Compressed air pipeline moisture is a common but serious phenomenon in many industrial environments. It can damage tools, inhibit processes, contaminate products, and lead to costly downtime. For engineers, plant managers, maintenance staff, and purchasing teams alike, the ability to be aware of, measure, and ensure water does not affect their operations is paramount to reliable operation. This blog outlines practical ways to consider managing moisture and highlights some useful equipment, such as compressed air filters, to maintain a dry and efficient system. 

Why Moisture is a Problem in Compressed Air Systems? 

Compressed air naturally contains water vapor. When air is compressed, the vapor becomes denser and forms liquid water. If not removed, this moisture can: 

1. Corrode pipes and tools 
2. Cause pneumatic equipment to fail 
3. This leads to poor product quality 
4. Increase maintenance and repair costs 

Detecting and managing this moisture early is key to maintaining a reliable compressed air system. 

Common Signs of Moisture in Compressed Air Lines 

You don't need high-tech devices to see warning signs. Look for:  

1. Water pooled in air lines or at outlets  
2. Rust or corrosion in piping  
3. Lack of air pressure or intermittent air flow  
4. A visible spray of water whenever you use air tools  
5. Routine maintenance of air-driven equipment  

These are obvious signs that show water is building up and needs to be addressed. 

Smart Ways To Detect Moisture in Compressed Air Systems 

1. Use Moisture Indicators 

Moisture indicators are a more low-tech means of monitoring humidity, and the moisture indicator level will indicate the air quality you are working with due to its changes in color, and provide some early indication of leaks or other issues. 

2. Use Pressure Dew Point Monitoring 

These types of sensors allow for the monitoring of the dew point of compressed air. The lower the dew point, the less moisture there is within a system, and if a dew point is rising, more water vapor is present. 

3. Conduct Regular Visual Inspections 

Inspect drain points, filters, and lines for moisture. This drastically easy, visual inspection is a really good way of detecting moisture ahead of time and solving issues before the moisture leak, etc., takes place. 

Effective Ways to Prevent Moisture in Compressed Air Lines 

1. Use Good Compressed Air Filters 

One of the best ways to get rid of moisture, oil, and other contaminants is with compressed air filters. Use the right filters for your system's air pressure and flow rate. 

2. Inject Sintered Filters 

Sintered filters are porous metal structures that can effectively trap water, oil, and particles in the compressed air stream. They are very robust, can withstand high pressures, and operate well in harsh environments. 

3. Buy Air Dryers 

Here are a few types of dryers:  

1. Refrigerated dryers: Good for most industrial applications 
2. Desiccant dryers: Ideal for environments that will require very dry air 
3. Membrane dryers: Compact and require very little maintenance 

Select the dryer based on moisture levels and your operational needs. 

4. Use Automatic Drain Valves 

Drain valves act to remove collected water in filters, receivers, and tanks. If the drain valve is automatic, that reduces manual effort and achieves consistency in removing moisture. 

5. Keep Piping Layouts Efficient 

Poor design of the piping can contribute to moisture getting into the compressed air stream. Sloped piping, drop legs, and drain points should be installed to get the water out of the air system. 

In The End 

Moisture in compressed air lines can have an extremely detrimental impact on your performance and safety. Fortunately, with the right equipment, such as compressed air filters, sintered filters, and air dryers, you can detect and prevent moisture. 

For engineers, plant managers, and maintenance people, the best form of moisture detection and prevention is always proactive detection and prevention. Therefore, performing these tasks leads to more efficient production with less downtime and maintenance costs.