under no circumstances shall flammable temperature, heat transfer surfaces
liquids be used to clean valves, filters, the air (for example intercoolers and water jackets) should
passages of coolers, air chests, air pipes or any other be regularly inspected and cleaned as necessary. For
part exposed to air flow during normal operation. If every plant, the time interval between cleaning
chlorinated hydrocarbon non-flammable liquids are operations should be made known.
used for cleaning, appropriate safety precautions
shall be taken against any toxic vapours liberated
during such usage. Carbon tetrachloride shall not be
used.
24.13 In the case of oil-lubricated compressors, the
delivery ports and all the pipework, vessels and
fittings between the delivery port and that point in
the system at which the air temperature can be
confidently expected to be below 80 °C, shall be
regularly inspected. Any carbonaceous deposit shall
be efficiently removed. The frequency of these
inspections and cleaning should be such that at no
time will the layer of deposit exceed the thickness
shown in Table 1.

12 © BSI 02-1999

Annex A Exposure to noise
(This annex is an integral part of the standard.)
A.1 Noise, even at reasonable levels, can cause
irritation and disturbance which over a long period
of time may cause injuries to the human nervous
system and can take forms such as lack of sleep,
irritation, etc. For more than 8 h exposure per day,
noise at sound pressure levels exceeding 90 dB(A) is
considered to cause hearing damage. For more
details relating to hearing damage, see ISO 1996,
ISO 1999 and national regulations on the subject.
A.2 It is often good practice to have a separate
compressor room in order to screen off the
compressor noise from the general working area.
Depending on the number of compressors and their
noise emission, the noise in the compressor room
can be considerable. Intake noise can, however, be
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
reduced to a satisfactory level by the use of suction
silencers.
The acoustic environment in the compressor room
can be improved and the general noise level reduced
by introducing absorbing materials on walls and
ceilings and putting up baffles for noise reduction
and to prevent formation of standing waves. Care
shall be taken that noise transmitted through walls
and windows does not create too high noise levels in
the surrounding environment.
It is recommended to follow the advice of the ISO
publications as regards the sound pressure level in
all places where personnel may be exposed for a
certain time.
A.3 Measurement of noise from stationary
compressors shall be carried out in accordance with
ISO 2151 or ISO 3989.
Annex B Design principles for the
pressure system of oil-lubricated
compressors
(This annex is an integral part of the standard.)
B.1 It is generally accepted that oil fires in
compressed air systems are nearly always due to the
ignition of deposits of oil coke. In a compressed air
system, high temperature and high partial pressure
of the oxygen lead to oxidation of the oil. When an oil
is oxidized, it generally becomes more viscous, and
sludge-like products are formed which in their final
stage convert into oil coke. If sufficiently thick
deposits are built up, this coke may self-ignite and
cause a fire in the pressure system. This fire can in
rare cases initiate an explosion (see Annex C).
© BSI 02-1999
BS 6244:1982
B.2 Practice has shown that the design of the hot
zone of the air discharge system of the compressor
has a decisive influence on the formation of coke
deposits, since it is mainly the design of the system
which determines the time needed for an oil
molecule to pass through the hot zone.
B.3 Some of the lubricating oil leaving the delivery
flange or pressure valve of the compressor is
“atomized” in droplets of such a small mass that
they will rapidly be transferred by the air directly to
the cold zone of the pressure system without
touching the hot walls. This part of the oil passes the
hot pressure zone so quickly that practically no
oxidation of the oil occurs.
B.4 Owing to their greater mass and inertia, the
larger oil droplets cannot be transported by the air
flow and are therefore deposited on the walls of the
hot system, where the oil may be exposed to
oxidation for a sufficient length of time for
decomposition to begin.
B.5 There are two principal ways of ensuring rapid
transport to the cold zone of the oil which has settled
on the walls. The first is by partial vaporization of
the oil and the second is to design the interior of the
pressure system in such a way that the sweeping
effect of the passing air, together with gravitational
forces, will assist the oil in creeping along the walls
towards the cold zone. As a rule, both of these
conditions must be positively exploited for a hot
compressed air system to remain clean. (See further
Annex D, clause D.4.)
B.6 Systematic investigations have shown that the
discharge system of a reciprocating, oil-lubricated
compressor will stay clean and free from deposits if
the air velocity in every part of the piping system
and its elements is above 8 m/s provided that the
proper oil viscosity and type is chosen according to
Annex D. At this air velocity, any oil deposited on a
vertical wall will creep upwards. Of course,
whenever possible the air flow should be directed
downwards so that gravitational forces will assist
the oil creeping.
B.7 As a consequence of the preceding clause, the
best aftercooler design will have the compressed air
inside the tubes and the coolant outside. Such a
design with narrow tubes will also give a good
