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Upgrading air compressor plumbing, any advice?

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Strouty

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Thank YOU for making this awesome thread for all of us to follow! :beer:

I hope more people post in this thread, I am learning as I go, but it has been a great project.

Strouty, thanks for the welcome.
Sorry to here about the stone issue.
Hope your doing ok and all is well.


Hopefully you will find lots of great info on this forum! As for the stones, I am doing OK, but when I get too active it feels like someone punched me in the kidney. Of course I have not yet had the experience of the exit.

:lol_hitti
 
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MTW

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Hi all, new to The Garage Journal.

It’s nice to see people so passionate about their interests, hobbies and work. Really enjoyed reading this thread, especially MTW’s posts, very educational.

I am wondering about 2 things:

• At the beginning of this thread, it was about installing a better plumbing system that would help to eliminate the accumulation of water in the piping system. MTW mentioned a good black iron pipe system installed properly would help considerably at eliminating this problem. He seems to imply the more pipe used in the system, the better for the radiator effect. Ok, this makes good sense.

Strouty, then runs with this information and installs his system, but installs it in
isolated sections. Each section is insulated from the other through a rubber hose.

Correct me if I’m wrong here, but this seems to defeat the whole purpose of
building a continuous metal piping system that creates the radiator effect in order
to dissipate the heat.

Would it have been better to use back to back 90 degree ells swiveled into place
bringing the vertical drops back into the plumb position? At least it would have
kept a continuous metal pipe thus making for a better radiator.
(Just my 2 cents)

• MTW has been drilling and tapping metal piping systems at various locations and
plugging as needed.

Again, correct me if I’m wrong, but this practice seems a little dangerous. I
realize for the most part he is just trying to salvage a bad installation, but I don’t
think the pipe is made to be drilled / tapped like that especially as thin as it is
and still maintain its structural integrity and PSI rating.

Well, don’t mean to come off sounding a little like sberry…LOL. I think this entire thread is great, and very educational.

Strouty, keep up the excellent work. I think your system is great; I just personally would lose the red rubber segments and find a way to keep it all metal. Either way, a great system. Looking forward to seeing it fully automated.

Hydraulic/Rubber Hose. Hose is OK to use, but not preferred. We all use hoses in our systems, but they are a failure point. Cost is the main factor for most home setups. The industrial solution is metal hose, sometimes called a flexible coupling, there are pictures of these in the photos posted. There a high dollar item, but have never seen one fail, even when attached to a compressor actually vibrating. Hydraulic hose is a good choice since it is metal reinforced, as is steam cleaner hose, and not too hard to find. Rubber/vinyl composition is all over the map. For any permanent flexible systems connection use the best that you can find, so that you can reduce failures and leaks as much as possible. Good hose is heavily reinforced, with tough fibers, and oil resistant. I advise that you don't use vinyl. For the **** type, look for 600 PSI rating, that will get you a hose that is sure to last.

Using hoses to allow for piping slope. I believe, I covered this earlier but to reiterate. My preferred method to achieve the the small bend (kick) is to hang the trunk from the ceiling instead of the wall. Point tee's down, and use back to back ell's to offset to the wall. Don't point tee's to the wall and then use one ell down, this will trap some water in the bottom of the tee, with iron fittings. In a garage you may be able to place the trunk on the top of a truss, or hang it from the rafters, and keep it out of sight.

To the heat insulating effect of short sections of hose. This is really a moot point. The small loss of radiating surface is minimal and can be neglected. The remainder of the pipe is still conducting effectively. Make sure that the hose slopes just like the pipe, so that you don't create a trap. You use rubber hose on your daily driver radiator, enough said.

Tapping Ports. Use at your own risk. I don't know of any engineering standard or codes on this, but have seen it many times inside pieces of industrial equipment. I only use this for test ports or the drain manifold, in small sizes, never for a point of use connection. There are different thickness of pipe, schedule 40 (SCH40) is the standard, SCH80 is much better wall thickness for the threads, but only available at industrial suppliers. 1/8" NPT is much finer thread and engages much better. 1/4" NPT is the largest you want to go, coarser thread. Anything else needs a fitting installed. When tapping, I make a tight accurate hole, and only run the tap in partially to keep things tight and leak free. Again for the **** type, weld in a coupling, as a bulletproof solution. Cut a coupling in half, drill a hole in the pipe and weld it on, observe which way the pipe taper is facing. By the way I use this method on the side of my auto transmission pans, for a convenient drain port.

