Potential for explosion of Bauer oil/water separators

Purpose
Background
The problem
Legislative requirements
Recommendation

Purpose

To alert owners and users of Bauer high pressure air compressors to a potential safety problem with the old type aluminium alloy final oil/water separator.

Background

There have been two recent explosions of aluminium alloy final oil/water separators fitted to Bauer air compressors installed on dive vessels operating in north Queensland waters. The explosion force was of sufficient intensity to have caused serious injuries or death should a person have been in the vicinity at the time of failure.

The problem

Some older model Bauer air compressors are fitted with a final stage oil/water separator manufactured from an aluminium alloy, which was designed for a maximum life of 85,000 load cycles. Due to the high load cycles being employed by some compressor operators in north Queensland, it is possible to exceed the 85,000 load cycle life of the separator, before reaching the maximum life of the compressor block.

Aluminium alloy final stage oil/water separators may explode if used beyond their load cycle life of 85,000. This problem does not exist with later model Bauer air compressors which are fitted with a separator manufactured from steel.

Legislative requirements

Part 3 of the Workplace Health and Safety Act 1995 imposes obligations on designers, manufacturers, importers, suppliers, employers and self-employed persons to ensure that plant is safe and without risk to health when used properly. The Act provides for severe penalties for breaches of an obligation.

Recommendation

Owners should ensure that the compressor manufacturer's guidelines on compressor operation are followed and that the separator load cycle life is not exceeded. Guidance on determining whether a specific aluminium alloy final stage oil/water separator is safe for continued service can be obtained from the Australian agent, Drager on 1800 677 787.

Last updated July 12, 2005