ESL-IE-05-05-10

Hank van Ormer

President

AIRPOWER USA

11520 Woodbridge Lane

Baltimore, Ohio 43105

MODERN COMPRESSED AIR PIPING SELECTION AND DESIGN

CAN HAVE A GREAT IMPACT ON
YOUR COMPRESSED AIR ENERGY DOLLARS
This paper introduces new concepts in compressed air piping, sizing, and system design beyond
the conventional pipe sizing charts and standard system layout guide lines.
The author shows how compressed air velocity has a very significant impact on the pressure
losses and piping performance. Case studies are used to show how conventional piping design
and sizing keep extra compressors on line preclude proper control operation waste energy
shorten filter life and have a negative impact on dryer performance.
The principles offered in this paper will help to trouble shoot old systems and help design new
systems. They will also help to avoid many common mistakes made over the last 30 to 35 years
with the ascendance in popularity of the rotary screw compressor package.

Prepared for

Prepared by
Hank van Ormer
President

AirPower USA, Inc.

11520 Woodbridge Lane
Baltimore, OH 43105
(740) 862-4112
www.airpowerusainc.com

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Have Any of These Things Happened to You

With Regard to Your Compressed Air System?
Plant personnel say the current 200-hp compressor is too small and wont hold the
system pressure. You purchase another 200-hp unit things get better but still seem to
be marginal?
Whats wrong? You doubled the air supply! Did you double production? If not, you should.
The cost of your most expensive utility compressed air has significantly increased!
The compressed air supply is on the north end of the plant. You have trouble holding
pressure on the south end. Those in the know claim that because its so far down
there, we need to either raise the compressor discharge pressure (a significant energy
cost increase) or install another air compressor on the south end (often the first step in
upsetting the system timing and efficiency!
The pressure problem isnt the distance its either the pipe sizing or system design or both.
The most economical fix is usually a well-planned piping modification, which is a one time
cost. The other solutions may have a high initial cost or not but the related electrical energy
cost increase goes on year after year.
You run four lubricant-cooled rotary screws (total 400 hp) during full production for two
shifts and during the third shift, you still run the same four compressors (400 hp), even
though the production is 50% or less during the third shift. You may run the same on
weekends and holidays no one is sure. You have tried shutting a unit off, but
sometime during the shift, it has to be manually turned back on in a hurry so you leave
it on.
The units have automatic start/stop controls, but they never turn off automatically. You
purchase a new central control energy management system with great promise. You are
still running most of the units most of the time.
This is a more complex issue with several factors, but the root cause of the issue is often the
pipe size and layout changes.
This list could go on and on with issues and opportunities fundamentally set up with improper or
poorly designed compressed air piping systems.
Over the last almost 20 years, we have reviewed almost 2,000 compressed air systems for
energy reduction and production and quality improvements. Our theories and ideas are not
theoretical they are based on field observation, and most importantly, on pre- and postproject measurement. The ideas and suggestions we present are not new many have been
lost or forgotten in transition. Compressed air is not complex, but the physics of compressed
gases and the knowledge of the operating parameters of the equipment must be utilized with
common sense.
Pipe size and layout design are the most important variables in moving air from the compressor
to the point of use. Poor systems not only consume significant energy dollars, but also degrade
productivity and quality. How does one properly size compressed air piping for the job at hand?
You could ask the pipe fitter, but the answer probably will be, What we always do, and often
thats way off base.

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Another approach is matching the discharge connection of the upstream piece of equipment
(filter, dryer, regulator, or compressor). Well, a 150-hp, two-stage, reciprocating, double-acting,
water-cooled compressor delivers about 750 cfm at 100 psig through a 6-inch port. But most
150-hp rotary screw compressors, on the other hand, deliver the same volume and pressure
through a 2-inch or 3-inch connection. So which one is right? Its obvious which is cheaper, but
port size isnt a good guide to pipe size.
Charts and Graphs
Many people use charts that show the so-called standard pressure drop as a function of pipe
size and fittings, which sizes the line for the what is referred to as an acceptable pressure drop.
This practice, too, can be misleading because the charts cant accommodate velocity- and flowinduced turbulence.
Some might call pipe sizing a lost art, but
we see the issue as a lack of attention to
detail, basic piping principles, and
guidelines. Read on to learn how to size air
piping using velocity, which when combined
with appropriate piping practice, ensures an
efficient compressed air distribution system.
As compressed air system consultants and
troubleshooters, we use certain guidelines
to design new piping systems and to
analyze existing system performance and
opportunities for improvement.
There are four different categories of
compressed air piping. They all have a job
to do, and therefore, require different design
criteria:

Inlet piping
Interconnecting piping of the air supply
Distribution piping headers/sub-headers
Piping to feed the process.

