Your Guide to Effective Condensate Management within Compressed Air Systems

 

Effective Condensate Management is an important topic for an air compressed system and is often overlooked; however, it is a critical part of the integrated compressed air systems.

 

As a result, of the compression process, all air compressors form condensate, which is mostly composed of water but is also contaminated with oils and particles. If this condensation is not properly removed it can severely damage products and equipment over time.

Condensation is a natural by-product of the compression process. In all cases air contains some level of water vapour, when air is compressed it creates heat, when combined it causes the air to reach saturation. When the saturated air passes from the compressor into the system, it starts to cool and expand, which causes the water vapour in the air to clump together into water droplets, also called condensate.

As the condensate passes through the system it becomes contaminated by collecting oils, chemicals and partials that have been drawn into and passes through the compressor. This condensate can start to pool at low points on the system or it can continue to travel downstream, where it can damage products and production equipment. The contamination process is a significant concern for your bottom line, for example: if a 18kw compressor is used for a year, it will operate for an average of 8000hours, during which time it can produce up to 15 000litres of condensate.

Typical Effective Condensate Management Installation

If a condensate management system is designed and installed correctly, it makes it easy to collect and remove condensate. Examples of the typical condensate management systems include condensate drains, oil and water separators and necessary piping to connect them.

An oil water separator is generally placed between the compressor and the air receiver however can be placed further along your airline as per your specific requirements.

In addition, filters are placed both upstream and downstream of the refrigerate dryer. Condensate drains can be connected to the oil water separator air receiver and the filters.

Components of a condensate management system

Condensate drains – When choosing a condensate drain there are several types available and a number of operating conditions that should be considered. These conditions include the amount of condensate the system discharges, the maximum pressure and temperature the drains will experience, the drain material, the orifice (opening size) and the NPT (adaptors/ fittings) connections.

The options available in order to make an informed selection are:

Drain Option	Pros	Cons
Manually Operated	The main value of these drains is that they are inexpensive Manual drains, such as ball valve drains are less affected by dirt, oil and other contaminants.	Manually operated drains are easily forgotten which will lead to a wide array of problems. If the drain is left partially opened it can waste a lot of air. If the drain is not opened often enough condensate will being to travel downstream causing damage to production equipment.
High Capacity Float operated	These drains do not require any power for operation are ideal for large sites that do not have any power readily available in all locations. We offer automatic magnetic float operated drains (AMDs) with large condensate drains that can handle between 200 Litres – 1892 Litres an hour. This wide range allows the user to avoid problems caused by incorrect sizing. An exclusive o ring design eliminates the need for gaskets and sealants	Float drains cannot provide a failure warning should failure occur Can often become stuck in either the open or closed position if not use frequently
Timer Controlled	These drains are more convenient and allow the user to set how frequently the drain will open. The condensate is blown out of the drain using compressed air. We offer a timed electric drain called the AUTODRAIN Combo, this contains a timer controlled drain as well as a mesh strainer to keep particles from blocking the valve’s orifice. The AUTODRAIN Combo is designed to have a long operating life and better resistance to higher temperatures.	Timer drains require adjustments on a seasonal basis Failure to adjust will result in excessive compressed air loss or system contamination through condensate carry over.
Intelligent automatic zero – loss	These drains collect and dispel condensate automatically, but without the use of compressed air. By Reducing the need for compressed air, these drains can significantly lower operating costs over the course of the year The Chicago Pneumatic LD 200 Condensate range, prevents condensate build up and the loss of compressed air by automatically dispelling condensate when detected by a capacitance sensor.	These Drains require electricity as a power source.

 

Oil/Water Separators – Oil water separators are an important part of condensate management. Certain laws prohibit the disposal of oil substances due to their damaging effect on the environment. An oil/water separator removes oil from the condensate before it is dispelled from the system. There is a variety of oil/water separators, described below

• Chemical: Chemical oil/water separators contains chemicals that attract oil practical’s while repelling water molecules. The amount of oil contained in the condensate determines the lifespan of a chemical separator. These filters are fully automatic environmentally friendly.
• Gravitational: Gravitational oil /water separators are not effective for use with emulsified oils that do not separate from the rest of the condensate. In gravitational oil/ water separators, the condensate moves into a settling tank where it then falls to the bottom of the tank and the oil particles rise to the surface. The oil is then skimmed off the surface.
• Mechanical: Mechanical oil/water separators are very effective at removing oil from the condensate however the separating elements will fail over time and need to be replaced. These separators remove oil from the condensate by first creating a pressure drop that causes the oil droplets to change phase and separate from the condensate. This condensate will then pass through a series of pores that attract oil droplets, then finally the condensate is passed through oil resistant filters.
• Vaporization: Vaporization oil/water separators use heat like electric or stream, to vaporize the water in the condensate leaving behind the oil partials. The oil can be drained for proper disposal. An important fact to take into consideration is that the oily residue can be corrosive so the materials used in the separator should be chosen with care.

The benefits of making use of a condensate management system

• Prevents serious damage to equipment and products caused by condensation.
• Decreases maintenance costs and scrap from reject percentages.
• Saves money on waste removal by treating the waste internally.
• Adding to your community by being environmentally conscious.

About Field Air Compressors

Field Air compressors (Pty) Ltd. Was officially established in 1992. We are a company based on family values with over 20-years’ experience in the compressed air industry. We offer many products, specializing in air compressors of most brands. We offer servicing, maintenance and spares for all types of compressors, as well as hire out units as required. We distribute Chicago Pneumatic Air compressors and air tools. Our sales team offer friendly service and we have an experienced technical team to offer you any technical advice when required.