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Topic Review (Newest First)
01-25-2010 06:45 PM
lanierledford
rusted holes in air compressor tanks

Well, I drain mine every time I use it the gas powered 1. The electric compressors, I installed a electric dump valve thats on a timer that blowes off every 8 hrs. for 30 seconds. Guess WHAT ? I don't have (haven't had ) that problem in 40 yrs.
01-25-2010 05:30 PM
knighthawk I think the point has been made, but I'd to comment once more..... hydrostatic tests are required on most air pressure tanks, and hoses, gas bottles, also fire extingushers, water is pumped in up to or beyond the pressure limit, even if, or when it explodes, all you get is big bath or shower
01-24-2010 03:12 PM
oldred
Quote:
Originally Posted by knighthawk
Our trucks had this very large air tank mounted under the cab, opposite the fuel tank and just as big, it was used for 'air starters' which were popular years ago . Anyway, a combination of problems caused the air tank to explode , the truck looked like land mine exploded under it, and , yes, the driver was killed ....money or your life...... you decide


Amazing how much damage one of those things can do! The one I mentioned involving a truck was at a mine in Kentucky, a DM800 Mack that was being used as a fuel service truck and had an air compressor to power the grease pumps mounted behind the cab. That one had been welded around one of the mounting feet where a crack had developed, probably due to vibration, and when it let go there was not enough left of the tank to determine for sure where the crack had started. Whether it started at the welded crack or another weakened area does not matter because the fact a crack had developed was a sure indication that the tank was finished and should have been scrapped! The force of the explosion ripped the top of the cab off and peeled it forward leaving it upside down on the hood, a mechanic working nearby was seriously injured to the point that it required MSHA (the mining equivalent of OSHA) being called in to investigate. These things do happen and it just gives me chills to think that someone would even consider welding a crack or a hole in a tank never mind cutting an old tank apart and trying to put it back together after patching it!
01-24-2010 12:21 PM
knighthawk I know this thread is done, but I'd like to make a comment. First I agree with what Red and what he said. Also, I used to work in a truck shop ( for 30 years) and seen some air tanks explode. One smaller verticle tank was welded around the seam at the top, due to a rust leak , and during the pressure check after welding, the top blow off with pieces of rust and metal in the guys body . Another one : Our trucks had this very large air tank mounted under the cab, opposite the fuel tank and just as big, it was used for 'air starters' which were popular years ago . Anyway, a combination of problems caused the air tank to explode , the truck looked like land mine exploded under it, and , yes, the driver was killed ....money or your life...... you decide
01-24-2010 12:15 PM
OneMoreTime An engine hoist is just the ticket fot moving one of those..all you have to do is straddle the compressor with the legs of the hoist..hook it up so you can lift the compressor just enough to clear the floor and roll the whole affair to where you want it..I have moved quite a few heavy articles that way and engine hoists are not just for moving engines..

Sam
01-24-2010 11:27 AM
jaguarxk120 Why not look into a new tank and controls. A new tank can't cost as much as a new unit. And your pump/motor is probably in good shape. Chances are the quality of your old pump is much higher than what you can buy now.

This is a good time to work on your welding skills, cut the old tank in two and make a bbq out of it.
01-24-2010 11:23 AM
oldred Sorry about this thread taking a left turn but honestly the point is exactly what you have arrived at- things do wear out and sometimes need to be replaced! All too often when someone asks a question like you had (very legitimate question BTW) it is too easy for some to sit at a computer and offer advice about something while giving little thought to the possible consequences and the actual size of the endeavor. In this case you were advised to go so far as to cut open an old tank that had already failed, cut out areas of damage, weld patches in place and then weld the whole thing back together! Just think about it, do you REALLY want to be anywhere near a compressor tank with patches on it? I sold and serviced compressors for over thirty years as part of my welding business during which time I have seen many failed tanks, along with the two that actually exploded, and I know from experience just how impractical and dangerous it would be to attempt some of the things suggested here. You made a very wise decision and you will certainly be much safer for it!