pressure pulsation damping. The length of the
pipework connecting the compressor and the
aftercooler must be designed to obtain the
maximum damping of the pressure pulsations.
To best utilize this pulsation damping, each
compressor should have its own aftercooler and
preferably also air receiver. Such a layout is also
favourable from service and maintenance
viewpoints.
13
 BS 6244:1982
Annex C The mechanism of oil coke
ignition and the origin of oil
explosions
(This annex is an integral part of the standard.)
C.1 Oil exposed to air is subject to oxidation. The
rate of oxidation increases with temperature, the
partial pressure of oxygen and the presence of small
particles of iron or iron oxides that act as catalysts.
Oxidation increases the viscosity of the oil and may
produce solid deposits (oil coke) in the hot discharge
system of a compressor if the residence time of the
oil in the high-temperature zone is sufficient. These
solid deposits continue to oxidize, and as the
oxidation reaction is exothermic, evolution of heat
occurs. Consequently, the necessary conditions for
spontaneous ignition exist.
C.2 In practice, the heat generated by oxidation is
removed both by the cooling effect of the air stream
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
over the layer and by the heat being conducted
through the layer to the metal on which the layer is
resting. When this heat balance is changed so that
less heat is removed, the coke temperature rises and
can, under special conditions, reach a temperature
at which the coke ignites spontaneously, generating
enough heat to weaken or melt the metal in the
walls of the pressure system. Although no real
explosion takes place, the sudden breakage of the
wall can be mistaken for an explosion.
C.3 Studies have shown that in order for an oil fire
to occur there must be a certain thickness of the
coke layer (about 25 mm at 7 bar (700 kPa) effective
pressure), a temperature around + 150 °C and a
degree of porosity (often called dryness) to limit heat
transfer through the layer. Under these conditions,
a fire can start when a reduction in the flow of
compressed air over the coke layer unduly reduces
the rate of heat dissipation. Such conditions can
occur at meal breaks, shift changes or when the
compressor is unloading. Alternatively, a fire can
start without any change in the air flow conditions
if the deposit layer builds up to such a thickness
that heat transfer can no longer maintain the
interior of the layer below the spontaneous ignition
temperature.
C.4 The critical thickness of the coke layer, in terms
of fire risk, can vary with each individual
compressor depending on air pressure and
temperature, foreign particles in the deposit, and
actual location of the deposit and the running
conditions of the compressor. Consequently, the
“safe” thickness of the coke layer will vary for
different installations. Some recommendations are
given in 24.13.
14
C.5 Occasionally, but in practice very seldom, an oil
fire in a pressure system can initiate an oil vapour
or oil mist explosion. For this to occur, a mixture of
air and vaporized oil, or oil mist, must be within the
explosive limits, and this mixture must further
come into contact with a source of ignition.
C.6 Fortunately, the range of air-to-oil ratio
necessary for an explosion to occur is limited. Either
too much oxygen or too much flammable material
inhibits the explosion. This might be the main
reason why explosions are rare. Nevertheless, the
risk must always be recognized.
C.7 Only limited information is available about the
precise cause of an initial compressor oil explosion
but the following explanation appears to be the most
likely: A fire is initiated when the compressor is
unloaded and no flow of air passes the burning zone
of the coke bed. After a while, the oxygen in the air
is consumed to an extent where incomplete
combustion occurs and carbon monoxide together
with decomposed and vaporized oil and oil mist from
the coke bed form a potentially flammable mixture.
The flammable gases and mists are transferred
downstream to a cooler part of the system, where
they mix with unburnt air to produce an explosive
mixture. Under these conditions, an explosion can
occur when the compressor starts to deliver air
again and the sudden increase in air flow loosens a
particle of burning coke from the layer and transfers
it to the explosive zone.
NOTE It must be taken into consideration that even if no
explosion occurs, the compressed air will be contaminated by
noxious gases from the incomplete combustion.
C.8 This initial explosion can be followed by violent
detonations according to the following:
The inside of delivery lines in systems connected to
lubricated compressors quickly becomes coated with
a thin film of oil. A sufficiently strong shock wave
from the initial explosion passing down the delivery
line can then strip the oil film from the pipe and
form an intimate mixture of oil-mist and air. If a
flammable mixture is produced and the
temperature at the shock wave front reaches the
spontaneous ignition limit, a second explosion
occurs, which accelerates the shock wave to the
speed of a detonation (supersonic) when brittle
fracture of the pipe walls takes place. The process
may repeat itself at intervals along the compressed
air line, frequently giving breakages at restrictions.
Explosions of this type are disastrous for the
pressure system and highly dangerous for people in
the vicinity.
C.9 If the formation of coke is minimized by strictly
following the rules set forth in this International
Standard, the risk of oil fires or explosion can be
minimized.
© BSI 02-1999

