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Can Your Compressed Air Dryer Cope This Summer?
As temperatures rise, your compressed air dryer has more work to do.
Warm air can hold more moisture than cool air, which means hotter and more humid conditions can increase the moisture load entering your compressed air system. At the same time, higher ambient temperatures can make it harder for a refrigerated dryer to remove that moisture effectively.
If the dryer cannot keep up, you may start to notice water downstream, reduced dryer performance or, in some cases, high-temperature alarms and shutdowns.
For businesses that rely on clean, dry compressed air, these problems can affect pneumatic equipment, processes and production.
So, before the warmer weather puts additional pressure on your system, there are a few things worth checking.
Why does summer affect compressed air dryers?
Compressing air concentrates the moisture naturally present in the atmosphere. As the compressed air cools, some of this moisture condenses into liquid water.
Your compressed air system uses components including aftercoolers, separators, drains and dryers to manage and remove this moisture before it reaches downstream equipment.
During warmer conditions, the amount of moisture entering the compressor can increase. Refrigerated dryers may also have to operate in higher ambient temperatures while processing warmer compressed air.
A correctly selected and well-maintained dryer should manage the conditions it was designed for. Problems can arise when operating conditions exceed its capacity, airflow is restricted or maintenance has been overlooked.
1. Is your dryer correctly sized for your compressed air system?
Dryer selection involves more than matching the unit to your compressor’s nominal flow rate.
The dryer also needs to suit the conditions in which it operates. Factors such as compressed air flow, inlet air temperature, ambient temperature, operating pressure and the required air quality can all affect dryer performance.
If operating conditions have changed since the dryer was originally selected, its effective capacity may no longer suit the system.
This can be particularly relevant if you have:
- Increased compressed air demand
- Installed additional equipment
- Upgraded or replaced your compressor
- Changed operating hours or production requirements
- Relocated equipment
- Experienced recurring moisture problems during warmer weather
If moisture only becomes a problem when demand or temperatures increase, it may be worth reviewing whether the dryer still suits the application.
2. Is your dryer getting enough ventilation?
Where your dryer is installed can have a significant effect on its performance.
A hot, confined or poorly ventilated compressor room makes it harder for air-cooled equipment to reject heat. During summer, this can become more noticeable as ambient temperatures rise.
Keep ventilation openings clear and make sure the dryer has sufficient space around it for airflow. Heat generated by compressors and other equipment also needs somewhere to escape.
Where compressor rooms regularly become excessively hot, improving ventilation or ducting hot air away from the room may help manage the overall operating environment.
3. Are the condenser and ventilation areas clean?
Dust and debris can restrict airflow through a refrigerated dryer’s condenser and reduce its ability to dissipate heat.
This is particularly important in dusty workshops and industrial environments, where contamination can build up quickly.
Regular inspection and cleaning can help maintain airflow and reduce unnecessary strain on the dryer. The appropriate maintenance interval will depend on the equipment, operating environment and manufacturer recommendations.
A dryer working in a clean, well-ventilated compressor room will generally face very different conditions from one operating in a hot or dusty area.
4. Do you have the right filtration?
Dryers and filtration perform different roles within your compressed air system.
Depending on the application and required air quality, filters can help remove particulates, oil aerosols and other contaminants from the compressed air. Correct filtration can also help protect downstream equipment and support the performance of the wider air treatment system.
Filter condition is important too. As filters become contaminated, pressure drop can increase and system efficiency can suffer.
The filtration arrangement should suit both the dryer and the air quality requirements of your application rather than being treated as a one-size-fits-all solution.
5. Are your drains working correctly?
Removing moisture from compressed air is only part of the process. The condensate also needs to leave the system.
Automatic drains are commonly fitted to components such as receivers, filters, separators and dryers to discharge accumulated condensate.
A blocked, failed or poorly functioning drain can allow water to build up and contribute to moisture problems downstream, even when other parts of the system are operating correctly.
Checking drain operation should form part of regular compressed air system maintenance.
6. When was your dryer last serviced?
Like your compressor, your air dryer requires regular maintenance.
The work required will depend on the dryer type, manufacturer and operating conditions, but routine servicing gives technicians an opportunity to check the condition and operation of the equipment before smaller problems become more disruptive.
For refrigerated dryers, this may include checking:
- Condenser condition and airflow
- Operating temperatures and pressures
- Refrigeration performance
- Automatic drains
- Filters
- Electrical components
- Alarms and controls
- General operating condition
Maintenance is particularly important when equipment operates in hot, dusty or demanding environments.
Signs your compressed air dryer may need attention
Water in your compressed air system is one of the more obvious warning signs, but it isn’t the only one.
You may also notice:
- Moisture at downstream equipment or points of use
- Higher-than-normal dryer temperatures
- High-temperature or other dryer alarms
- Frequent dryer shutdowns
- Poor or inconsistent dew point performance
- Increased pressure drop
- Drains that are not discharging correctly
- A noticeable change in dryer operation during hotter weather
These symptoms do not necessarily mean the dryer itself has failed. The cause could sit elsewhere in the system, which is why looking at the complete compressed air installation is important.
Don’t wait until water reaches your equipment
Moisture can contribute to corrosion, affect pneumatic equipment and interfere with processes that depend on clean, dry compressed air.
If your dryer struggled last summer, you have increased your compressed air demand, or you are starting to notice moisture downstream, it is worth having the system checked before the hottest conditions arrive.
At Nessco Pressure Systems, our team can inspect and service compressed air dryers as part of your wider compressed air system. We can also review filtration, drains, ventilation and system requirements to help identify the cause of ongoing moisture or dryer performance problems.
Call our service team on 1300 290 638 or contact us to discuss your compressed air dryer servicing or system requirements.
