By Ron Marshall for the Compressed Air Challenge
A metal products manufacturer was well aware of the benefits of large storage receivers installed on their system of load/unload compressors. The receivers act as a quiet zone where water and lubricant can settle out of the air before entering the system dryers. In this zone, the air cools making it easier to dry. And the significant storage reduces the compressor’s load/unload cycle frequency, which reduces the energy consumed.
The processor purchased a large 1,060-gal storage tank, which was placed on the wet side of his refrigerated air dryer. All was well for many months—until the maintenance personnel noticed the compressors cycling excessively. The air dryer was also performing poorly, allowing water into the downstream piping, fouling air operated tools.
An experienced auditor was called in to take a look at the system. After checking the compressor settings, the dryer and filter differential, and examining the piping, he took a look at the wet receiver condensate drain. For some reason, the automatic drain had failed. A manual valve was opened and about 1,000 gal of water was released after draining the tank for what seemed like hours! A failed drain had caused the tank to completely fill with condensed water over a period of time, making the receiver ineffective in improving the system. The free water that gurgled out was overwhelming the air dryer.
The plant engineer was very concerned, as the completely full tank was very heavy and could have causes mounting structures to collapse. The drain was replaced and compressor operation returned to normal. The plant now has a regular maintenance schedule to test the drains.
Learn more about condensate drains in our next Compressed Air Challenge seminar in your area. Visit www.compressedairchallenge.org for more information.
Filed Under: Pneumatic Tips