Annex D The selection of lubricants
for air compressors8)
(This annex is an integral part of the standard.)
D.1 “Oil-free” rotary and reciprocating
compressors
Almost all oil-free compressors have oil-lubricated
bearings, drive mechanisms or gear transmissions.
The lubricated part of the machine is sealed off by
packing glands or other means from the part of the
machine where the air is compressed, to avoid all
contact with the oil.
a) In the lubricated part of the machine, the risk
of unsatisfactory lubrication causing wear and
subsequent breakdown is normally very limited.
b) For some high-speed compressors, starting and
stopping are the critical periods for lubrication.
These machines are therefore often equipped
with safety devices to control the oil pressure
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
during these operations. In some machines, this
problem is solved by having a separate oil pump
which is started and develops pressure before the
compressor is started.
c) In some compressors, the seals between the
lubricated and oil-free parts of the machine are
subject to a certain amount of wear, and this may
result in oil leaking into the compression
chamber. This leakage can make the compressor
unsuitable for service and can also result in the
formation of oil coke in the pressure system.
Table 2 gives oil recommendations for normal
operating conditions.
D.2 Oil-lubricated compressors
Air compressor lubricants must be selected not only
to satisfy normal lubrication requirements but also
with the aim of eliminating or at least minimizing
the formation of oil and carbon deposits in the
compressed air system.
D.2.1 The type and grade of oil which is
recommended by the compressor manufacturer
should generally be used. There have, however,
been important recent developments of improved
oils with better oxidation resistance for use in air
compressors, and oil recommendations contained in
instruction books may soon become obsolete. The
following information has been prepared to enable
designers and users of compressors to obtain a
better understanding of the processes involved in
the formation of oil coke and the risk of fires and
explosions as a background to correct lubricant
selection.
8) Thisannex will be revised on completion of studies being carried out by ISO/TC 28 on the classification and specification of
lubricants for air compressors.
© BSI 02-1999
BS 6244:1982
D.2.2 It is now recognized that the main cause of
fires in lubricated air compressors is the formation
of solid oil degradation products (“oil coke”). Recent
developments have been directed at producing
lubricants that are less prone to degradation and
the formation of deposits. Two features are of
importance: the oxidation resistance of the oil and
the time the oil is exposed to hot air in the delivery
system.
D.2.3 Good oxidation resistance is achieved by
selecting base stocks with inherent oxidation
resistance and/or by incorporating oxidation
inhibitors that are stable at the temperatures
encountered in compressor delivery systems. The
exposure time of the oil depends on the physical
shape of the pressure system (see Annex B) and on
the oil viscosity.
D.2.4 The lower the viscosity of the oil, the more
quickly it will creep along the pipes. Some
vaporization also occurs and it is essential therefore
to use an oil with appropriate distillation properties.
If an oil has too broad a distillation range, the more
volatile portion may tend to evaporate, leaving
behind the heavier ends that, because of their
higher viscosity, will tend to remain much longer in
the hot zone.
D.2.5 The conditions for oxidation in compressed air
systems are somewhat different from those in most
other lubrication systems. A future International
Standard will consider specific tests as conventional
oxidation tests are not appropriate for evaluating
the oxidation stability of compressor oils.
Pneurop (The European committee of
manufacturers of compressors, vacuum pumps and
pneumatic tools) has developed, in conjunction with
a number of oil experts, a method for determining
the carbon-forming tendencies of oils in the
presence of iron oxide to simulate the catalytic
action that may occur in compressor delivery
systems, and field tests have been carried out to
obtain a correlation between oils of different
