Adding A Tank To An Air Compressor

Air Compressor Tank Augmentation: A Practical Guide

Modifying an air compressor by adding a secondary tank can extend its operational capabilities. This process, while seemingly straightforward, demands careful consideration of several factors to ensure safety and optimal performance.

Understanding Compressor Limitations

Many smaller air compressors feature limited tank capacity. This can result in frequent motor cycling, particularly when powering tools with high continuous air consumption. Adding a tank essentially increases the total air reservoir, mitigating the cycling frequency. The original compressor unit's specifications are crucial for determining the suitability of adding a tank.

Tank Selection and Compatibility

The selection of an appropriate secondary tank is paramount. It must be rated to withstand the maximum pressure output of the existing compressor. This pressure rating is typically expressed in pounds per square inch (PSI). Employing a tank with a lower pressure rating than the compressor's output is a significant safety hazard.

Tank material is also a consideration. Steel tanks are common, but aluminum tanks offer weight advantages and corrosion resistance. Regardless of the material, ensure the tank is ASME (American Society of Mechanical Engineers) certified. This certification indicates that the tank has met specific design and manufacturing standards for safety and reliability.

Essential Components for Integration

The connection between the existing compressor and the auxiliary tank requires several key components. These components manage air flow and ensure safe operation:

• Check Valve: This valve prevents backflow from the auxiliary tank into the primary compressor tank when the compressor is not running.
• Pressure Relief Valve: A critical safety device that releases air if the pressure in the system exceeds a safe limit. The pressure relief valve should be set slightly above the compressor's operating pressure but below the tank's maximum pressure rating.
• Pressure Gauge: Allows for monitoring the pressure within the auxiliary tank.
• Air Hose/Fittings: High-pressure-rated air hose and appropriate fittings are necessary to connect the components. Ensure the fittings are compatible with the hose and tank connections.
• Thread Sealant: Teflon tape or pipe dope is essential for sealing threaded connections and preventing air leaks.

Plumbing and Connections: A Step-by-Step Approach

The connection process generally involves these steps:

1. Depressurize the Compressor: Before beginning any work, completely depressurize the existing compressor tank. Disconnect the power supply.
2. Install the Check Valve: Connect the check valve to the outlet port of the existing compressor's tank. The check valve should be oriented to allow airflow from the compressor to the auxiliary tank.
3. Connect the Air Hose: Attach a high-pressure air hose to the outlet of the check valve. Use appropriate fittings and thread sealant to ensure a leak-free connection.
4. Prepare the Auxiliary Tank: Ensure the auxiliary tank has ports for the air hose connection, pressure relief valve, and pressure gauge. Install these components using thread sealant.
5. Connect to Auxiliary Tank: Connect the other end of the air hose to the auxiliary tank's inlet port.
6. Install Pressure Relief Valve and Gauge: Install the pressure relief valve and pressure gauge on their designated ports on the auxiliary tank.
7. Leak Testing: After all connections are made, slowly pressurize the system. Use a soap-and-water solution to check for leaks at all fittings and connections. Tighten any leaking connections as needed.

Electrical Considerations

Adding a tank does not typically necessitate electrical modifications unless the compressor is being upgraded to a more powerful unit. However, ensure the existing electrical circuit can handle the compressor's amperage draw. Consult the compressor's manual for its electrical specifications.

Safety Precautions

Safety is paramount when working with compressed air systems. The following precautions should always be observed:

• Eye Protection: Always wear safety glasses or a face shield when working with compressed air.
• Pressure Testing: Perform a thorough pressure test after making any modifications to the system.
• Regular Inspections: Regularly inspect the tank, hoses, and fittings for signs of wear or damage.
• Proper Ventilation: Ensure adequate ventilation when operating the compressor, especially in enclosed spaces.
• Emergency Shut-Off: Know the location of the compressor's emergency shut-off switch.
• Never Exceed Pressure Rating: Never exceed the pressure rating of any component in the system.

Performance Evaluation

After adding the auxiliary tank, monitor the compressor's performance. Note the time it takes to reach its maximum pressure and the frequency of motor cycling. The added tank should reduce the cycling frequency and provide a more consistent air supply. Documenting these performance metrics can help identify any issues or areas for further optimization.

Potential Problems and Troubleshooting

Several problems can arise after adding a tank:

• Leaks: Air leaks are the most common problem. Thoroughly inspect all connections and fittings. Reapply thread sealant if necessary.
• Check Valve Failure: A faulty check valve can allow backflow, reducing the effectiveness of the auxiliary tank. Replace the check valve if necessary.
• Pressure Relief Valve Activation: If the pressure relief valve activates frequently, it could indicate over-pressurization or a faulty pressure switch in the compressor unit. Investigate the underlying cause and rectify.
• Reduced Compressor Efficiency: In rare cases, adding a significantly larger tank could strain the existing compressor motor. Monitor the motor's temperature and ensure it is not overheating.

Code Compliance and Local Regulations

Before making any modifications to an air compressor, research and comply with all applicable local codes and regulations. Some jurisdictions may have specific requirements for compressed air systems, including tank certifications and installation procedures. Failure to comply with these regulations can result in fines or other penalties.

Concluding Remarks

Adding a secondary tank to an air compressor can be a beneficial modification, but it demands a meticulous approach. Proper tank selection, careful plumbing, and adherence to safety precautions are essential. Prioritize ASME-certified tanks, use high-pressure-rated components, and always test for leaks after installation. By following these guidelines, you can enhance your air compressor's performance while maintaining a safe and reliable system.

Key Takeaways:

• Tank pressure rating must exceed compressor output.
• ASME certification is crucial for tank safety.
• Proper plumbing with check valve, pressure relief valve, and gauge is mandatory.
• Thorough leak testing is essential.
• Adhere to all safety precautions and local regulations.