As we look at each of these groups, we will list some of the rules of thumb or guidelines, which
are appropriate.
Inlet Piping
Guidelines: It is important to air compressor efficiency and integrity that the inlet is as cool as
possible, at as high pressure as possible, and free from contaminants such as dirt, pollen, birds,
etc. and water.

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Inlet piping is often ignored today, because many of the fully packaged units have the intake
inside or on the package and take in room or ambient air. However, some plants will remove
the room air intake (particularly when it is contaminated) and install a pipe to an outsidemounted filter for a more appropriate air source. Many larger compressors, such as centrifugals
or oil-free rotary screws, will have cooler outside inlet where the cooler inlet air has a much
higher impact on performance efficiency then a lubricant-cooled rotary compressor.
When this happens, what size pipe? Dont size the pipe by the size of the inlet opening!
The objective is to deliver the air to the compressor inlet at the highest possible pressure after it
leaves the outside intake filter or pick-up point. Like all piping, the pressure loss is a function of
flow (scfm), pipe material, distance, and turbulence.
Size for negligible pressure loss by function it doesnt usually cost much to step up to the next
size.
It can be good practice to provide a large volume
in the suction lines as shown here, just before
the compressor intake flange. This will:

Act as a pulsation dampener

Trap any condensation (be sure to install

drain and trap).

Material: The proper inlet pipe brings the air from the filter to the compressor with no pressure
loss and should not create operational problems with any type of self-contamination on the
inside. It is important to realize that the ambient inlet air condition may well dictate the selection
of one type of pipe over another.
GALVANIZED INLET PIPING has the advantage of resisting corrosion better than standard iron
pipe. However, over time when the corrosion does set in, the galvanizing material then peels
off. The inlet pipe is now a producer of potentially very damaging, solid contaminants between
the filter and the compressor. This would be particularly dangerous to the mechanical integrity
of a centrifugal compressor.
During high humidity weather, it is quite conceivable that condensation will form in the inlet
pipe (therefore, the OEM installation manual should recommend a drain valve be installed on
the pipe before the inlet). Condensation in the pipe will obviously accelerate the time frame
before the coating breaks down. This time frame is dependent upon where the thinnest portion
of the coating is applied.
Stainless steel inlet pipe is the best possible material or such large-diameter, low-pressure
inlet air, as long as it is installed properly and the inside is properly cleaned.

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There are also many grades of plastic material suitable for inlet air piping.
Summary: We recommend either stainless steel or proper plastic-type material for inlet piping
and do not recommend galvanized piping.
Design: Heres where common sense comes in:
Tight turns may cause pressure loss through turbulence run as straight and smooth as
possible and as direct.
We want the air to stay cool if you have to run the pipe into a hot room, or by a heat source
such as a boiler -- then insulate it.
With reciprocating compressors, be sure you are not in critical length. Support the weight of
the inlet pipe dont let it hang on the compressors.
Assuming the filter does its job on dirt, frogs, etc. as contaminants is there any chance of
internal piping condensation. If so, just to be safe, install a drain point at the low point in the
inlet pipe just before it enters the compressor. On centrifugals and oil-free screws, we always
recommend this drain.
Seem simple? All these moves seem logical and easy to follow, particularly having read the
guidelines. We have corrected problems in all these areas time and time again in the field. For
example, recently in a foundry, we found:
Inlet air to compressors 6 pipe
260-300 ft measured vacuum 18
Hg = 9.5 psia inlet pressure
assuming a normal 14.2 psia/inlet
pressure, this lowers the scfm
from 725 scfm at 60F to 501
scfm at 60 -- a loss of 31%
volume per unit.
To supply required 1400 scfm, the
plant had to run one extra 150hp full load estimated electrical
energy cost wasted -- $54,000
/year for 26 years = $1,400,000
wasted energy!