oxidation performance in this test and their
behaviour in air compressors. This test method is
being considered by the appropriate committee of
ISO with a view to incorporating it in a specification
for air compressor oils.
Special air compressor lubricants complying with
the requirements of this test are available from oil
companies.
15
 BS 6244:1982
D.3 Oil-flooded compressors
Coke formation is not normally a problem in
oil-flooded rotary compressors because of the lower
air delivery temperatures, but as the oil is recycled
it should have good oxidation resistance to ensure a
reasonable life. A special oil for oil-flooded rotary
compressors or a circulating oil with good
demulsibility should be used (for example an
inhibited turbine oil, ISO VG 329) or hydraulic type
oils). The oxidation inhibitor should have a
sufficiently low volatility at the temperatures
prevailing in the compressor to ensure that the oil is
well protected during the time it remains in the
compressor between oil changes.
D.4 Oil recommendations
In general, the type and grade of oil recommended
by the compressor manufacturer should be used,
and any proposed change from this discussed with
the compressor manufacturer. Oil oxidation can
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
lead to the formation of aldehydes with low
spontaneous ignition temperature, which therefore
are potentially hazardous.
D.4.1 The commercially available oils which are
currently the most widely used in compressors are:
a) good quality straight mineral oils;
b) special air compressor oils with or without
additives;
c) turbine oils or hydraulic type oils containing
anti-oxidants and other additives;
d) single-grade engine oils containing
high-temperature anti-oxidants and
detergent/dispersant additives;
e) synthetic oils.
f) automatic transmission fluids.
D.4.2 Single-grade diesel engine oils are
recommended in many cases for the smaller sizes of
industrial compressors because of their ready
availability. The suitability of particular grades
should be checked with the compressor
manufacturer. Multi-grade engine oils should not be
used.
D.4.3 Synthetic oils may be used in special
circumstances. Full discussions should be held with
the oil supplier, the compressor manufacturer and,
where relevant, the national authorities for
worker’s protection before they are adopted.
D.4.4 Lubricating oil recommendations for different
types of compressors under average conditions are
summarized in Table 2.
9)
See ISO 3448.
16
Compressors may be classified as light, medium or
heavy duty depending upon such parameters as:
a) The compressor design, for example, type of
cooling, number of stages, valve velocities, oil
retention time.
b) Ambient conditions, for example, intake air
temperature, coolant temperature presence of
catalytic dust or gases.
c) Operating conditions, for example, continuous
or intermittent service, layout of the pressure
system, maintenance, oil change periods, etc.
D.4.5 The viscosity grade should be chosen so that
the oil has
a) an adequate viscosity to ensure satisfactory
lubrication of running gear and cylinders;
b) a sufficiently low viscosity at the expected
minimum ambient temperature to ensure
satisfactory lubrication at each compressor start.
D.4.6 For oil-lubricated compressors operating
outdoors or in unheated premises, the calculated oil
viscosity shall not exceed 2 000 mm2/s at the lowest
temperature likely to be experienced, and the pour
point shall be approximately 5 K below this
temperature.
D.4.7 If the ambient temperature is especially high,
an oil of higher viscosity grade may be necessary.
D.4.8 Special care should be taken in cases where
the air may be inhaled, to ensure that the oil is
non-toxic. The oil supplier shall provide information
enabling the user to evaluate any health hazard in
relation to his intended use of the compressed air.
National regulations should be met.
NOTE The Threshold Limit Value (TLV) for oil mist in air is
often laid down to be 5 mg/m3.
D.4.9 Summary
An oil with the lowest viscosity grade compatible
with the lubrication requirements should be chosen.
It should be suitable for both the lowest starting
temperataure and the highest running
temperature. In special cases, it may be necessary to
change the oil viscosity grade for different seasons of
the year.
© BSI 02-1999
 BS 6244:1982