As a side note about building a drain manifold. While at the big box store I saw a header manifold made from swedged copper, intended for plastic plumbing connections, I made a mental note to try one of these on another build. Looked to be adaptable for the purpose with less work, and non rusting.

I'm glad to see continued interest in this thread, Thank Strouty for getting it going, and Sberry for keeping it down to earth. Post your comments, builds and results so that others may learn from you too.

MTW ;)
 
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Strouty

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Nice to hear from you again. So far it works exactly as you described. I made one mistake on my plumbing and need to fix it. My 1/2" air reel takes off from an end run and it takes water, the 3/8" one is taking off the top and it does not seem to have any issues. I too was thinking about a manifold setup like you are talking about. My next project is the automatic drain or at least some sort of collection system, it gets messy when I drain the system right now. My plasma cutter works so much better than it has ever worked. That was the original reason for doing this, so at least I have met my goal. My water separator actual has water in it as well, first time I have had anything except vapor in it.
 

MTW

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Glad to hear that the advice worked for you. Making mistakes is one of the best ways to learn, when learning this way you tend not to forget what you learned. The other great way to learn is from the mistakes of others (experience), learn to be observant, it's a lot cheaper too.

Hope you pass that stone soon, I've heard it can be painful, good luck with it.
 
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Strouty

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Glad to hear that the advice worked for you. Making mistakes is one of the best ways to learn, when learning this way you tend not to forget what you learned. The other great way to learn is from the mistakes of others (experience), learn to be observant, it's a lot cheaper too.

Hope you pass that stone soon, I've heard it can be painful, good luck with it.

I wish I had 1" plumbing right now.
 

wehtjns

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Nice artistic talent (comment for Jimmythemonkey),, ;) Thankfully it looks better now completed.
 

Firebrand

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Thanks to all the posters in this thread! This is quite possibly one of THE most informative threads on this Forum!! Just because a plan is formed by conventional wisdom doesn't make it the best solution to the problem. If everyone always relied on that 'wisdom,' we'd never have sailed the oceans to the New World because the Earth was deemed flat by localized conventional wisdom. Expecting the different results from the same methods is considered a mild form of insanity by many experts in that field.

For my own applications, I am seeking to maintain a quality of dry compressed air for the usual garage applications, but also for another form of flying in the face of conventional wisdom--snowmaking at home in New Hampshire! Many locals think I'm around the bend crazy for building a home system given that we typically receive anywhere from 6 to 14' of snow in a Winter season. My issue is that I would like to start my family Winter activities as soon as temps permit, rather than waiting for Mother Nature to send the snows. So here's my basic system components:

Air comes from my Champion VR5-8 which is a 5hp 1Ø 2-stage pump making 18CFM at 150psi...
11615136874_010c8cf2d8_b.jpg


Of which I only need 85psi (about 20CFM) to run this custom fan gun...
12197580625_48b587c160_b.jpg


12197989324_a4614a1d86_b.jpg


12197996924_d8aa9680e0_b.jpg


This is the extent of my current air plumbing...
11614796065_a32fd72def_b.jpg


My snowmaking airlines are actually comprised of several elements: 1. 1" Fire hose (50' lengths) with 1" cam lock connectors; followed by 2. 5/8" rubber garden hose fitted with 1" cam lock connectors which mate to the fan gun and my simpler tower guns. I use the fire hose first since this has been a way to get the moisture to freeze out of the air along the first length and not plug up the later runs of hose. Needless to say I would like to add a finned-copper pipe cooler BEFORE the regulator and first fire hose length; thankfully I have a 20 section that I removed when installing some 1000 square feet of radiant flooring in the house that should make a nice compact radiator to be hung near the compressor station. Also, I need some drops inside my 2.5 car garage located just to the left of the compressor station for the usual functions. Already have the 3/4" hydraulic hose parts to make the drops plumb along with a 3' snubber for the compressor to cooler connection.
 