FOUNDRY LONG SMALL INLET PIPE

1040 gal
6 - 300 Ft of inlet pipe

Filter Separator

Filter

Separator

Separator

SULLAIR

20-

20-

20-

150L

150L

150 HP

2
SULLAIR

SULLAIR

150L

Zurn RA 1400
Refer Dryer

Filter

150 HP

150 HP

Interconnecting Piping
This is the piping area where we find the most opportunities in compressed air systems,
particularly in those installed after the late 1970s. The older systems were put in more carefully
and the introduction of lubricant-cooled rotaries created many misconceptions recommended by
well-meaning but untrained personnel.
Guidelines: the higher the pressure the compressor has to produce, the more electrical energy
is required to run (1/2% per psig). With a few exceptions, the most energy efficient point for all

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ESL-IE-05-05-10

compressors to run is at full flow. A well-designed and controlled system will have no more than
one unit at less efficient part load all others at full load or off.
The piping from the compressors to the filters, dryers, and the air receiver is what we call the
interconnecting piping. At todays recognized energy costs, its job is to get the air from the
compressor discharge to the dry air receiver (or system header, if there is no receiver with the
lowest possible pressure loss.
Part of this loss is filter and dryer selection, which is either implemented well or not. However,
we often find significant problems, particularly in multiple compressor installations in pipe sizing
and even more in layout or design.
Too much backpressure in the interconnecting piping can have many consequences, not
immediately obvious:

Reduce effective storage and cause short cycling in step-controlled units not only
wasting electrical energy, but also shortening the life of coolers, motors, air end, and
coupling.

Keep modulated-type controlled units from being fully loaded and subsequently running
multiple units at plant load.

Cause the compressor to run higher pressure to deliver appropriate pressure to the
system.

Nominal
Pipe Size

2
Schedule
40

Cfm
Free
Air
75
100
150
200
250
300
400
500
600
800
1000
1250
1500
1750
2000
2250
2500

Line Pressure -- psig

10

15

20

30

.19
.28
.69
1.20

.16
.24
.57
1.00
1.53

.13
.20
.49
.85
1.31
1.89

.10
.16
.38
.66
1.02
1.47
2.50
3.87

40

50

.13
.31
.54
.83
1.20
2.04
3.16
4.50

.11
.26
.46
.70
1.01
1.73
2.67
3.81

75

100

12

150

.19
.33
.51
.73
1.25
1.93
2.75
4.87
7.55

.15
.26
.40
.57
.98
1.51
2.15
3.82
5.90
9.12

.12
.21
.33
.47
.80
1.24
1.77
3.13
4.85
7.49
10.8

.10
.18
.28
.40
.68
1.05
1.50
2.66
4.12
6.35
9.17
12.5
16.3

200

250

300

350

.14
.21
.31
.52
.81
1.05
2.04
3.16
4.87
7.02
9.54
12.5
15.8
19.4

.11
.17
.26
.42
.65
.93
1.65
2.56
3.96
5.70
7.74
10.1
12.8
15.8

.15
.21
.36
.55
.79
1.39
2.16
3.32
4.80
6.50
8.50
10.8
13.3

.13
.18
.31
.48
.68
1.20
1.86
2.87
4.14
5.62
7.35
9.30
11.4

Most often, inexperienced compressed air system design personnel use only the Standard
Pressure Loss Charts (see above). These charts reflect pressure loss in piping what we
normally call friction loss the air pressure being lost to the friction on the pipe walls. As you
see, the chart is in psig loss per 100 of pipe based on flow (scfm) and entry pressure (psig).
This is generally very accurate and satisfactory for distribution air, but in the interconnecting
piping, we have to consider another cause of pressure loss turbulence.

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Pressure Loss in Pounds for Each 100 Feet of Straight Pipe

The impact of turbulence on pressure loss is velocity dependent. If the air system designed is
not considering turbulence, then they are not up to modern times.
Interconnecting piping is usually short runs tying many pieces of equipment together, perhaps
with bypasses. It can become very convoluted.
Using only the standard pressure drop charts will indicate low friction loss of smaller pipe due to
the short runs. As the pipe selection gets smaller, the velocity increases. The velocity also
increases as the pipeline pressure falls.
These higher velocities, combined with some thoughtless piping practices by installers or
designers not familiar with gas transmission, can lead to some very significant pressure losses
and completely upset the system. Often they run for years like this because the maintenance
personnel cannot see any damage.
For example, the following schematic shows two separate compressor rooms in the same
foundry. Both have three 750 cfm @ 100 psig compressors. The piping dictated apparently by
the size of the connection is significantly different.

6 Discharge Line

2 Discharge Line

6
2

3 Header

6
2

Three 150-hp Class 750cfm Reciprocating

Compressors
1968 units

Electric Cost of 18 psig @ .05

kWh / 8760 hrs = over
$60,000 /year wasted

The large reciprocating units were

installed in 1968 6 discharge to a
10 header with directional angle
entry. The velocities are 7.9 fps to
8.4 fps.
The calculated pressure loss is less
than 1 psig by the standard
pressure chart and the actual
measured pressure loss is less than
1 psig. This system is done by the
book and works fine.
The other system constructed in
1978 (audited in 2001 & corrected)
uses 2 lines to a 3 header with
crossing tee connection.

