Frequently Asked Questions

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1. Top 10 Air System Mistakes
2. Poor condensation management

Poor condensation management

Condensation is the moisture that drops out of airflow as it cools. The condensation in a compressed air system is a constant threat to cause expensive problems. The following are a few examples:

1. Moisture washes lubrication from air tools and production equipment causing downtime and maintenance.
2. An inconsistent supply of dry air causes production quality problems.
3. Excessive rust and scale often forms in the air distribution system.
4. Water can back up into the compressor and wreck the machinery.
5. Air dryers can become overloaded.
6. In-line filters can be destroyed.

The problems get worse if you operate lubed reciprocating or oil flooded rotary screw compressors, which is just about everyone. Compressor oil makes its way into the distribution system with the compressed air. The mixture of oil, water, dirt and heat tends to build up a sludge that will ultimately jam or clog production equipment, air tools and drains. The situation is further complicated by climate and seasonal weather changes. This is because the amount of condensation generated will change according to changes in the temperature and the relative humidity of the inlet air. Consider that a 200 horse power compressor operating in a climate of 60 degrees F with 40% relative humidity will generate approximately 50 gallons of condensate a day. However, that same compressor operating in a climate of 90 degrees F with 70% relative humidity will generate approximately 260 gallons of condensate a day. The typical compressed air system is designed to remove condensation at strategic locations. This means there are drains at the after cooler separator, receiver tank, air dryer, in-line filters and at drain points in the piping. The problem is that there are shortcomings with the products being used to drain the condensation. A condensation drain should automatically remove condensate when it appears at the drain without wasting air or clogging.