If your compressor is the voltage source of your operation, and the pneumatic devices are light bulbs, then your compressed air piping is certainly the electrical wires connecting everything together. It is essential to choose the right compressed air piping as the piping is transporting your compressed air to its intended end-use applications. It’s not only the system design that impacts this efficiency; it’s the piping materials themselves.
What piping materials should I use for compressed air?
Pipes used for transporting compressed air are available in a variety of materials such as – plastic, iron and aluminum among others. Compared to plastic, metal is the generally preferred installation material for its long-standing track record and a more common experience for technicians with its installation. In the Middle East, four types of metal pipes are commonly used in compressed air distribution.
Galvanized pipe
Galvanized pipe is perhaps the most common type of compressed air pipe used in the Middle East. It’s a material that installing technicians are very familiar with. The galvanizing coating prolongs the pipe’s life expectancy and provides a level of rust protection. Galvanized pipes have higher friction factor than any other piping material, which increases pressure drop across network.
It is, however, still susceptible to corrosion. The galvanizing plating is deteriorated over time, flakes of it causing blockages or becoming safety hazards in air stream applications. Installation involves high skilled plumbers who need to use cutting, threading, machineries and in case of welding expert welder is required.
Another disadvantage of galvanized compressed air piping is that it is difficult to maneuver, and threaded or welded joints are prone to failure. It is also heavy, requiring higher strength from suspension and fixing methods.
Aluminum pipe
Aluminum has the same anti-corrosive properties of stainless steel but without the weight, making it extremely easy to install. Line losses are reduced because of its smooth interior, and it is corrosion-resistant; this means Aluminium compressed air piping has the same corrosion-resistant properties of stainless steel but without the weight, making it extremely easy to install. Line losses are reduced because of its smooth interior, and it is corrosion-resistant; this means that aluminium piping far outpaces galvanized air pipe in terms of starting and long-term efficiency. The operating costs and maintenance costs are lower than with other materials.
An additional advantage of aluminum compressed air piping is the simplicity in reconfiguring the system, should the facility grow or move. Its lightweight and modular design contributes to reduced maintenance, increased durability, and better overall performance.
Stainless steel pipe
The main advantage of stainless steel piping is that there is no risk of corrosion or degradation on the interior or exterior of these pipes. A few industries have stringent requirements like Pharmaceutical, hospitals, research labs, clean rooms, and healthcare facilities, wherein the type of piping recommended is Stainless Steel SS304L or SS316L. Also, NFPA has approved stainless steel for vacuum applications in healthcare facilities.
Copper pipe
This metal is corrosion-free and easy to cut and weld. It is lightweight and has a wide range of fittings available due to its frequent use in plumbing. It is easy to suspend, and a large number of plumbers are familiar with working with this material. Copper pipes are mainly used in medical application due to its anti-microbiological properties and as specified by NFPA.
Plastic pipe
People also look to plastic piping to build a compressed air piping system because it is cheap, resistant to corrosion and easy to install. However, you can’t use just any plastic pipes for compressed air distribution. Using PVC pipe in any compressed air application is extremely dangerous and NOT recommended by multiple associations and manufacturers.
When air is compressed inside of PVC piping, the pipe can swell and burst at a high pressure, sending PVC shrapnel outward like a bomb, potentially injuring or killing anyone within close range. PVC pipe also deteriorates over time and becomes brittle, making the chance of a leak or an explosion more likely as it ages.
In addition to the obvious dangers of using PVC piping for compressed air it is also an OSHA (Occupational Safety and Health Administration) violation to use PVC piping for transportation of compressed air and gases. In doing so, you run the risk of hefty fines from OSHA and a potential shutdown of your business if you have too many violations.
Use the correct piping materials
When designing a futureproof compressed air distribution system, more facilities are choosing aluminum compressed air piping for installations due to its structural strength, light weight and high resistance to corrosion. Although the upfront cost in materials will be higher than galvanized pipe, the savings on the installation labor will more than make up for the difference in material cost.
Stainless steel piping is recommended for plants that use oil-free compressors to avoid corrosion problems and resulting downstream contamination. In the past, welding stainless steel was your only option and was very time consuming and costly. However, new innovations have been made and stainless steel crimped air systems are now available. This new installation technology can cut installation costs to a fraction of what they once were.
To get the most out of your piping configuration, it’s important to follow the manufacturers’ instructions and recommendations on how to install the system. Be sure to adhere to all specifications and limitations listed for pressures and temperatures. If you’re interested in learning more, please contact an Atlas Copco expert.
FAQs
1. What is the most efficient piping material for compressed air systems?
Aluminium piping is considered one of the most efficient options due to its corrosion resistance, lightweight structure, and low pressure drop, contributing to reduced operational costs.
2. Why is PVC not recommended for compressed air piping?
PVC poses significant safety hazards when used in compressed air systems. It can burst under pressure, creating dangerous shrapnel and violating OSHA standards.
3. How does piping material impact energy efficiency in a compressed air system?
Piping materials affect airflow, pressure losses, and air leaks. Materials like aluminium and stainless steel offer smooth interiors and corrosion resistance, reducing energy losses and maintenance needs.
4. Can I mix different materials in a compressed air network?
Mixing different materials (e.g., copper and galvanized steel) is generally not advised due to potential corrosion reactions and compatibility issues. It’s best to stick to one material type for optimal performance and durability.
5. What should I consider when installing a compressed air piping system?
You should consider pressure, temperature, length of the system, installation cost, materials, fittings, future scalability, and overall efficiency. Always follow the manufacturer’s guidelines for optimal performance and safety.
