ST Gui
240Robert
T_C said:
The tank isn't the only thing that will 'clang'. I read your words but would really have to get comfortable with the science before I tried that. LOL!
Air compressor tank failure...
- Thread starter Dale_I
- Start date
The tank isn't the only thing that will 'clang'. I read your words but would really have to get comfortable with the science before I tried that. LOL!
OP
OP
OK... pictures... more information.... maybe a plan:
Here is the offending beast:
As you can see I have excellent access to the bottom of the tank. There is a 10 inch (or so) hole cut in the platform below it to access the condensate drain. (dwalby: Properly called a condensate drain, we all call it an air purge, but that could be a location thing. A solenoid opens a valve for 30 seconds twice a day. I've never seen water come out, but do see mist every now and then. You hear a Psssshhhhttt!
BakerBoy: You reminded me. I have an endoscope. I picked it up a few months ago when someone posted it on a thread in these forums.
Here is a pic of the exterior fissure where the air is coming out:
You can see the rust in the seam.
Here is an interior view of the same location. You can see a half circle of weld that looks rusted:
I pushed it in a bit further and, other than the rust around the weld seam and where you can see where water can pool, the tank itself is in good condition.
I'm not going to buy a cheap compressor to get the tank. I would just be getting a cheap tank. I already have a cheap tank. I would want one rated for 200 psi anyway because my operational storage pressure is 135 psi. Looking at the cheap HF units they advertise "no mag starter needed" like it was a good thing. I'll take a strong enough motor to need a mag starter any day... especially if you are requiring 240v.
I've sourced a Manchester Tank, supposedly made right here in the US of A. I put one on order and it should be a few weeks before it gets here. Less than a cheap HF compressor, it was still over $500, but I'm hoping will last at least another 15 years (but would really expect 20 or 30 if it is made well). Pressure listed at 200 psi... comes with a platform for the motor and pump (302412 if anyone is interested).
I don't think a self-tapping screw/plug or drilling a hole and repairing it will be an option since this isn't a pinhole rust through of a plate, but a rust of the weld seam. I would think rewelding it would work as long as there is enough good plate to be useful.
And... that is the next question....
I'm not a certified welder, but I weld more than your average bear. I have a good old Hobart wire feed and enough experience to know if I've penetrated well or if I'm just blowing out the metal.
I'm thinking about running a bead down the middle of the "crack", then sistering in a couple beads next to it just to give it some support. If I run my welds short in time duration and I pre-heat the tanks end cap area I shouldn't run a risk of distorting anything.
It isn't going to fail catastrophically, or it would have. Also, the damaged area is all contained within the end cap base ring, which would protect any shrapnel from going anywhere but down. The compressor is both bolted to the rack and has metal cable tied with tensioners in opposite directions anchored to the wall. It isn't going anywhere.
Should I see if I can weld it? Got a new one coming anyway......
Here is the offending beast:
As you can see I have excellent access to the bottom of the tank. There is a 10 inch (or so) hole cut in the platform below it to access the condensate drain. (dwalby: Properly called a condensate drain, we all call it an air purge, but that could be a location thing. A solenoid opens a valve for 30 seconds twice a day. I've never seen water come out, but do see mist every now and then. You hear a Psssshhhhttt!
BakerBoy: You reminded me. I have an endoscope. I picked it up a few months ago when someone posted it on a thread in these forums.
Here is a pic of the exterior fissure where the air is coming out:
You can see the rust in the seam.
Here is an interior view of the same location. You can see a half circle of weld that looks rusted:
I pushed it in a bit further and, other than the rust around the weld seam and where you can see where water can pool, the tank itself is in good condition.
I'm not going to buy a cheap compressor to get the tank. I would just be getting a cheap tank. I already have a cheap tank. I would want one rated for 200 psi anyway because my operational storage pressure is 135 psi. Looking at the cheap HF units they advertise "no mag starter needed" like it was a good thing. I'll take a strong enough motor to need a mag starter any day... especially if you are requiring 240v.
I've sourced a Manchester Tank, supposedly made right here in the US of A. I put one on order and it should be a few weeks before it gets here. Less than a cheap HF compressor, it was still over $500, but I'm hoping will last at least another 15 years (but would really expect 20 or 30 if it is made well). Pressure listed at 200 psi... comes with a platform for the motor and pump (302412 if anyone is interested).
I don't think a self-tapping screw/plug or drilling a hole and repairing it will be an option since this isn't a pinhole rust through of a plate, but a rust of the weld seam. I would think rewelding it would work as long as there is enough good plate to be useful.
And... that is the next question....
I'm not a certified welder, but I weld more than your average bear. I have a good old Hobart wire feed and enough experience to know if I've penetrated well or if I'm just blowing out the metal.
I'm thinking about running a bead down the middle of the "crack", then sistering in a couple beads next to it just to give it some support. If I run my welds short in time duration and I pre-heat the tanks end cap area I shouldn't run a risk of distorting anything.
It isn't going to fail catastrophically, or it would have. Also, the damaged area is all contained within the end cap base ring, which would protect any shrapnel from going anywhere but down. The compressor is both bolted to the rack and has metal cable tied with tensioners in opposite directions anchored to the wall. It isn't going anywhere.
Should I see if I can weld it? Got a new one coming anyway......
Go ahead and try it. Ingersoll Rand was a good name in air tools; I'd expect far higher quality than a HF compressor. Maybe, like BakerBoy said, its coated on the inside. I'd suggest you grind the outside of the weld clean, and the surrounding area if you will be laying down parallel beads.
