How Does Humidity Impact Pneumatic Systems?

This will help to avoid breakdowns and ensure that your system continues to operate efficiently.

Understanding how heat and humidity affect pneumatic systems will help you address issues of condensation and excess moisture while minimising wasted energy. Start by following the OEM’s guidelines for the care and maintenance of your machinery and implement a preventive maintenance programme. In this way, you can extend the useful lifespan of your compressor and other pneumatic equipment.

Impact Of High Temperatures On Compressed Air Systems

A compressor draws in atmospheric air and compresses it to a higher pressure. At this stage, it still contains impurities and water vapour. Once compressed, the pressurised air is channelled into an aftercooler, which removes the heat generated by compression. As it cools, compressed air can’t hold on to large amounts of moisture, so the excess water vapour condenses. More condensation comes from further cooling via pipes and air dryers. The more the temperature rises, the more the ambient air will be influenced by this moisture and increased density levels. This can affect your compressed air system in the following ways:

Lower Air Density

Air density decreases in humid conditions, making your compressor less efficient. With less dense atmospheric air, the compressor has to work harder to produce the same amount of compressed air. This can put a strain on the pneumatic system and its components, as well as increasing energy consumption.

Increased Moisture

Hotter air often comes with higher humidity levels, which can cause moisture-related issues like condensation. Excess moisture in the air compressor system will accumulate in various places, such as filters, pipelines and air receivers. This will reduce the quality of the compressed air and can cause corrosion and other potential damage to downstream equipment.

Increased Contaminants

Along with humidity, higher temperatures tend to increase the quantities of airborne contaminants like pollen, dust and debris. If these contaminants get into the compressed air system, they can clog up filters and have a negative impact on overall performance.

More Frequent Oil Changes

A higher content of moisture and contaminants in the air can cause rapid deterioration of the oil in an oil-lubricated compressor. This will diminish its lubricating properties and may lead to potential damage to the compressor’s internal components. More frequent maintenance and oil changes will be required.

Some Effects Of Humidity On Pneumatic Systems

We’ve seen that these issues can force your compressor to work harder in higher temperatures. Some negative consequences of heat and humidity on air compressor systems include:

Reduced Efficiency

Ambient heat and humidity will make your compressed air systems less efficient, and create the risk of problems, including clogged filters. This can lead to pressure drops and strain on your pneumatic system, increasing its power consumption as it works harder to maintain operational efficiency.

More Frequent Maintenance

You need to reduce the intervals between scheduled maintenance when it’s very hot or humid. This will probably mess up your scheduling, but it’s critical to prevent equipment failures and ensure continuing efficiency. Otherwise, you’ll be looking at more downtime, disrupting operations and productivity and incurring greater costs.

Equipment Damage

The worst case scenario is that your compressor and its components can be damaged through excessive strain or overheating. You’ll likely get components failing, which will require expensive repairs or replacements.

How To Reduce The Impact Of Humidity On Compressed Air Systems

Having considered the causes and effects of humidity on pneumatic systems, it’s vital that you take preventive measures to reduce them:

Check The Ventilation

The room where your compressor is situated must always be well-ventilated, especially when the temperature begins to climb. To prevent humidity and overheating, you can install air conditioning or fans to maintain an appropriate working temperature for the compressor.

Check Coolers And Filters

Low coolant levels can make your compressor overheat, causing breakdowns or potential damage, so always keep them topped up. Ensure filters are clear of contaminants with regular checks, cleaning and, if necessary, replacement.

Clear Accumulated Condensate

The condensate drain is an important part of your compressed air system. After cleaning filters and/or dryers, you must be sure that any condensate is expelled from the system. If the collected condensate isn’t discharged, it will attract more particles of water and/or oil. This in turn will reduce the efficiency of your filters, carry contamination into the system and could freeze up in colder temperatures. Drains blocked by condensate debris can get stuck in the open position, causing a lot of energy wastage.

Clean The Cooling System

The cooling system – compressors and air dryers – should always be clean and unobstructed, so you need to be sure all dust or debris is removed from the cooling fins. You might also think about adding an air compressor cooler to maximise the efficiency of your cooling system.

Check Pressure Settings

Your compressor will probably be working harder in higher temperatures to maintain the necessary pressure levels. You should check the pressure settings and adjust them if necessary, to ensure optimal energy efficiency and performance.

Check Dew Point Settings

If you’re using an air dryer, check its dew point setting to ensure it’s set to the correct level for your application. Higher dew points may be acceptable in higher temperatures, which can help to reduce your energy consumption.

Monitor For Leakage

Make sure you check regularly for any air leakage in your pneumatic system, and fix it promptly. Leaks are a significant cause of energy wastage, which increases your costs.

Implementing these preventive measures will help reduce the impact of excessive heat and humidity on your pneumatic system. In this way, you’ll get better performance, greater efficiency and a longer lifespan for your compressor and operating equipment.