Moisture is the enemy of productivity in your compressed air systems. Productivity is dependent on dry compressed air being adequately and consistently supplied to your tools and air system. The air around us is filled with little moisture particles that go unnoticed in our day-to-day lives. Once that air has been compressed, all the free-flowing particles and molecules are crammed into a small space and will start to combine and form what is called condensate.
These water particles condensed together and become trapped in the air stream. The condensate will pool up in piping and tanks if it is not adequately treated. Build-up of condensate can be detrimental to the air system as a whole. It can create pressure drops and could even stop the whole process from working.
This build-up can happen due to a number of different variables, from the moisture in the ambient air to the dewpoint of the compressed air, the environment it is running in, and the outside temperature, to name only the big ones. The different degrees of quality determine the level to which your air will need to be dried.
Internal condensate is the silent killer of air systems. From the outside perspective, everything seems to be running smoothly, but in reality, large quantities of condensate could be downstream from the compressor, wrecking productivity alongside the proficiency and lifespan of the compressor. This inability to see the condensate emphasizes the importance of maintaining a routine maintenance schedule. Avoid large-scale build-up and provide peace of mind for your company.
When you are working to protect against condensate build-up, it is a year-round endeavor. The more humid the ambient air is, the more water vapor will get pulled into the air compressor. More time and energy will be necessary to reach the same dryness level as normally achieved. This can cause wear and tear on the system and can be harmful to the overall life span of the machine. Not only can compressors and air systems have trouble during the summer with more humid air, but the dry cold air of winter can cause problems too, due to the lower quantity of moisture in the air.
As it typically is, water is the enemy of equipment due to the problems it can cause internally or productivity-wise. It wears away at equipment over time and can become detrimental to productivity and operations because of this. The water can block airflow downstream resulting in less air being able to reach the end of the line and that means some pneumatic tools will not be receiving enough dry compressed air to operate properly. Keeping constant airflow is the key to keeping constant productivity, without it, the levels of pneumatic tool output will vary. Internal components can be hurt by water and condensation build-up:making dry compressed air vital.
Water build-up can exist unnoticed by users as it happens so gradually. Water hammer, which is when water in the pipes can slam into equipment or internal barriers and the sound resonating off sounds like a hammer banging, can occur from condensate build-up. Knocking other internal particulates loose and reintroducing them into the airstream. This can degrade the quality of the product air that is coming out at the end of the line and this may cause problems when dry compressed air is a necessity.
Excess moisture can cause problems in several areas along an air system. It can be detrimental to the success of air tools, piping, dryers, air tanks, and all the other equipment that the air passes through. So when it comes to having dry compressed air, quality is something to consider with your dryer. The ramifications of the dryer can be felt all along the system, especially when the dryer does not work well. When considering a dryer it is important to look at specific aspects such as what cfm you need and how airflow can be affected by the dryer size and output.
Whether you are looking to create an air system or modify your current one it is important to know the specifications of what you need so that you can ensure your system works properly and produces dry compressed air when you need it. When you are lining up your system it is important to know the following measurements and information about your system:
Knowing this specific information is the key to your system’s success. With this, you can align the specific pieces you need to ensure that the airflow will be smooth and continuous when needed. Information like flow rate can be used to determine the speed at which the air will move through the system and to avoid drops in speed downstream.
The water content/humidity in the ambient air is important and so is the temperature of the air. It can be difficult to cool air when it has been so compressed and all of the molecules are moving. So when the compressed air coming in is hot it can take even more time to cool down and can even slow down the system as the air moves slower.
Temperature plays an important role in the health of your air system, especially the air inlet. This temperature measures the temperature of the air as it enters and can affect the compression rate. If the air is warmer, it is harder to condense, causing problems with pressure and moisture in the air. When considering the pressure of your air system, it is important to note the pressure so you can maintain a consistent flow of dry compressed air downstream, and when more pressure is applied to the air, fewer moisture particles exist in the air due to the lack of space.
Finally, Pressure Dew Point is another important factor to be considered. It is the standard used to measure the water content in compressed air and the temperature at which water begins condensing. It is the point at which the air can no longer hold any more water and it begins forming condensate. Different types of dryers can change the air’s dewpoint and are something to consider as well. When you have dry compressed air, the temperature at which the water condensates, the dew point, is lowered so that the air has to drop in temperature for the moisture to turn to liquid.
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The Words Warthog and the Stylized Warthog are Registered in U.S. Patent and Trademark Office. Reg. No. 7,109,357 and 7,109,356