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Strouty

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Making snow in your back yard in New Hampshire. I think this should be in the WTF thread. All joking aside, I would love to see the final product as well as any steps in between. The more that gets posted, the more info people have.
 
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Strouty

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I am back at it again, I need to relocate my compressor and I have to add on to my existing system. This should be fun, last time I had help, this time I may be all alone. I would like to report that the air is still nice and dry and that I really like everything so far. This summer will be the test, especially if it gets humid.
 

MTW

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Strouty,

Looking for a report back on effectiveness, its summer now, have you had some real humidity yet for a real evaluation? GJ'ers want to know.
 
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Strouty

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I have not had a lot of humidity yet, but I it is early for us in Maine. I will say that there is always water in the drains, except the one farthest from the compressor. Just as you said, I have yet to ever see it wet.

I have another compressor I am hopefully going to be plumbing up this summer.
 

Steeltech

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This thread is awesome! Such a wealth of information for someone like myself in the planning stages. Thank you to everyone for sharing and especially for showing examples of the work you have done. The pictures have really helped to get the ideas across.

What do you guys think of the rapid air aluminum/pex style air distribution systems currently available? I don't have any plumbing tools at all and believe that by the time I purchase the pipe, fittings, and tools (pipe threader) to get the job done, I may be better off investing in this new style setup. The more expensive 3/4 line is aluminum wrapped in some sort of polymer. Do you think that it would have sufficient conductive properties to help cool the air as opposed to the smaller 1/2 air line that appears to be all plastic like PEX rated for airline pressure. The billet aluminum manifolds can be really expensive but make for a very clean installation when all is said and done. Am I correct in thinking that black pipe, or even copper for that matter really isn't that cheap?

I picked up a two stage 60 gal Ingersoll Rand lately that needed a flywheel. Still working on getting it hooked up and finally sourced the flywheel for less than the $300 some places quoted me. I plan on Sand blasting and HVLP use so I'm doing my research in ridding the air of water for when I install everything. Florida humidity makes this especially important.

I wonder about the sloping directions discussed in this thread. I definitely see merit in the design suggested by MTW and employed by Strouty. At the same time, I'd rather not have water in the tank at all, as that is really the most expensive piece of metal in the system to rust out. Otherwise, I see no value in using gravity to effectively assist water in traveling TOWARDS my air tools. So in that instance I like the idea of sloping backwards towards the air source.
 
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Strouty

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I wonder about the sloping directions discussed in this thread. I definitely see merit in the design suggested by MTW and employed by Strouty. At the same time, I'd rather not have water in the tank at all, as that is really the most expensive piece of metal in the system to rust out. Otherwise, I see no value in using gravity to effectively assist water in traveling TOWARDS my air tools. So in that instance I like the idea of sloping backwards towards the air source.

Glad you find the thread useful.

As for sloping the piping toward the compressor, as long as you have a drop before the compressor the water will never enter the tank. You will still get moisture in the tank regardless and you will need a drain for the tank. MTW has demonstrated to me that it is the best way to go. As I have stated before, I get water at the first drop, a little less on the next drop, barely any on the next one and the last one gets no moisture at all.

If you don't drain the lines and the tank on a regular basis, you will have moisture collecting in them. MTW has shown some interesting ways to automate it, but it can be done manually.

As for the rapidair setup, I am sure it would cool the air enough to get the moisture out. I only went with black iron because I felt it was the most durable way for me to go. I am going to have to move it around once I get my new compressor hooked up. I am not sure if it was much less than copper, but I had all the tools available to do the threading myself. The main point is to try and get the air to cool, so make sure you have at least 20' or more of the tube to help get the moisture out.
 

theoldwizard1

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If you don't drain the lines and the tank on a regular basis, you will have moisture collecting in them. MTW has shown some interesting ways to automate it, but it can be done manually.
Many years ago I was the evening assistant manager at a Sears auto center (glorified porter).

