How to choose the right compressed air piping system?

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 to connect 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, and it’s not only the system design that impacts this efficiency; it’s the piping materials itself. 

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 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.

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.

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.

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.