Drain

I have a notification system that lets me know when the temperatures are expected to drop below freezing. Yes, it’s great to know ahead of time so I can plan an indoor day but the real reason for this is to notify my clients through twitter (www.twitter.com/fe_airsystems)

As most already know, compressed air systems can be devastated by freezing temps if your not ready.

When I received my first notice of the season last week I was shocked at far into the year we were. I guess it was the extended summer temperatures that caught me off guard and then but I noticed this weekend my area is predicted to see a low temp of 25 degrees.

I hope you’re keeping track better than me but if not, It’s time to get your compressed air system ready for the cold weather.

This is the first of several posts to help you be cold weather prepared.

Of course maintenance takes place all year long, whether by your own maintenance staff or bringing in your preferred compressed air service specialist but there are a list of additional checks and corrections that need to be made ahead of freezing temperatures.

Check all drains for proper operation

Check drains for obstructions or inefficiencies. If a drain is malfunctioning it can cause serious issues when the temperatures drop. In compressor rooms that are not heated, improperly drained condensate could freeze. If the drain trap is left open, it blows expensive compressed air to the atmosphere and let’s face it – efficiency means everything to companies today. If not already installed consider adding no air loss type auto drains. Be sure to inspect drains in the air system equipment, including dyers, receivers and filters.

Maintain air filters

Filters should be checked regularly for clogs or other problems indicated by a high differential pressure. This unnecessary pressure drop can decrease end-use pressure, causing the entire system to work harder and use more energy. Again, efficiency is king! Coalescing filter housings partially filled with water are at risk for freeze and rupture event and nobody wants to be around that time bomb. .

Locate and repair leaks

Leaks can account for up to 25 percent of compressed air use. Identifying and fixing leaks can lead to huge savings. Did I mention efficiency? Some larger leaks can be heard just walking through the area but smaller leaks will require monitoring equipment. You can purchase and utilize an ultrasonic acoustic leak detector or hire a “Quality” compressed air auditing firm. An auditing company can perform a leak audit only or you can go all out and have them perform a supply & demand side audit to determine additional potential savings for your entire system.

These are the first steps to take when winter is just around the corner. Follow the blog to learn more pre-cold weather tips.

Industry is beginning to understand the true cost of compressed air and it is not cheap. We work with a host of companies every day to reduce their compressed air cost and improve on the reliability of the compressed air system.

If your company only takes one step on it’s own to create a more efficient system for yourself then consider installing the correct condensate drain valves.

Using compressed air for an intended purpose is an obvious goal but we often find that the compressed air ends up being used in unnecessary and wasteful ways. Like blowing debris from parts or workers which is an obvious waste of a utility. Even more concerning is waste that occurs from improperly selected equipment and drain valves fall firmly on that line.

Everyone knows that compressed air systems create huge volumes of water that must be eliminated from the system at any location in the system where the air temperature drops, thus creating liquid water. These area’s typically include intercoolers, aftercoolers, refrigerated dryers and receivers . At these points, equipment (drain valves) must be installed to remove the liquid water from the system collection points.

A simple solution utilized in many systems is a timed based solenoid drain.

There are a couple of potential problems with a solenoid type drain valve. First, most of these drains utilize a very small orifice (port) where the water is discharged from the system making it susceptible to blockage by dirt, sludge or rust particles. Second, the drain discharges compressed air with the water which is a waste of the utility and Third, the timed function of the drain never takes the amount of water into consideration. Maybe the drain is open too long or perhaps the timed event is too short and the water is not completely discharged from the system.

A much better approach is to utilize a zero air loss type automatic drain like the Dehydra 52 shown below.

How It Works

Condensate enter the drain through one of he two inlet connections. A non-metallic float is tethered to a float arm. As condensate is collected and the translucent reservoir fills, the float rises. When the condensate reaches a designed level, the float lifts the trigger assembly and a drain cycle is initiated. The trigger assemble opens and directs control air to the valve actuator, which in turn opens the full-port drain valve.

The compressed air line from the water collection point is closed and condensate will then exit the unit. As the condensate level drops, the trigger assembly closes and the valve actuator closes the drain valve. The drain is returned to a standby condition.

Thus the collection point is fully drained and the during the draining process, no compressed air is lost from the system.

The drain valve is an area your company can easily make an impact to improve your compressed air system.

Winterization

Proper Drains Create A More Efficient Compressed Air System