How piping wastes energy
Every restriction, long run, tight bend or undersized pipe causes pressure drop. To overcome it, the compressors must run at a higher pressure, which costs energy and increases leakage.
What to check
Look at:
- Pipe sizes relative to flow and length
- Restrictive fittings, valves and filters
- Dead legs and unused branches that leak
- Condensate build-up that narrows the pipe
- Ring mains versus long single runs
Improve the layout
Larger pipe on the main, a ring main or loops to balance flow, and removing unnecessary restrictions can reduce pressure drop. Measure pressure at the compressor and at the far points to find where the drop occurs.
Verify
Compare pressure drop and compressor power before and after. The benefit is plant-specific.
Starting data
To start, it helps to have:
- Compressor make, model, rated power and controls
- Operating pressure settings and the lowest pressure the processes need
- Operating hours and shift pattern
- Any existing power, flow or pressure records
Frequently asked questions
How much pressure drop is acceptable?
It should be as low as practical, and the target depends on the system. We measure what you have first.
Is it better to replace small pipe or raise the pressure?
Raising pressure costs energy continuously. Improving the pipe usually pays back over time, but it should be assessed.
Can poor piping cause tools to lose power?
Yes. Pressure drop at the tool reduces its performance even if the compressor pressure is fine.
Field guide
Distribution losses: pressure lost between compressor and user
If the compressor runs at one pressure and the furthest user receives much less, the difference is being paid for at the compressor. Pipework that is too small, too long or badly laid out is a permanent energy cost.
Causes
- Main pipes undersized for today's demand after years of expansion.
- Long dead-end runs instead of a ring main.
- Restrictive fittings, quick couplings and hoses at the point of use.
- Corroded steel pipe reducing the bore.
- Undersized drops and filter-regulators at machines.
Improvements
- Measure pressure at the compressor, after treatment, along the main and at key users.
- Fix the biggest drop first; often a single undersized section or fitting.
- Close the loop into a ring main where users are spread out.
- Upsize drops and point-of-use equipment where needed.
- Then lower generation pressure to collect the saving.
The pipe sizing calculator helps check whether a pipe is adequate for its flow and length.
What to send for a quotation
- Compressor make, model and rated power of each machine.
- Electricity tariff and annual running hours.
- Typical pressure at the compressor and at the furthest user.
- Any measurements you already have (power, flow, loaded hours).
Send it through find my part or the spare parts enquiry, or call +91 99590 60718 or +91 92468 88812.