01Sizing the main line
Connecting machines to the compressor correctly is extremely important, especially since a poorly designed and installed compressed air distribution system can cause leaks, large pressure drops or even compressor faults. If the piping diameter is too small, the air speed through the pipes increases. Higher air speed causes turbulence at valves and T-pieces, which makes accurate pressure readings in the network impossible.
02An example: diameter and pressure drop
Below is an example of the effect that pipe diameter and length have on pressure drop and the efficiency of the whole compressed air system.
Say we have an 18.5 kW screw compressor with a capacity of 2.8 m³/min and a working pressure of 10 bar.
Moving the same compressor from DN 25 piping to DN 32 piping will significantly reduce pressure drop and save the user 1.5% in electricity. Further savings are possible by reducing the number of elbows and manifolds in the network – not only do they cause pressure drop, but they are all potential leak points.
03Joints and leaks
Besides an inadequate main line diameter, the biggest potential consumers of compressed air in a distribution installation are joints and possible leak points.
For example, a hole of just 2.4 mm in an installation at 8 bar loses as much as 400 litres of air every minute – every single minute! In electricity terms that is the equivalent of 2.2 kWh.
How do you know whether your compressed air distribution system is properly sized and installed? Our experts are equipped and trained for energy analysis of compressed air systems and, without disrupting your normal operations, can measure and analyse the efficiency of your system and show you every opportunity for improvement, savings and, as a result, greater efficiency.
