Sir

I seek you support and guidance on a trouble shooting.

1. 
   

    The problem – Condensate at the point of use in an air system that uses a correctly sized refrigerated air dryer – With considerations to compressor FAD, inlet air pressure, inlet air temperature, ambient air temperature and required pressure dew point. There have been no compromises in this aspect.
   
   

   
   


2. 
   

    The system – A 300 HP air cooled screw compressor followed by an on line particulate and coalescing pre-filter followed by a correctly sized refrigerated air dryer followed by a 5000 Liters air receiver. The dew point recorded is a consistent 3 Deg C.
   
   

   
   


3. 
   

    My analysis – The dew point in the microprocessor based controller of the air dryer is a consistent 3 Deg C and there is no evidence of condensate in the 5000 Liters air receiver. The application is operation of bag filters and a few low air requirement applications. The site has a 500 Liters air receiver that works in series and is located after the 5000 Liters air receiver. There is condensate in the 500 Liters air receiver. My logic is, by using a 500 liters air receiver downstream the 5000 Liters air receiver, there is a forced pressure drop and therefore drop in air temperature, resulting in condensation. However my this analysis does not sit with the client who claims he has a similar arrangement elsewhere and there is no condensate issue in that plant.
   
   

   
   

Please guide me on this trouble shooting and support me with inputs on the causes for the condensation that I can put forth.

Regards

Ram Hariharan

B.I.Marketing and Services Limited