Every night after closing I had to drain the compressor. This compressor had twin motors (probably 7-10 hp each) and a 200+ gallon tank.

Even with a 1" - 1.5" valve it took more than 10 minutes for all the pressure to get out.
 
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Strouty

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Many years ago I was the evening assistant manager at a Sears auto center (glorified porter).

Every night after closing I had to drain the compressor. This compressor had twin motors (probably 7-10 hp each) and a 200+ gallon tank.

Even with a 1" - 1.5" valve it took more than 10 minutes for all the pressure to get out.


Also ear piercing.

That is what my new compressor is. I am going to try and automate the drains so I don't have to worry about the water. I do not think I will drain the air out of the tank, but I will have a nice disconnect for the power to the actual compressor.
 

Garagebound1

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I just purchased a new compressor. My old one was set to 125 psi max.the new one is 175 @shut-off. Can someone tell me should I regulate this down and to what pressure? I'm running die grinders, air impacts, air ratchets, etc. I never had one with the old system but I would assume a filter system might be advisable. Any reccomendations? Thanks.
 
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Strouty

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I just purchased a new compressor. My old one was set to 125 psi max.the new one is 175 @shut-off. Can someone tell me should I regulate this down and to what pressure? I'm running die grinders, air impacts, air ratchets, etc. I never had one with the old system but I would assume a filter system might be advisable. Any reccomendations? Thanks.

You would want to regulate it based on the tool recommendations, the manufacturer would usually state what they want as a maximum PSI.
 

Jurious

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Hi, I'm new to the forum. Looking forward to participating.

I'm setting up a compressor for home use (spraying auto paint), and I have to tell you -- WOW -- this thread has been the most informative I've run across. Thanks for sharing your experience(s), guys.
 
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Strouty

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Welcome to the forum Jurious, glad you could pull some info out of it. I will be updating the thread in the next month or so, because I got a different compressor. It will be good timing as the humidity will be back in the air.
 

devildog93

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Strouty, i noticed you said you were running a plasma cutter off of this. I am setting up my home shop to do exactly the same thing. I didn't see any air dryer or aftercooler, so i am guessing you are just getting the water out via water traps? As you stated earlier, you have no water in the last trap, so i guess mission accomplished the way it was done. This leads me to believe my aftercooler and dryer installation is probably overkill. Did i miss something or is this how you got the moisture out? Also, what are the plans for the new one?
 
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Strouty

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I ran the plasma cutter off the third drop, I had a regulator and water separator where it went from the black iron to the hose reels. I also have a small filter on the plasma cutter itself. Once I did this I had no issues with moisture, I am in Maine so my humid is not the same as everyone's humid. I do not think that having an air dryer or after cooler is overkill, I think that getting the air as dry as possible is great. The after cooler will also help keep your tank from rusting as quickly.
 
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Strouty

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I actually just plumbed my "new" compressor up the other day. It has an issue that I am chasing right now, seems like the unloader is leaking and not allowing the compressor to pump to full pressure. She is a big girl and I actually am getting another one just like it for free in a few weeks.





 

devildog93

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Yea that is pretty damn stout looking. How many hp and how big is the tank. I have a curtis 5hp with an 80 gallon tank and that looks significantly bigger than mine. Also, what plasma cutter are you running?
 

Jurious

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I appreciate the welcome, Strouty.

I've read the entire thread, but I have a remaining question about "sloping" your piping.

Okay, I'm going to slope the initial length of pipe upward so that water drains back toward the compressor (as per MTWs recommendation). But further away from the compressor, down the line, I want my pipe to gradually slope downward toward a tee (from which I run a vertical down line to a drain), and then continue the run upward -- away from the tee. In other words, the "tee" will be a low point to collect water.

See my diagram (deduct points for poor artistic talent). The diagram is looking down from the ceiling. The compressor is on the right. The initial pipe (in orange) slopes upward to drain water back to the compressor. It then makes a right turn in the shop, at which time the pipe slopes downward toward the first tee (top center), then slopes upward away from the tee. I rinse and repeat on the long wall to the left, where I again slope downward toward the second tee (left), then upward, away from it. My objective is to maximize the water drainage at each tee.

