Appropriate compressed air distribution

Fixed compressed air distribution networks should be dimensioned, so pressure drops in the pipes don’t exceed 0.1 bar. This measurement is in relation to a compressor's most remote point of consumption. When calculating pressure, connected flexible hoses, couplings, and other fittings must be considered. The largest drop frequently occurs at these connections.

The best solution involves designing a closed loop ring pipe system. From this starting point, branch pipes can run to various consumption points. This approach provides uniform compressed air supply, as air is led to the consumption point from two directions.

To maintain ideal pressure, all air compressor installations should use this system. The only exception is if there's a great distance between the machine and point of consumption, where a separate main pipe is added.

One or more air receivers are included in each compressor installation. Their size is related to the compressor capacity, regulation system, and the consumer's air requirement pattern. The air receiver creates a buffer storage area for compressed air, balances pulsations, and cools and collects condensation.

Consequently, the air receiver must be fitted with a condensate drainage device. The following equation applies when dimensioning the receiver's volume. Note that this calculation only applies for compressors with offloading/loading regulation.

In the scenario above, a separate air receiver should be dimensioned for maximum output and placed near the consumer point. In more extreme cases, a smaller, high pressure compressor is used with a larger receiver. This set up meets short-term, high volume air requirements at long intervals.

This formula does not take into consideration how a compressor can still supply air during the emptying phase. Learn more about air receivers and how to size them.

When designing and dimensioning a compressed air network, it's good to start with an equipment list detailing all consumption points and their locations. It's ideal to group these points into logical units and use the same distribution pipe for air supply from air compressor plant risers.

A large compressed air network is typically divided into four main parts.

1. Risers
2. Distribution pipes
3. Service pipes
4. Compressed air fittings

The risers transport compressed air from the compressor plant to the consumption area. Distribution pipes split air across the distribution area. Service pipes route air from distribution pipes to workplaces/consumption points.

As an alternative to the above formula, a nomogram (shown below) can be used to find the most appropriate pipe diameter. The flow rate, pressure, allowed pressure drop and the pipe length must be known in order to make this calculation. Standard pipe of the closest, largest diameter is then selected for the installation.

Equivalent pipe lengths for all parts of the installation are calculated with a list of fittings and pipe components. In addition, flow resistance is expressed by correlating pipe length. The network's selected dimensions are then recalculated to ensure pressure drop won't be significant. Individual sections (service pipe, distribution pipe and risers) should be calculated separately for large installations.

Strategically placed air flow meters facilitate internal debiting and economic allocation of compressed air utilization within the company. Compressed air is a production medium that is part of the production cost for individual departments within the company. From this viewpoint, all parties concerned could benefit from attempts at reducing consumption within the different departments.

Flow meters available on the market today provide everything from numerical values for manual reading to measurement data. This information is fed directly to a computer or debiting module. Flow meters are generally mounted close to shut-off valves. Ring measurement requires particular attention, as the meter needs to be able to measure both forward and backward flow.

We hope this article helps you evaluate your setup for optimal performance with minimal pressure drops and leakage. Using the equations mentioned is a good starting point. If you're still uncertain of the best approach, feel free to get in touch. Our team is happy to help.

Learn more about the process of installing a compressor system below.

The airline network's routing, design and dimensioning are important for the efficiency, reliability and cost of compressed air production. Sometimes a high pressure drop in the pipeline is compensated by increasing the working pressure of the compressor from 7 bar(e) to 8 bar(e), for example. This offers inferior compressed air economy. Moreover, when compressed air consumption is reduced, so is the pressure drop and the pressure at the point of consumption consequently rises above the allowed level.

The starting point when designing and dimensioning a compressed air network is an equipment list that details all compressed air consumers, and a diagram indicating their individual locations. The consumers are grouped in logical units and are supplied by the same distribution pipe. The distribution pipe is, in turn, supplied by risers from the compressor plant. A larger compressed air network can be divided into four main parts: - Risers - Distribution pipes - Service pipes - Compressed air fittings. The risers transport the compressed air from the compressor plant to the consumption area. Distribution pipes split the air across the distribution area. Service pipes route the air from the distribution pipes to the workplaces.