If you are using MIG, for short circuit transfer (up to 3/16" inch) you should be using a flush nozzle and maintain a a 1/2" contact tip to work distance.
If you are using MIG, for short circuit transfer (up to 3/16" inch) you should be using a flush nozzle and maintain a a 1/2" contact tip to work distance.
OP
OP
It's a MIG with Zargon and I've got good tips. I got the metal pretty clean with just carb cleaner. They must not prime these tanks and probably just spray them quick and slap stickers on it.
That's part of the problem. You're right... IR is a trusted brand. However, these were lowest price leaders using substandard motors that were prone to catch fire. There was a class action thing for a bit. Anyway, I just bought a good motor and moved on. But, I don't know if they were using the same tanks or if they were substandard as well. Once you spray them beige and slap stickers on them... they all look the same.
I'll grind/clean/see what trouble I can get into... Sunday. I've got to brown some meat for chill tonight because I'm out the door early tomorrow. I'm riding into Canada to meet with a friend to ride back into Spokane. He's been on a 5 day trip and I'm sure lunch will be full of stories. Chili should be done by the time we arrive
:eat2: 
I've got to brown some meat for chill tonight because I'm out the door early tomorrow. I'm riding into Canada to meet with a friend to ride back into Spokane. He's been on a 5 day trip and I'm sure lunch will be full of stories. Chili should be done by the time we arrive
Maybe you can post the chili recipe....
:eat2: It would be better than another oil thread....
I have a Rolair JC10. It's not completely silent, but it's the quietest compressor I've heard. The reviews are pretty good too.
I have an very old compressor that had the same thing happen. I was using it painting and had no time to play with it. I stuck a sheet metal screw in it with some never-seize on it, to help the screw from rusting and that was 4 years ago. And by the way the compressor tank will not explode and send shrapnel flying like some other post had mentioned. It will just start hissing somewhere else.
California air tools. I bought a small one (around $200) and it is so much quieter than my old sears pancake compressor that there is no comparison. They make bigger ones too...
OP
OP
Those pictures are of the bottom of the interior of the tank. The tube coming from the bottom fitting is the endoscope wire, which has a camera on the end. I bent the endoscope wire at 180 degrees about 3 inches from the camera and stuck it up the hole to get pictures of the bottom of the tank.
BakerBoy
It's all small stuff.
Al, while rare, they do explode. Here's one caught on video:
https://www.youtube.com/watch?v=KVP_A7eGYxw
Apparently the guy lived, after 3 mos in the hospital. And there are other examples not caught on camera but which show the splattered tank--they most often fail at the weld seams and spread open like a popped balloon.
I'll get struck by lightning twice before that happens.
BakerBoy
It's all small stuff.
LOL, yup! 
Just didn't want folks to believe it can't happen--a failure initiation point (such as a leak at a corroded weld) can lead to a catastrophic rupture.
Interesting about "lightning twice" though ... my grandpa was hit by lightning on 2 separate occasions, fortunately not by the main bolt either time. Apparently the 'good thing' about lightning is that it also instantly cauterizes the tissue damage.
Just didn't want folks to believe it can't happen--a failure initiation point (such as a leak at a corroded weld) can lead to a catastrophic rupture.Interesting about "lightning twice" though ... my grandpa was hit by lightning on 2 separate occasions, fortunately not by the main bolt either time. Apparently the 'good thing' about lightning is that it also instantly cauterizes the tissue damage.
wjbertrand
Ventura Highway
Thanks for posting that. I've seen the aftermath of an air compressor tank failure. Luckily happened at night when the service station was closed. The destruction was significant. You can't predict how the failure will happen. If in question buy a new tank!
Sent from my iPhone using Tapatalk Pro
OP
OP
I'm thinking if mine ever failed catastrophically... it would more than likely blow through the back and side wall of the shop. I don't know where the pieces would land, but being 6 feet up and without anything hindering their progress, I wouldn't want to find out. Although the end caps look like they become progectiles, I would worry about the pump and the motor. Both are extremely heavy. Even dropping them on your foot would break it, I can't imagine them landing after hitting a 16 ft ceiling and then coming down. 4:
4:
OP
OP
Maybe you can post the chili recipe....
3 cans Pettete Diced Tomatoes
2 cans Pinto Beans
1 can Chili Beans
1 can Kidney Beans
1 lb hamburger, browned
1 lb pork seasoned pork sausage, browned
1 large onion (or 2 small)
1 large garlic clove (or 2 small)
4 Bell Peppers (1 green, 1 yellow, 1 red, 1 orange)
2 TBL Chili Powder
1 TBL Adobo Seasoning
2 TSP Cumin
1/2 TSP Salt
1/2 TSP Pepper
1 large Chipotle Chili in Adobo Sauce
The large Chipotle Chili in Adobo Sauce is a small can in the Hispanic section of your store. You can use what you need and put the rest in a bag and freeze it. I break off a frozen chunk as needed.
Combine ingredients in a crock pot... stir well.... set it on low.... and walk away. Come back in 10 hours with some cornbread.
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ColinW1981
Site Supporter
How about some of that green slime stuff?
Thanks. Sure beats another oil thread....
now we have to see if his compressor blows up!!!:bsflag: its fake http://www.businessinsider.com/what-to-expect-when-you-survive-lightning-2016-4