By the time the air gets to the third tee (bottom left) I'm hoping it will be cool and dry (at which point it passes through a filter and moisture separator, etc).

Does this make sense? I'll be painting cars, so moisture at the end of the run has to be GONE.

BTW: I'm using about 60 feet of 3/4" semi-rigid blue Rapidair Maxline piping.
 

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MTW

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Jurious, critique of your drawing.

Install a tee and drain at the compressor location, do not try to drain the condensate thru the flex connection to the tank. The flex line will usually hold water due to its curvature, you want to avoid that at all costs.

Your multiple low points for collection is OK, but it is more maintenance to regularly drain all of the collection points. At your collection drip legs, make sure that your drip leg is sufficiently long, 6" minimum, to hold a decent amount of water. That way when you forget to drain, as we all do, you will not have liquid pouring out your side takeoff. More separation between the stored liquid water in the drip leg and the passing air the better.

MTW Ω
 

Jurious

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MTW -- right you are.

So here's my thinking on the flex-hose attachment:

On the attached diagram, the compressor is on the left. An output tube leaves the compressor from the right. I'll put a tee there, with one line going up and another going down. The "up" line connects to a regulator, which in turn connects to the Flex-hose. The Flex-hose goes straight up and back and connects to my piping.

The "down" line is essentially a drain line (18-24" long) with a valve at the bottom. About 4-6" down that drain line, I'll have an unregulated tool output for when I need full pressure (say for a stubborn bolt, ball joint, etc.).
 

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Strouty

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Jurious, can you do the flex like mine? Then you can have the plumbing mounted to the wall so it is not putting a strain on the tank bung.

Also instead of sloping the line to a midpoint what I had planed to do when I turned my corner was to use a flex hose to essentially allow for a drop to the next upward sloping section. You really don't need much slope at all, I went with more but probably had no reason to do so much. Think of a gutter, they can be almost perfectly flat and water will still drain.


Devildog, it is a 10 HP motor, I only have one pump running at this point and I am using the pulley from the old 7.5 so it is only making 23 CFM. I intend to change the pulley so I can get over 30 CFM. The tank is a 200 gallon one.
 

jrobb316

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I read this whole thread, very good info. I will be doing a set up in the near future with copper pipe. I will use L pipe and wrot fittings with a 95/5 solder. That should be heavy duty enough without breaking the bank.
 

Jurious

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Thanks, Strouty. Yeah, I'm a little concerned about the strain on the bung, especially if someone (me) bumps into the output lines. I'll have a look to see if I can mount the output assembly to the wall. Maybe...but my work space is pretty crowded. I'd kill for a pole barn or 30X40 workshop.

Jrobb316. Copper is ideal, but I don't want to sweat joints. Instead I'm using Rapidair semi-rigid 3/4" Maxline. It's a much easier install, but may not have the radiant cooling capacity of copper.
 

MTW

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Compressor Tank & Drain Piping Manifold

Here's a sketch of my preferred setup for the tank piping setup. It may seem over complicated to some, but it is what I use. It works well, is convenient to use and is easy to service or modify when required.

CompressorDrain.jpg

Your piping layout most likely will be different, but the concepts should remain similar.

I don't recommend placing a pressure regulator in the main trunk line leaving the compressor for a couple of reasons. First is, it doesn't drain very well, regulators have a diaphragm, small pressure sensing orifice ports and a precision moving valve spool. This will eventually get corroded and cease to function properly, when placed in a drain line. Second is, in the main line it should be sized for the full capacity of the system, meaning larger and more expensive. You can usually obtain several smaller units for the price of one large unit rated at the full capacity. On a small system the second point may be a moot point.

On the tank drain. I like a street elbow screwed into the tank bung, that's the best way to keep the drain line as far above the floor as possible, gives more clearance for piping and a drain collection container. It's important to keep this as large a trade size as possible, eventually it will be required to pass chunks and flakes of rust particles, sludge and oil. If your tank only has a 1/4" NPT drain bung I recommend to enlarge it to a 3/8" size minimum, as soon as possible, personally I like to keep it at 1/2" NPT. Extend the drain line past the tank edge before installing the isolation valve for easy access and piping. This would normally stay wide open, unless you need to depressurize the main trunk.

