With any large machine such as an air compressor, there is always the chance of it breaking down due to mechanical failure. These breakdowns are not only a hazard to the machine, but to you and your workplace. Anyone working around an air compressor should be aware of how to handle these emergency situations.  
Too much pressure is a major, and common, problem of air compressor issues. Oftentimes, a machine cannot handle pressure levels above its recommended limit, so be sure to follow the manufacturer’s recommendations for PSI limits. Check all your gauges routinely to ensure that you are getting the proper reading from the machine.

An effect of pressure misuse is leakage, which occurs in the pneumatic hoses attached to the machine. If too much pressure is being put out; rips and tears can occur in the hoses, which cause leakage. Not only is this situation hazardous, but it is also a serious financial problem as well. Leaks can cost a company thousands of dollars a year if not properly treated and corrected.

A third problem that might arise has to deal with the condensates in your system. Compressed air causes moisture such as water vapor and oil to build up in the system, both the hoses and the unit itself. This can cause corrosion in the pipes and hoses, once again leading to tears and leakage. Condensate build ups can also block air flow from moving throughout the system, another problem that will cause it to rupture. In order to prevent this from happening, having an industrial air compressor dryer, either a desiccant or refrigerated dryer, will eliminate the condensates from your unit.

As with most problems involving your industrial air compressor, preventative maintenance goes a long way in ensuring that you keep those problems to a minimum. Checking valves and gauges regularly ensures that your PSI readings are correct, preventing any ruptures, tears, or leaks. Managing your condensates is another step that goes a long way in caring for your compressor, as getting rid of all the condensates in your system will increase the efficiency of your compressor. Finally, make sure everyone who handles the air compressor is qualified to do so. Accidents are the worst thing that can happen on a work site, and knowledge is the best way you can keep everyone safe.

A condensate drain is a necessary component of a compressed air system because it disposes of potentially harmful condensates in a safe way. Condensates form from the cooling of moisture in the air system, and must be drained properly and regularly. If the condensate is not drained, water vapor and other contaminants would not be properly removed via refrigerated air dryers or mist eliminators. These drains are categorized into zero air loss drains and timed electric drain traps.

Zero air loss drains operate automatically via pneumatic power and waste no compressed air when they discharge condensate. These condensates are continuously measured by ultrasonic sensing technology systems, allowing for constant monitoring of the process. The discharge from these drains can be executed at a rate of up to 60 gallons of condensate per hour. The state of the condensate is irrelevant and, as such, it can be dirty, emulsified, or clean. Regardless of the state it is in, all condensate is discharged through this process. Zero air loss drains expel no compressed air, hence the term “zero air loss”. Once a predetermined amount of condensate has accumulated in a reservoir, the drain discharges the condensate safely and efficiently.

The second type of condensate drains are timed electric drains. These drains are programmed to drain condensates at specific time intervals, and are designed to discharge condensates at pressure ratings as high as 720psi. External knobs adjust the open time and duration between cycles, while valve-open lights display operating conditions. A motorized ball valve is also used for the timing of these electric drains.

The third type of condensate drains are automatic drain traps, also known as float drains. These drains operate without electricity and are used to discharge both clean and heavy emulsion condensates. These automatic drain traps are relatively compact in size and operate automatically, saving both space and energy costs.
After the drains have discharged the condensate, oil and water separators are used to reduce hazardous waste in these condensates. Oil and water separators work by siphoning out materials such as mineral oils, semi-synthetic lubricants, synthetic lubricants, 24KT fluids, and polyglycols from the compressed air. Because oil and water mixtures are not safe to release back into the environment, the lubricants are trapped in these systems, allowing water to pass through.

All these drains are used in compressed air systems to keep the air free of water vapor and other contaminants. Draining condensates is one of the most important aspects when dealing with industrial air compressor maintenance. Not only will a well drained system function more smoothly, but it will also save you valuable time and money.