Jack, I work for the Ingersoll-Rand industrial compressor distributor, in Knoxville, TN. So maybe I could help. Sounds like your compressor is probably OK. Overhauling it will not solve anything unless its knocking, using oil or the capacity is down. Condensate is a problem that has to be dealt with in any compressed air system. The only real way to get rid of it is thru use of either a refrigerated dryer or a desiccant dryer. Short of investing a substantial amount of money, the easiest way to get a reasonable air quality is to install a drip leg on the tank outlet, with a drain, drain the receiver often (several times a day) and install an inline coalescing filter. The amount of condensate depends on relative humidity, volume of air compressed, pressure in the receiver, and radiant cooling of the receiver. The problem is that ambient air at x relative humidity becomes compressed air at 10x relative humidity when compressed to 150 psi, it then quickly condenses to the saturation point still leaving 100% RH inside the receiver (lots of vapor) It's fairly easy to get rid of the liquid, water vapor may be a problem, as it condenses in hoses, and out of tools, nozzles, etc., as the air re-expands to atmospheric pressure. Keep your air tools well oiled, they will probably be OK. Just a little water or oil could ruin a paint job.
I may be able to find a good used filter and automatic tank drain at work that I could send to you. I deal with these kind of problems on a daily basis, but it's sometimes hard to justify a big outlay of cash for a unit you use at home. email me off the list if you have any other concerns or if you want me to try to find those items for you. Best Regards, Riley Collins Rutledge, TN
