The hazards of condensate in air compressors
Condensate buildup in air compressors can lead to serious hazards, including equipment damage and safety risks. Learn how to prevent and manage condensate in this guide.
Condensate is a major problem for air compressors. Failure to drain it in a timely manner can lead to internal corrosion of the unit, reduce the properties of lubricating oil, and affect the operation of the unit. So what is the principle behind the production and discharge of condensate?
Formation of Condensate
Condensate is a term used to describe the liquid that forms when water vapor in the air is cooled and condensed into a liquid state. In the case of air compressors, condensate is primarily formed from the moisture present in the air that is drawn into the compressor. As the air is compressed and heated, the moisture evaporates and is then cooled and condensed into liquid form as it passes through the compressor’s storage tank. During periods of high humidity, such as during rainy weather, more condensate is likely to form.
When an air compressor operates at extremely low temperatures, it can cause condensation. If the operating temperature of the unit is lower than the evaporation temperature of water, the moisture in the air will directly condense and form water. This can lead to the formation of condensation. Therefore, it is important to avoid prolonged operation of the unit at extremely low temperatures.
Harm of water in oil to air compressor
In oil and gas separation tanks, moisture in the air can condense, especially in humid weather, when the exhaust temperature is lower than the dew point of the air, resulting in more condensation water. This process is heavily influenced by temperature and humidity levels.
Excessive water content in oil can lead to emulsification of lubricating oil, which can affect the safe operation of machinery. It can also cause poor lubrication of the compressor, reduce the efficiency of oil and gas separation, increase the pressure difference in the oil and gas separator, and cause rusting of the main engine and other components. Additionally, water is incompressible, which can lead to overloading of the main engine.
Condensate Drain
There is no clear regulation on the dumping time of condensate. Generally, it depends on the humidity of the intake air and working conditions of the unit. Generally, customers will drain the condensate after it is fully accumulated before start-up or shut down, so as not to affect the normal use of the unit and ensure the drainage effect of the drainage pipe.
To drain the drainage pipes, the air compressor must be turned off, and the oil and gas separator tank must be depressurized, allowing the condensate to settle. Most air compressors come equipped with an air compressor storage tank, which has a drain valve at the bottom for easy drainage. To facilitate the discharge of condensate, most customers install automatic drain valves. These valves can handle the shut-off condition when there is no pressure, and when the condensate reaches a certain level, the valve will automatically open, allowing the water to be discharged under the pressure of the air, reducing the buoyancy of the water and preventing blockages in the outlet.