Table 2 — General lubrication oil recommendations for air compressors

Type of compressor Oil viscosity (ISO 3448)a Oil typeb

1 “Oil-free” compressors

Oil-free screw and reciprocating ISO VG 46 or 68 Turbine or hydraulic type oil

compressors or
special compresspor oils
2 Lubricated compressors

a) Air-cooled reciprocating ISO VG 32, 46, 68 or 100 Light duty:

compressors with shaft inputs up
to 20 kW
b) Air-cooled reciprocating
compressors with shaft inputs
above 20 kW
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
ISO VG 32 for ambient temperatures
below – 10 °C
ISO VG 32, 46, 68 or 100ISO VG 32 for
ambient temperatures below – 10 °C
Single-grade engine oils meeting API
Classifications SD, SE, CC or CD.
Multi-grade engine oils should not be used.
Medium duty:
Special compressor oils.
Heavy duty:
Special compressor oils.
Light duty:
Turbine or hydraulic type oils
or
special compressor oils.
Single-grade engine oils meeting API Classification

CC or CD may be used as an alternative, provided

that the compressor manufacturer agrees.
Multi-grade engine oils should not be used.
Medium duty:
Special compressor oils.
Single-grade engine oils meeting API Classification
CC or CD may be used as an alternative, provided
that the compressor manufacturer agrees.
Multi-grade engine oils should not be used.
Heavy duty:
Special compressor oils.
c) Water-cooled reciprocating ISO VG 68 or 100 Light duty:
compressors Turbine or hydraulic type oils
Medium duty:
Special compressor oils.
Heavy duty:
d) Vane-type rotary compressors ISO VG 100, 150 or 220 Special compressor oils.
c ISO VG 32 Light duty:
3 Oil-flooded rotary compressors
Turbine or hydraulic type oils
Medium duty:
Special compressor oils
Heavy duty:
Special compressor oils
a Typical values. It is recommended to follow the recommendations of the manufacturer.
b Whether the compressor duty is to be classified as light, medium or heavy duty, depends on many parameters, for example:
a) the compressor design, for example type of cooling, number of stages, valve velocities, oil retention time;
b) ambient conditions, for example intake air temperature, coolant temperature, presence of catalytic dust or gases;
c) operating conditions, for example continuous or intermittent service, layout of the pressure system, maintenance, oil change
periods, etc.
As general guidelines for displacement compressors can be taken:

© BSI 02-1999 17
 BS 6244:1982

Duty Reciprocating oil-lubricated compressors Oil-flooded rotary compressors

Light Stage pressure ratio < 2,5 or compressor shaft power < 20 kW and Discharge air temperature < 100 °C
a self-draining pressure system so designed that it remains free
from oil coke deposits

Medium Stage pressure ratio > 2,5 Discharge air temperature in the range 100
to 110 °C

Heavy If coke formation occurs in the discharge system, when a medium Discharge air temperature > 110 °C
duty oil is used
c
For oil-flooded rotary compressors, the high-temperature safety switch shall be set at a temperature 10 K above the maximum
discharge air temperature unless national regulations specify otherwise.

Annex E Precautions against E.7 Because it is difficult to eliminate the causes of

crankcase explosions
(This annex is an integral part of the standard.)
E.1 Crankcase explosions result from ignition of a
combustible mixture of lubricating oil and air.
Combustion pressure which develops following
Licensed copy:Foster Wheeler, 22/12/2007, Uncontrolled Copy, © BSI
explosions, relief devices are sometimes installed to
prevent pressures exceeding the strength of the
crankcase. Relief devices may range from
spring-loaded coverplates to specially designed
valves fitted with flame traps.
E.8 Bursting discs are forbidden since the inrush of

ignition within the confined space frequently air to fill the partial vacuum created by an explosion
exceeds the strength of the crankcase, and may lead to a second explosion, sometimes more
destructive failure occurs. The ignition source is violent than the first.
generally an overheated part. E.9 As to sizing relief devices, investigations,
E.2 Prevention of crankcase explosions requires including full-scale tests, have shown that it would
either elimination of the ignition source or not be practical to provide sufficient relief area to
prevention of flammable atmospheres. maintain a safe pressure level when conditions are
E.3 Elimination of the ignition source is not feasible favourable to an explosion developing maximum
as some form of mechanical seizure is always intensity. However, experience has shown that
possible. Technical difficulties inherent in many typical crankcase explosions can be safely
measuring temperatures of all moving parts relieved with conventional crankcase explosion
preclude any attempt to prevent potential ignition relief devices, if the total throat area of the devices
sources through early detection of overheated parts. satisfies the requirement:
E.4 However, proper maintenance and operation A > 0,07 V
are recommended as a means of minimizing where
mechanical failure. If a machine is shut down owing
to mechanical trouble which might involve an A is the total throat area, in square metres;
overheated part, inspection doors should not be V is the crankcase volume, in cubic metres.
opened immediately. This is to allow for a period of
cooling of the heated part before air is permitted to
enter the crankcase, and thereby minimize the
possibility of an explosion.
E.5 Approaches sometimes recommended to
prevent flammable mixture include forced
ventilation of the crankcase or operating the
crankcase below atmospheric pressure. When such
methods are employed, it should be recognized that
under certain conditions crankcase ventilation may
dilute a rich mixture into the flammable or
explosive range.
E.6 As an alternative to ventilation, the crankcase
may be continously purged with inert gas. The
volume of gas required to effectively purge a large
machine will usually make this approach
impractical.

18 © BSI 02-1999
 BS 6244:1982

Publications referred to

See national foreword.

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© BSI 02-1999
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