Air Dryer Maintenance Checklist: Why is It Necessary?
Has your air compressor started acting up every now and then?
Do you feel that the performance of your air dryer has declined?
Like every machine, air dryers require maintenance too.
Sometimes a part requires adjusting and sometimes you might need to replace a part. If taken care of at the right time, you can save up time and money otherwise spent on major fixes that result from lack of maintenance.
And especially, in the humid and hot weather of the United Arab Emirates, running an air dryer maintenance checklist is crucial to ensure smooth functioning.
It is necessary to pay extra attention to the air dryers as the air compressors need dry compressed air to work at optimum capacity. In case of any blockage or fault, the air dryer will not do you any good.
In this blog, we’ll explore the importance of regular air dryer maintenance especially during summers, the air dryer maintenance checklist, and the consequences of not doing not using dry compressed air.
Why do we need to dry compressed air?
The atmospheric air entering into a compressed air system comprises of a mixture of gaseous contaminants which always has some content of water in the form of water vapors. However, the amount of water vapor that air can carry varies and is mostly dependent on temperature.
As the temperature of air increases, which is common during summers, so does its ability to hold water – resulting in more humidity. However, when air is cooled it becomes capable of holding significantly less moisture – resulting in low humidity and condensed vapors.
The condensed vapors are then removed through a centrifugal separator and an automatic drain, or the air receivers’ automatic drain.
But the problem doesn’t end here and that’s where the air dryer comes into action!
It helps to control the humidity of the air, and spare businesses the unwanted costs associated with compressed air system failure, production downtime and repair and fixing.
In case you are wondering if location of the air compressor affects air dryer performance, it does.
Even though air dryers help control the humidity of compressed air systems, placing them in cooler locations definitely helps as it results in better and more efficient performance.
The air dryer maintenance checklist you must follow
Generally, the assistant engineers are responsible for running the air dryer maintenance checklist, and the head of the engineering department is accountable for the implementation of it.
Before starting the air dryer maintenance checklist, assistant engineers must do the following things.
- Notify all concerned individuals before running the air dryer maintenance checklist.
- Confirm that the respective machine is not functioning.
- Ensure that the electrical supply is disabled temporarily.
- Put up a display board saying "UNDER PREVENTIVE MAINTENANCE" on the electrical panel and air compressor so that everyone is well informed.
Run the following air dryer maintenance checklist one by one.
- All electrical terminals of the main supply and machine panel are functioning smoothly.
- No blockage in the pre-line filters.
- Gas pressure of the refrigeration unit at pressure gauge. Check if the pressure gauge is functioning properly.
- No gas leakages in condenser coils and pipes. Use soap solutions to identify and fix them.
- Solenoid valves are correctly draining the condensed water.
- Exhaust fan and motor properly working.
- Temperature controller working correctly.
- Restart and run the air dryer machine in all modes.
- Observe and fix any unusual noise in the air dryer machine.
What are the consequences of not using dry compressed air?
Moisture is the biggest enemy of your compressed air systems!
If you think that not using dry compressed air will save you a few bucks, you couldn’t be more wrong!
We have compiled a list of issues you are likely to face if you don’t use dry compressed air.
Let’s have a look:
Rusting
Increased moisture in the compressed air systems causes rusting of the essential components of the air dryer, such as the air pipes and valves which leads to loss of energy and doesn't allow the compressed air systems to work at their optimum capacity. Rusting is common in humid weather, so you need to take extra care in the humidity-hit United Arab Emirates.
Once your machine starts getting rusted, know that you’re in trouble. If you notice any signs of rusting, take immediate action and only trust a professional to help control the rusting of your air dryer.
Lower performance
Due to the high moisture content, the compressed air systems function poorly and affect the performance of the air dryer. For spray painting applications, the quality of the finish such as the color, adherence and finish of the paint are compromised – resulting in bad quality products, which means frequent complaints from the customers!
These bad quality products get rejected and also affect your sales and profit margins. Why take that risk?
Jeopardized process
Not using dry compressed air can affect the functioning of pneumatic controls. These controls can malfunction due to rust, scaling, and clogged orifices which can lead to unwanted disruptions and even a sudden halt in the business operations altogether!
You don’t want your machine to just give up in the middle of work. With regular maintenance, the chances of unexpected issues are minimized.
Incorrect readings
Abnormal air content and temperatures in the compressed air systems sometimes lead to false or incorrect readings of instrumentation, which leads to interruption or even unexpected shutdown of plant processes.