The velocities are 69.8 fps to

92.6 fps.

The calculated pressure loss

from standard charts is 8.0
psig -- relatively high, but
acceptable at the time.

Actual measured pressure

loss was 18 psig--10 psig of
implemented pressure loss
was turbulence-driven
caused by high velocities and
crossing tees.

Three 150-hp Class

750-cfm Rotary Screw
Compressors
1978 units

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Typical Crossing Tee and Dead Head

At higher velocities, these create significant turbulencedriven pressure loss

Directional Angle Entry

A proper directional angle entry

1968 to 1978 What a Difference a Decade Makes!

The short cycling created by these high velocities and piping configurations basically helped to
cause the plant to run three 150-hp compressors when the original sizing called for two units.
At (.05 kWh @ 8760 hours 176 bhp this is a waste of over $60,000 /year in electrical energy
costs for over 20 years -- $1,200,000!!
There are some very
distinct guidelines for
pipeline velocity, which we
have found to work very
well in the real world.

Interconnecting piping
should never exceed 20
fps. There is no such
thing as too low velocity
(or too large pipe) for
this application.

Guidelines for Interconnecting Piping from Compressor(s)

through Filters, Dryers, etc. to System

1 Pipe

56.8 scfm
20 fps

2 Pipe

838 scfm
20 fps

492 scfm
20 fps
3 Pipe
All pipeline velocities to be
20 fps or less at 100 psig.
For Example:

4 Pipe
3295 scfm
20 fps

1901scfm
20 fps
6 Pipe

Avoid all dead heads,

crossing tees, chokes
for flow meter use
large enough pipe and
long ells.

220 scfm
20 fps

8 Pipe

5191scfm
20 fps
10 Pipe

At velocities below 20
fps, design is much less
critical.

7368 scfm
20 fps
12 Pipe

Use Long Ells

for turns.

90o Turns

Crossing T
Dead Head

Use 45o directional (to flow)

connection for two conjoining
air lines.

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The Hidden Factor in Poor Interconnecting Piping

LOSS OF EFFECTIVE STORAGE
All air systems will do better with storage between the user and the process. Some types of
control systems are more sensitive to lack of acceptable minimum storage than others.
The amount of effective storage for any control system is really a function of where the
operating control band (full load pressure to no load pressure) is equalized by the backpressure
in the system.

4 psid

Control Band 10 psig

5 psid

If the compressor is set

to full load at 100 psig
and unload at 110 psig
and pressure loss in the
interconnecting piping
and equipment reaches
10 psig at the afterfilter
as in the figure at left.
The effective storage is
537 gals /71.84 cft. The
storage value of the
distribution piping is not
being utilized. This is
much too small to allow
efficient operation of the
compressor at full range.

4 Header
2000 ft
176.5 cuft
1321 gallons

4 psid

500
gallon

1 cuft

1 cuft

500 cfm
100 hp

66.84 cuft

3 cuft

EFFECTIVE STORAGE
71.84 cuft / 537 gallons

The example at right shows

the same system set up with
a special low pressure drop
coalescing filter, oversized
heat sink-type refrigerated
dryer (and good piping).
The operating pressure
band includes all the
headers throughout the
system. The system is
optimized with regard to
controls. The effective
storage now is 1857 gallons
or 248.34 cft minimum

Control Band 10 psig

<1 psid

<2 psid

500
gallon

500 cfm
100 hp

66.84 cuft

4 Header
2000 ft
176.5 cuft
1321 gallons

Oversized Heat
Sink Cycling
Dryer

2 cuft

3 cuft

EFFECTIVE STORAGE
248.34 cuft / 1857 gallons

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Discharge Piping or Interconnecting Piping

