Most factories rely on a complex distribution network of piping to ensure the compressed air is supplied to the correct equipment as needed. Under normal circumstances, after the network is installed, it is forgotten about. Often the system will grow and change as new equipment is added or moved within the factory.
Compressed Air Velocity for Main Distribution Pipes
When sizing pipework for compressed air systems, ideally the main distribution velocity should be kept below 6m/s (20ft/s) and droppers kept below 9/ms (30ft/s) which is relatively easy to achieve once the end user requirements are identified.
A simple rule is the lower the velocity is, the lower the pressure drop will be. So, increasing your pipework by one or two sizes will improve the performance of the compressed air system and allow you to run the compressors at a lower set pressure.
Pressure Drop
Best practices suggest that from your compressor to the outlet of your compressor room, you should have a maximum pressure drop of 0.3 bar (4.5psi). From the outlet of your compressor room to the furthest point in your system the pressure drop should be no greater than 0.1 bar (1.5psi).
Pipe Intersections
Thought should be given to the use of bends, elbows, branches, and tees. Where two compressed air flows are merging, they should not be opposing each other and by oversizing the intersection, less turbulence will be created. Ideally merge the two flows at a 45 degree angle rather than a straight in at 90 degrees.
Using long radius elbows (at least 5 x pipe diameter) allow for smoother transitions in direction, reducing turbulence.
If possible, joins should be eliminated by bending pipe which creates much cleaner lines of flow. Using full bore ball valves that do not interfere with or restrict the flow will also aid in the overall performance of the system.
Oversizing Compressed Air Pipes
Check that the sizing of filter, dryer and receiver connects are equal to or larger than the desired pipework which helps avoid unnecessary restrictions.
Oversizing the droppers (machine supply), from the main system, will ensure that the system is not the cause of your machine issues.
And there is an added bonus, increasing your pipework increases the total storage capacity of the system which can improve the efficiency of the entire system.
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