APPENDIX II
AIRFLOW TROUBLESHOOTING
Chikezie Nwaoha
Control Engineering Asia, Ten Alps Communications Asia, Aladinma, Nigeria
Many industries utilize air for production purposes, as in
mixing, pressurizing, atomizing, and agitating applications.
Applications include oil and gas, food, pharmaceutical,
and others. By managing compressed-air systems and
controlling airflow in such scenarios, users can improve
production efficiency by up to 50%. Compressed air flows
as a result of pressure differential (Fig. II-1). This implies
that pressure drop is the major cause of insufficient airflow.
To maintain adequate airflow, much attention should be
focused on the pressure losses that are caused by obstacles
in the compressed-air systems [1].
II.1 COMMON OBSTACLES TO PROPER
AIRFLOW
Obstacles in a compressed airflow system alter the pressure
of the flowing air. As the push to optimize production
continues, it becomes imperative for production personnel
to identify and combat such problems.
1. Air quality. Air cleanliness affects the airflow
required. Atmospheric air contains a large amount of air-
borne contaminants: dust, dirt, water vapor, and in an
oil-related industry, oil vapor in the form of unburned
hydrocarbons. In many applications, dirt and dust parti-
cles can pass through the air compressor and gradually
form deposits on the interior surface of the compressor.
As these deposits accumulate, friction increases and the
compressor loses it ability to generate the head required for
airflow [2].
Process Plant Equipment: Operation, Control, and Reliability, First Edition. Edited by Michael D. Holloway, Chikezie Nwaoha, and Oliver A. Onyewuenyi.
© 2012 John Wiley & Sons, Inc. Published 2012 by John Wiley & Sons, Inc.
While many operators are concerned about the risk
of dirt and dust particles, oil vapor and water vapor in
the airstream also pose a problem. During compression,
oil and water vapor escape with the compressed air,
and after compression the air is cooled in the interstage
cooler, resulting in condensed vapors. If this condensate
is not removed, it causes corrosion and blockage to
the compressed-air systems, hence reducing airflow and
production efficiency. To prevent this, filters must be
located properly in the system, and an interstage cooler with
automatic drain traps must be fitted to the air compressor.
2. Air compressor type and operation. The air compres-
sor can also be an obstacle to airflow. Air compressors
make use of lubricating oil for sealing and lubrication and
use cooling water (mostly applied) for cooling (Fig. II-2).
During operation, cooling water and lubricating oil may
seep into the compressed air as a liquid or aerosol. The
resulting leakage causes contamination problems similar to
those of condensed oil and water vapors [1]. The type of
compresssor also affects proper airflow. A turbine-driven
air compressor, for example, utilizes more lubricating oil
and cooling water for operation than does an electrically
driven compressor, so a turbine-driven compressor is more
susceptible to lubricating oil and/or cooling water seepage.
3. Improper configuration of distribution systems. The
main objective of proper sizing and configuration of
distribution systems is to transport the maximum expected
volumetric airflow from the compressor to the point
of use with minimum pressure drop. Poor distribution
system configuration can lead to insufficient airflow, and
659
660 AIRFLOW TROUBLESHOOTING
Figure II-1 Newly installed air compressor. (Courtesy of Port
Harcourt Refining Company, Nigeria.)
TABLE II-1 Troubleshooting Insufficient Airflow [1]
Airflow Problems
Low air pressure at point of use
Is the distribution piping leaking?
Is the filter element clogged?
Is the pressure regulator faulty or not installed properly?
Is the air receiver leaking?
Liquid in the air lines
Is the drain trap too small?
Is the air compressor cooling system leaking?
Is the drain trap clogged?
Is the compressed air dryer undersized or faulty?
Is the compressor sealant leaking?
Low air pressure at compressor discharge
Is the suction pressure adequate?
Is it leak free?
Is the discharge valve worn out?
Is the air capacity system adjusted improperly?
Dirt or scale in the air lines
Is the filter application correct?
Is the distribution piping aging or corroded?
Low air level in the receiver
Is the level indicator in good working condition?
Are the air compressor loading valves functional?
Is the air receiver leak-free?
Figure II-2 The author adjusting cooling water in an air
compressor. (Courtesy of Port Harcourt Refining Company,
Nigeria.)
Remedies
If so, refer piping for inspection and maintenance.
Clean the filter element.
Refer pressure regulator for maintenance, or check
manufacturer’s manual for installation procedures. If not,
install pressure regulators at various points in the system.
Request inspection. Check status and refer for repairs.
If so, install a properly sized drain trap.
Refer cooling jackets for maintenance, or install a new one.
Clean, repair, or replace the drain trap.
Check the status of the air dryer. Refer the dryer for
maintenance.
Refer for sealant replacement.
Maintain suction pressure.
Check the compressor for leakage. Refer for maintenance.
Install a new valve.
Refer to the manufacturer’s recommendation for adjustment
of air capacity systems.
Check the filter status, and install a proper-sized filter based
on the application.
Install a new distribution piping. Check for moisture content
in the airstream, and install a filter along the line.
Confirm status. Refer for repairs or install a new indicator.
Refer faulty valves for maintenance.
If so, request inspection and refer for maintenance.

thus affects the discharge pressure, robbing the user of
expensive compressed air power. This is not limited
to the interconnecting piping from the discharge of the
air compressor to the header. It also applies to the air
storage system and the distribution line conveying air
to production areas. To prevent this, international quality
standards and guidelines must be adhered to strictly when
sizing distribution systems [2].
II.2 TROUBLESHOOTING
Quickly diagnosing and correcting application issues will
help ensure that small problems don’t become big ones.
REFERENCES 661
Thus, it is important always to keep in mind the old truism:
“A problem identified is half solved.” Table II-1 provides
guidance on troubleshooting five common problems.
REFERENCES
1. Nwaoha, C., Airflow troubleshooting strategy: achieving
production efficiency through proper air systems maintenance,
Flow Control , vol. xv, no. 7, July 2009, pp. 28–29.
2. Nwaoha, C., Process optimization: controlling air flow, Steam
and Boiler Review , vol. 3, no. 11, November 2009, pp. 22–24.