Safety should always be your first priority when working with compressed air, no matter the setting. Air compressors are common in construction sites, factory settings and, of course, automotive garages. It may seem like a simple tool and you might be tempted to blast a coworker with a burst of air, or use the compressed air to blow dirt or dust away from your skin, but this is dangerous behavior.

Condensation can overload in the air dryers and ruin the in–line filters. The problems with condensation are often especially pronounced in rotary screw dental air compressors, where the compressor oil will sometimes spread into the air system when mixed with the condensate. The combination of oil and water can lead to dirt deposits that ultimately clog the drains and pneumatic tools.

Another factor that can impact condensation is the ambient temperature that surrounds a facility. Simply put, condensation levels multiply as temperatures rise from average to humid. For example, a 200 hp compressor will produce roughly 50 gallons of condensate over the course of a 60–degree day. However, that same machine will generate more than five times the amount of condensate if the temperature is 30 degrees higher.

Further inefficiency can stem from problems with the system drains, which are designed to deal with condensation. Drains are placed at strategic points along an air compressor system, such as the tank, dryer and aftercooler. The trouble emerges when the drain fails to do its job properly, and sludge accumulates along the drainage points from a mix of water, oil and dirt.

System operators will often expect the drains to handle such issues automatically, but this is a big mistake. Condensation can lead to a huge waste of system resources if the issues that lead to condensation are not monitored and rectified on a regular basis.

When you know the behavior of a fully functional air system, it’s easier to spot the emergence of problem issues before they spiral out of hand. Some of the worst problems with an air conditioner will start slowly and gradually lead to more costly issues down the line, yet time and money can be saved when such issues are identified sooner. Trouble is, the management at certain facilities fail to record and evaluate data on system operations. Without that knowledge, it’s hard to spot inconsistencies in system patterns.

The secret here is to collect data on system performance on a regular basis to determine the range of behaviors that characterize a fully functional air system within a given setting. Readings should be taken at various points along the system, including the compressors, aftercoolers, receivers, filters and pneumatic tools. Once the accepted patterns have been established, deviations in performance can serve as red flags of potential system issues. Most importantly, information should be gathered of how a compressor normally operates at full load.