Preventing corrosion in your compressed air network

Corrosion, also known as rust or oxidation, is a natural process that occurs when untreated metal comes into contact with corrosive elements such as oxygen, hydrogen, or water. Over time, this process deteriorates the metal, compromising the integrity of your compressed-air network.

Corrosion in compressed-air systems primarily occurs due to exposure to water, which contains both hydrogen and oxygen. Water is especially problematic as it accelerates the corrosion process. Protective coatings and treatments can help, but water often finds a way into your system, leading to problems. Therefore, eliminating moisture and condensation is the key to preventing corrosion.

Removing moisture from your compressed-air system is the first step in preventing corrosion. Here are some effective strategies to remove water and prevent it from reaching your pipes:

• Draining Tanks Regularly: Drain the air compressor tank after each use to remove condensation. This can be done manually or with an automatic condensate drain valve.
• Store in a Dry Area: Store your air compressor in a dry, well-ventilated area to reduce exposure to humidity.

Installing specific equipment can greatly reduce the chances of corrosion:

• Cyclone Separators: A cyclone separator with an automatic condensate separator can be installed directly in the compressor or downstream of it. It is highly effective at removing moisture.
• Aftercoolers: Aftercoolers can be used to cool compressed air, causing water vapour to condense, which can then be removed before it enters the system.
• Compressed Air Dryers: Use a cooling or adsorption dryer to remove moisture from the compressed air. This is a highly effective way to prevent water build-up in the network.

Reliable piping systems such as AIRnet Aluminum can help prevent corrosion by providing durable, leak-proof connections. Aluminum pipes are corrosion-resistant, unlike steel pipes that are more prone to rust.

Routine checks and maintenance play a crucial role in preventing corrosion:

• Regular Tank Draining: Draining the air compressor tank regularly helps prevent water accumulation that can lead to rust.
• Apply Rust Inhibitors: Rust inhibitors can be applied to the inside of the tank to provide an extra layer of protection.
• Keep the Tank Pressurised: Keeping the tank pressurised when not in use can help reduce rust formation.
• Use the Right Oil: Use an air tool oil that is specifically designed to lubricate internal parts without causing corrosion or build-up.
• Maintain Filters: Keep filters clean and replace them when necessary to prevent moisture and impurities from entering the system.

For facilities that rely heavily on their compressed-air systems, advanced maintenance techniques can help in early detection of corrosion or other issues:

• Ultrasonic Testing: Ultrasonic testing helps detect thinning of pipe walls or tanks before leaks or breaks occur.
• Vibration Analysis: This technique helps identify mechanical issues within the compressor that could lead to excess moisture or corrosion if left unchecked.