BTW, In spite of the common myth tank size has next to nothing to do with compressor performance so if the two compressors you were looking at were comparable in CFM ratings then you did not lose any performance by selecting the compressor with the 60 gallon tank.
01-24-2010 11:16 AM
CQNRQY
You made the right choice

Glad to hear you're going to buy a new one
As has been said it's not a good idea to weld up a tank thats failing
18 years of service is long time !hopefully your new one will last as long


Quote:
Originally Posted by HotRodMan
OK, this is hotrodman the original poster of the compressor tank leak. Thanks for all the information and advise. I certainly received more information than expected. I have looked inside the tank with a mirror and light and decided the tank has too much rust, the cut off switch was starting to give me trouble, and the unit is 18 years old, so I decided it is not worth fixing. I am going to buy a whole new unit.

1. I want at least the 60 gallon vertical tank design that I had. Two people can get this into a truck and maneuverd into place at the garage. Can any of you recommend one brand over another?

2. The compressor I really wanted was an 80 gallon vertical tank design, but the weight of the unit is close to 500 pounds. Not sure how to get this to the garage and maneuvered into place without hiring a delivery crew? Any ideas?

Will use the compressor at home for all types of body and paint work, pumping up tires, sandblasting, and cleaning parts.
01-24-2010 10:56 AM
HotRodMan
Suggestions on new compressor?

OK, this is hotrodman the original poster of the compressor tank leak. Thanks for all the information and advise. I certainly received more information than expected. I have looked inside the tank with a mirror and light and decided the tank has too much rust, the cut off switch was starting to give me trouble, and the unit is 18 years old, so I decided it is not worth fixing. I am going to buy a whole new unit.

1. I want at least the 60 gallon vertical tank design that I had. Two people can get this into a truck and maneuverd into place at the garage. Can any of you recommend one brand over another?

2. The compressor I really wanted was an 80 gallon vertical tank design, but the weight of the unit is close to 500 pounds. Not sure how to get this to the garage and maneuvered into place without hiring a delivery crew? Any ideas?

Will use the compressor at home for all types of body and paint work, pumping up tires, sandblasting, and cleaning parts.
01-23-2010 08:15 PM
oldred
Quote:
Originally Posted by jaguarxk120
I'm assuming that this unit is used at home, if not does not matter. YOU repair the tank and later in time something happens and the tank ruptures, thats what they do not explode, what ever dammage that should take place falls on your shoulders!!! Nothing will be covered by home owners/commercial insurance. YOU made unauthorised repairs to a piece of machinary. No insurance co. anywhere will pay off, your taking too much of a chance.

Of course if they are anywhere near the darn thing then they won't have to worry about it!
01-23-2010 08:13 PM
oldred
Quote:
Originally Posted by CQNRQY
I'd buy a new tank
In all likelyhood the tank is rotten. (how old is it?)
If you want to fix it .
Try to just weld the hole up.(if you blow thru it & the hole gets bigger. Then you know it s rotten. If you feel you still want to fix it.
I'd cut the bottom out of it slightly up the sides so you can see inside of it.
If the rest of the tank appears solid AND you're a good experienced welder you could weld in a new bottom. Might be safer to buy a new one and a lot less work.

That is the kind of thing that causes accidents and could very possibly get someone killed. Think about what you are suggesting, if the tank is rusty and there is a hole in it then obviously the metal is weakened by the rust and will be easy to see. If the tank was cracked instead of rusted and you cut the tank apart as suggested it might look OK inside but is it? If the dang thing is cracked then it is from metal fatigue caused by the repeated expansion and contraction of the tank during normal use and from vibration form the pump/motor. This DID NOT occur only in the small area of the crack and most of the rest tank will have fatigued too but you can't see that! If the crack is welded or, as was also suggested, a patch is welded in then the tank may have that tiny spot strengthened but the rest of the tank will still be dangerous. This entire subject is simply ridiculous, this is a dangerous and irresponsible thing to do that could very well cause an accident that could seriously injure or even kill someone! Fellas even suggesting to someone else to weld on a tank is irresponsible because there is no safe way to do it no matter how good the weld or skilled the welder, the rest of the tank is just as old and nearly as weak as the small spot that failed. Do you guys suggesting this ridiculous approach have any idea how much damage a 60 gallon tank can do? I have no doubt you do not or you would never recommend doing something so darn stupid!



