What piping must do
The piping carries air from the compressor room to every point of use with acceptable pressure drop, clean air, safe containment and the ability to be isolated and serviced. A design that meets only the first requirement is often hard and costly to maintain.
Pressure loss
Pressure loss builds up from:
- Pipe that is too small for the flow and length
- Restrictive fittings, valves and sharp bends
- Filters, dryers and regulators in the main line
- Condensate and corrosion products narrowing the bore
- Long dead-end runs feeding large users
Reduce it by design
Design measures:
- Size the main for the peak flow with allowance for expansion
- Use loops or ring mains to feed users from two directions
- Keep branches short and take them from the top of the main
- Choose low-restriction fittings and valves
- Place filters and dryers where flow and temperature suit them
Integrity and leakage
Integrity matters because leaks waste energy and joints fail over time. Good practice includes:
- Choosing pipe material and joining method suited to the pressure, temperature and air quality
- Supporting pipe properly to avoid stress and vibration damage
- Providing for thermal movement
- Pressure testing new work and recording it
- Labelling the system so that lines are clearly identified
Maintainability
Make the system easy to look after:
- Install isolation valves so sections can be shut without stopping the plant
- Provide drain points at low points and drop legs
- Keep access for inspection and leak detection
- Keep drawings and a record of changes up to date
- Plan connections for future expansion
Measure before you change
Measure pressure at the compressor, at the far ends and at peak demand. The pattern of drops shows whether the problem is the main, a branch, a filter or a user, and avoids replacing good pipe or raising the pressure unnecessarily.
Frequently asked questions
Which pipe material should I use?
It depends on the pressure, the air quality, the site and local requirements. Common options include steel, stainless steel, aluminium and plastic systems designed for compressed air, and we help you choose on the facts of your project.
Why is my pressure lower at the far end of the plant?
Pipe that is too small or restricted, a leak or a heavy user nearby can all cause it. Measure along the line to locate the loss.
Is a ring main better than a single line?
A ring feeds users from two directions and generally reduces pressure drop, but the best layout depends on the plant.
How do I keep the piping in good condition?
Survey for leaks, drain condensate, protect against corrosion and keep records of changes and tests.
Can I add a branch myself?
Any change should be designed and tested so it does not cause pressure drop or a safety issue elsewhere. We can help you plan it.