The second drain line ball vale is the one you use for your daily drain flushing. This setup will flush the trunk and tank at the same time, into the same refuse container. The third valve is a boiler drain valve, to choke down the output flow to a reasonable level of discharge. This is set at a level to not spray all over the place, and has a downward slope hose bib connection, for placing the container under it, or a hose connection if you desire. I don't recommend using the boiler drain by it's self, as it has a rubber seat and will eventually leak, when being closed against the crud passing through the drain pipe. A ball valve used by itself has the unwanted tendency to spray crud all over the place when it is cracked open slightly. I leave the boiler drain loosely attached, turn it up slightly to fit a larger container under it, then turn down for the fill cycle. Turning it back up makes it easy to remove a full container without spilling it all over the place. Again some may consider it OCD, but I like it that way. A little more upfront cost but is easy and reliable for the long haul.

At this point in the drain line you could add the automatic drain valve. If your system is larger and has additional things that needed draining (aftercooler, refrigerated dryer, coalescer, another tank drain) a manifold could be added here before the automatic drain valve. A single drain for all system components, discharging to a single container. Easy Peasy and Automatic.

MTW Ω
 
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Strouty

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I never thought of using the drain like that, seems like it would be a good additional brace. Now I may have to rethink mine.

MTW, what do you use for the clear lines for the drains? I am trying to find the specific product so I can make an automatic master drain.
 

MTW

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Never use metal ferrules on plastic tubing, it will cut it off in short order. I don't trust plastic ferrules for airline use, cyclic drain pressures may cause it to come loose.

Pneumatic press lock fittings are the way to go, they are designed for this type service. Many brands available out there.

Samples
https://www.zoro.com/legris-male-cnctr-pushcx-38-tube-x-mnpt-pk10-3175-60-14/i/G1297037/

https://www.zoro.com/parker-male-elbow-90-deg-np-brass-38-in-pk10-w169plp-6-4/i/G1089532/

A manifold I saw at the box stores looked to be interesting for modification into a drain manifold, but never tried it.
http://www.homedepot.com/p/SharkBite-3-4-in-Barb-Inlet-x-1-2-in-Barb-3-Port-Closed-Manifold-22783/202721979

https://www.zoro.com/zurn-pex-pex-manifold-copper-pex-11-12-in-l-qcm43-4gx/i/G3744815/

MTW Ω
 
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Strouty

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I bet those fittings are the same as what I use on air brake lines. I have never looked at the rated pressure before, now I am curious.
 

LHC

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Lads - this is a fantastic thread. I came across it a while back and it's now become my go-to source for information as I plan my garage piping layout.

I've got a couple of questions that maybe MTW can answer as they came into my head as I was reading his detailed dissertations on drain lines.

I'm planning to run a radiator on the wall behind my compressor in a vertical fashion with the bottom "U"s having a downward pointing tee and then some drain lines off of them. Because of cramped space, I have to remote the drain lines to another location about 10' away on the wall and up a few feet. If I simply fashion the drain line into a loop or like a P trap, can I then count on the air pressure driving the slug of water that distance to the valve when I open it 10' away?

Also - this brings up another question - could I not use the same technique to remote the drain for the tank itself? (It's a 60 gallon upright) - i.e. line coming off the bung on the bottom of the tank will have a bit of a P trap fashioned into it before it goes up the wall and along the wall about 8 feet away?

As to the drain lines themselves, I have come across a local Parker store and the lads there were showing me this push-lock hosing that, while not clear, would certainly handle the pressure for the drains - I would probably be using 3/8 or 1/4. Have not come across any clear stuff - at least with the proper fittings - yet.

Thanks again for the great thread and all the input here. It's really helped me to understand the dynamics of the situation and hopefully will save me countless hours of re-work and wasted money.

Lewis
 
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Strouty

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This is one of my next steps, my tank is the lowest part, so I too would have to drain it uphill. It seems that it would work fine that way.
 
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