People have been killed in the past and are likely to die from tank explosions in the future, it does happen! There simply is no argument that it does not, there are many documented cases of this happening and as I have said repeatedly I myself have seen two and both had been "repaired". It DOES happen and it CAN happen to you!
01-23-2010 07:03 PM
jaguarxk120 I'm assuming that this unit is used at home, if not does not matter. YOU repair the tank and later in time something happens and the tank ruptures, thats what they do not explode, what ever dammage that should take place falls on your shoulders!!! Nothing will be covered by home owners/commercial insurance. YOU made unauthorised repairs to a piece of machinary. No insurance co. anywhere will pay off, your taking too much of a chance.
01-23-2010 06:33 PM
matt167 yep.. if a tank is rusty, replace it.. I had a portable air tank that I could hear rust scale in it... I cut the bung out of it, cleaned it out and turned it into a fuel tank.. couldn't trust it's integrity anymore

heres proof even new tanks can blow.. this is a tank used for air ride suspension from DNA, and it got bad enough DNA had to inform and recall the tanks because it was a manufacturing flaw and happened to others



think about the potential energy that is in the tank.. even a small leak could cause an explosion if the preassure is high enough, simply because of the amount of force the preassure puts on the hole
01-23-2010 06:17 PM
CQNRQY
Quote:
Originally Posted by HotRodMan
I have an air compressor with a 60 gallon tank. There is a hole about one eighth inch in diameter on the bottom of the tank. I was planning on welding the hole up to repair it.

Is there a better way of doing this, or is this what most of you would do?
I'd buy a new tank
In all likelyhood the tank is rotten. (how old is it?)
If you want to fix it .
Try to just weld the hole up.(if you blow thru it & the hole gets bigger. Then you know it s rotten. If you feel you still want to fix it.
I'd cut the bottom out of it slightly up the sides so you can see inside of it.
If the rest of the tank appears solid AND you're a good experienced welder you could weld in a new bottom. Might be safer to buy a new one and a lot less work.
01-23-2010 05:35 PM
oldred
Quote:
Originally Posted by 65GTO455
I think you mean 100%

But anyways, I think you should read the entire thread before blasting away.

Also another thing to take into account is Regulators. There was been little talk on regulators and what it means if one fails. Will the pump burn out before pressure builds too high? Sounds like another topic for discussion.

Some people in this world shouldn't even be around ladders. I have a feeling more people have died from falling off ladders as apposed to being injured by compressors. I tried looking up compressor related injuries but couldn't find any statistics. I do however have a sneaky feeling that more people die from choking on bar peanuts, quite frankly. Even spoons can kill people.

If you can't use your brain, you shouldn't be around an air compressor.

It does take someone who knows what they are doing.

Can someone safely repair an air compressor? Yes. But only if the previous line is taken into account.

Also, do you know what an air compressor tank is? Sheet metal welded together.

[End]


Read the whole thing? Sure I did and what I read was advice to weld on this old tank which is extremely dangerous whether you believe that or not! The statement was clearly made that tanks do NOT explode which they in fact certainly do! Argue to the contrary if you like but there are many examples of them doing just that. Like I said I have personally seen two and have seen several safety bulletins of more examples, the vast majority being old and/or repaired tanks. Darn right I came on strong because that kind of advice can get people hurt or killed and there should be no misunderstanding of just how dangerous this practice is, I am speaking from many years of dealing with these things and I know first hand just how dangerous it is.

The fact that tanks are welded together means nothing because these are welded using new metal while a cracked/leaking tank is rusty and/or fatigued. "Can someone safely repair an air compressor"? I assume you mean tank? then no you can not because even if the crack/hole is "repaired" you still have a dangerous, weak, rusty and fatigued tank which almost certainly will be damaged even more in the attempt to weld it. When a tank has reached the end of it's service life then a fatigue crack or rust hole should be considered a safety warning that the tank is finished and attempting to extend it's service life is setting it up for disaster. Like I said before it makes no difference how skilled the welder is or how good the weld is the tank is STILL seriously compromised.



Quote:
Originally Posted by 65GTO455
If you can't use your brain, you shouldn't be around an air compressor.

It does take someone who knows what they are doing.

If you use your brain you should know better than to attempt to do this and someone who knows what they are doing will not attempt it!
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