Water in compresed air systems

Problem: Our compressed air system contains a lot of water, but we don’t have the budget for a dryer. Is there another solution?

Solution: In compressed air systems, compression causes the water in the air to form droplets (condensate). If the compressed air is not pre-processed by a compressed air dryer, water must be expected in the entire pipeline network.

In this situation there are various guidelines to be followed when installing the pipeline, in order to prevent damage to devices using the air.

Temperature gradients: Where possible, the compressed air lines should be laid so that the air does not cool down when flowing through. The air should be heated gradually. If the absolute humidity is constant, the relative humidity will then fall. Condensate will then be unable to form.

Pipelines with gradients: The pipelines must be laid with a gradient of approximately 1.5% to 2% in the direction of flow. The condensed water in the pipeline will then collect at the lowest point of the line.

Vertical main line: The main line directly behind the compressed air receiver should rise vertically. The condensate that occurs when cooling takes place can then flow back into the receiver.

Condensate drain: Drains must be installed at the lowest points of the system in order to drain off the condensate.

Connection lines: The connection lines must branch off upwards in the direction of flow. The pipeline here must be as straight as possible to avoid unnecessary pressure loss.

Fittings: A service unit with filter, water separator and pressure reduction valve should always be installed. A compressed air lubricator may also be needed, depending on the application.

Thanks for this tip go to BOGE America Inc.’s Compressed Air Guidebook.