The presence of water in pneumatic systems is a serious challenge that requires attention. Water accumulation in these systems can negatively impact components and overall performance.
If water buildup is left unchecked, it can cause severe consequences such as corrosion, mold, decreased performance, and damage to pneumatic components. These are not just potential risks but real threats that demand immediate attention.
In this article, the Bawalaksana team wants to discuss how to remove water from pneumatic systems and its benefits. This discussion continues from our previous article on 10 Essential Steps for Maintaining Your Pneumatic Systems.
Why Does Water Accumulate in Pneumatic Systems?
Water can accumulate in pneumatic devices due to various factors, including air compression and temperature changes along pneumatic lines.
When air undergoes compression, it generates heat, condensing water vapor into liquid form. This process resembles the evaporation of hot water, whereby high pressure and temperature cause water molecules in humid air to adhere to nearby surfaces. Over time, the accumulation of these adhering vapor particles results in the formation of water droplets.
Environmental temperature fluctuations can also cause water vapor condensation in pneumatic devices. Similarly, temperature changes from hot to cold along the lines will cause water vapor to condense.
All these factors contribute to water vapor accumulation and condensation, leading to water pooling at various points in the pneumatic system.
There are numerous effective methods to remove water from pneumatic systems, such as draining the compressor tank, installing drain valves, water separators, and using refrigerated air dryers.
These methods are not just theoretical solutions, but practical tools that can effectively combat water accumulation.
Here are some methods to remove water accumulation in compressed air systems.
Draining Water from Air Storage Tanks
Regularly draining the air storage tank is one of the most straightforward methods for eliminating water from pneumatic systems. This essential task should be carried out consistently, particularly during high humidity.
During the summer months, when the humidity levels are higher, it is important to regularly carry out the process of draining sediment from storage tanks to ensure the integrity and purity of the stored contents.
While more comprehensive solutions exist to prevent water accumulation in pneumatic devices, implementing this practice as a preventive measure at the upstream section of the pneumatic system is beneficial.
Additionally, it is highly advisable to employ supplementary components to prevent water molecules from accumulating at other susceptible points in the system.
Manual Draining from FRL Units
In pneumatic systems, it’s crucial to remove water from the FRL unit side effectively. This can be achieved manually by pressing or opening the water drain channel on the FRL.
Please remember that water can accumulate in pneumatic systems from the upstream, which includes the air compressor, to the downstream, involving pneumatic cylinders or air tools.
Therefore, eliminating standing water in the air service unit is vital to prevent potential issues and maintain the optimal performance of the pneumatic system.
Using Drain Valves
Drain valves play a crucial role in removing water vapor from pneumatic devices.
These valves are typically installed in areas where water vapor accumulates, such as storage tanks, air dryers, or specific points within the pneumatic system.
Drain valve components come in various types, including:
- Manual drainage
- Timer-based drainage
- Automatic drainage
It’s important to conduct daily checks for manual drain valves and those using timers to ensure efficient drainage and to monitor water accumulation.
Automatic drain valves, on the other hand, can operate automatically when water accumulation reaches a specific level.
Installing Water Separators
Water separators are specifically designed to remove accumulated water vapor from compressed air lines. These separators come in various types and sizes and are incredibly effective at reducing the water content in the system.
Water separators operate on the principle of centrifugal force. As compressed air moves swiftly and circularly into the device, the water separates from the air. Afterward, the water can be gathered in a tube and discharged from the airline.
Make it a habit to regularly drain water from the water separator in a pneumatic system to maintain peak performance and prevent damage. The frequency of draining the water may differ based on environmental conditions and system usage. We recommend draining the water separator daily or whenever there is a shift change.
Using Air Dryers for Severe Cases
Air dryers are the best solution when dealing with high humidity problems and excessive water accumulation.
They remove moisture and filter out dust, contaminants, and dirt that can harm pneumatic devices.
There are two main types of air dryers commonly used: Refrigerated Air Dryers and Desiccant Air Dryers.
Refrigerated Air Dryer
Refrigerated Air Dryers function similarly to refrigerators. They rapidly cool the air to a dew point of 3°C (37.4°F), causing water vapor to turn into droplets, which are then collected. The dry air is then directed to other pneumatic devices.
Desiccant Air Dryer
On the other hand, Desiccant Air Dryers use materials like silica gel or alumina to absorb water vapor from compressed air. When the absorbent material becomes saturated, it needs to be regenerated or replaced for optimal functionality.
Desiccant Air Dryers may use chemicals like sodium chloride and sulfuric acid to bind water vapor, which can potentially lead to corrosion in compressed air devices.
Nonetheless, this method is considered adequate and cost-efficient in reducing humidity.
Please remember that when selecting an air dryer, it’s crucial to consider the humidity levels, system capacity, and available budget. We highly advise seeking guidance from industry experts to ensure you receive the most suitable and practical recommendations for your company’s needs.
Why is Removing Water from Pneumatic Systems Very Important?
Compressed air systems often contain moisture and are highly susceptible to condensation. Various factors can influence the moisture level within the system, including air volume, ambient temperature, and the malfunction of air dryers.
If left unaddressed, condensation and water buildup in pneumatic systems can rust components such as solenoid valves, cylinders, and air tools.
Water entering the compressed air system essentially “cleans” pneumatic components, washing away the lubricant that protects them from friction and corrosion.
Additionally, excessive moisture and water accumulation in hoses can significantly diminish their performance, particularly for products with hygroscopic properties, like low-quality Nylon or Polyurethane hoses. (Read: 6 Causes of Pneumatic Hose Failure and How to Prevent Them)
When hoses absorb substantial moisture, they may undergo dimensional changes, becoming stretched, inflexible, worn, and no longer airtight.
This transformation also makes pneumatic tubing more susceptible to breakage. If left unattended, this could harm or shorten the lifespan of components or lower the overall system performance.
Furthermore, humidity can lead to the formation of mold and bacteria, contaminating products, which is especially risky for specific food items and other sensitive processes. As previously discussed, clean and dry air is critical for adequately functioning pneumatic systems.
The earlier we can prevent air humidity and condensation, the better we can safeguard downstream pneumatic equipment.
Accordingly, appropriate preventive measures can alleviate the workload on dryers and other pneumatic components.
The next article will explore preventive measures to avert water accumulation in pneumatic systems.
PT Bawalaksana Central Industrial is a distinguished industrial parts supplier that specializes in providing comprehensive solutions for the maintenance and repair of pneumatic systems.
As the official distributor of Metal Work Pneumatic, we deliver complete solutions for pneumatic automation devices and components. Furthermore, we have been appointed as the authorized distributor of Mebra Plastik Italia, a recognized manufacturer of pneumatic hoses and industrial tubing.
Should you encounter challenges with your pneumatic system and require high-quality spare parts, our team is prepared to offer professional and comprehensive support.
We encourage you to engage with our Sales Engineer to receive personalized recommendations and advantageous offers to enhance your pneumatic system’s efficiency and productivity.
Please click the consultation button below to access the best support available.
Romanta Pinrih Linuwih
Pneumatic Automation Systems Expert
This article was written in collaboration with Romanta Pinrih Linuwih, an expert in Pneumatic Automation Systems, to ensure accuracy and high quality.