Here we have more complex considerations:
Materials: The discharge air from the compressors can be at 250F to 350F (for centrifugal,
oil-free rotary screw and reciprocating types), or from 200F to 220F (for lubricant-cooled rotary
screw compressors), so the pipe must be able to withstand those temperatures.
Even if there is an aftercooler that drops the temperature to 100F, consideration must be given
as to the consequences if the aftercooler were to fail.
Compressed air-generated condensate tends to be acidic. In oil-free compressors (such as
centrifugals and oil-free rotary screws), it is usually very aggressive.
The basic objective of the interconnecting piping is to deliver the air to the filter and dryers and
then to the production air system with little or no pressure loss, and certainly with little or no selfcontamination.
Galvanized piping will have the same problems once it begins to peel as we described on the
inlet application. In all probability, due to the aggressive acid characteristics of the condensate,
the galvanized coating life may be much shorter.
Regardless of the plastic-type manufacturers claim, we never recommend any plastic-type
material for interconnecting and distribution header piping. Most of these materials carry
cautions not to be exposed to temperatures over 200F and to avoid any types of oil or
lubricants.
Here again, stainless steel or appropriate copper is our number one recommendation for the
interconnecting piping from the compressor to the filter/dryers when the compressed air is oil
free. It will obviously resist corrosion much better than standard schedule 40 black iron. Some
other considerations:
Most areas will allow schedule 10 stainless steel in lieu of schedule 40 black iron.
For the same diameter pipe, stainless steel or copper will be much lighter and easier to handle,
usually lowering the labor cost.
For welded connections, stainless steel usually just requires one bead, while black iron pipe
usually requires three beads (weld-fill-cover). This should also lower the labor cost.
Stainless steel does not usually seal well when threaded. It will do much better with Victaulictype connections when welding is not practical.
Distribution Piping: It is the job of the air distribution piping to deliver compressed air to all
parts of the plant with little or no pressure loss. Should certain areas of the plant have surge
demands high flow demand over very short time frames it also has to handle this, feeding
full flow full pressure to that process and not pulling from other processes.

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In this case, the header

piping itself is acting as a
storage vessel for the
processsometimes a
supplemental storage
vessel (air receiver) at the
right location can be very
effective if the headers
are too small. This type
application has to be
evaluated on a case-bycase basis.
Sizing Distribution Pipe:
Modern thinking would
call for 0 psig pressure
loss in the distribution by
design. The real trick is
estimating how much flow
capacity is in any one
section at the highest
possible load.

Dead Head

Old abandoned Orifice Plate

Flow meter 3-5 psid

6
Air from Compressor
Room 1

Air from Compressor

Room 2

All processes total area fed

by 1 small 1 drop
subheader

Drop at bottom of header

should be top

1 Air Line from

Compressor Room 2

Crossing Tee

High Pressure Loss

Tie in at bottom of drop

should be -

1/2

Air Leak

1/2

Common Compressed Air Distribution Piping Mistakes

We start with what scenarios the average flow and size for 20 fps or less velocity (although
many feel up to 30 fps is all right and actually will work). Then we check for friction loss for the
maximum flow at the largest runs. You will have to know or estimate accurately the process
demand for this.
As stated earlier, oversized header can act as storage and perhaps be the most economical
selection.
Oversized Header Piping to create effective storage at the process. Often this can work, as
show below.
In Figure 1, the plant installed a large air receiver with an intermediate controller trying to hold a
critical steady pressure at the regulator discharge for optimum production and quality. There
was a 200 run of 4 pipe from the intermediate controller or regulator and the pressure varied
from 85 to 90 psig as the regulator opened and closed randomly. The process regulators also
delivered erratic pressure to blow off and usually well below the setting. The pull down band in
the main 4 feed was 4 psig. The regulator feed variance was much greater some well above
10 psig.
The following actions were taken (see Figure 2):

Move receiver and intermediate controller closer to the process

Increase main feed line from 4 to 6 to eliminate pressure loss.

Oversize feeder header to the regulator to 12. This now created enough storage that
regardless of the timing of the regulated bursts of air, there was enough storage to feed
each line at full capacity without pulling the inlet pressure down at the nearby feeds or
even in the overall header.

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59 PSIG

AIR PEELER

AIR PEELER

AIR PEELER

61 PSIG

AIR PEELER

64 PSIG

AIR PEELER

4
HEADER

65 PSIG

AIR PEELER

72 PSIG

72 PSIG

72 PSIG

AIR PEELER

72 PSIG

AIR PEELER

71 PSIG

AIR PEELER

72 PSIG

AIR PEELER

68 PSIG

AIR PEELER

72 PSIG

AIR PEELER

85 PSIG

3200 GAL

4 FROM
COMPRESSOR ROOM
MULTIPLE 90O TURNS

5 OR 6 STRAIGHT
FROM COMPPRESSOR
ROOM

Figure 1

85-80 PSIG

Figure 2

90 PSIG

Sometimes It Doesnt Work and You Need the Auxiliary Storage

Provided by Properly Sized and Applied Air Receiver
The figure below is a process that feeds a large product collector requiring eight cubic feet of air
in .75 seconds every five seconds.

1 1/2

1 1/2

Supply Air
CIP Solenoid

Regulator

105 psig

Cashco Regulators

Check valve

Air to Pulsers
90-50 psig
1

1/2

Filter

Instrument Air
Filter

Regulator

The main 2 feed from the air system is at

105 psig. The regulators and piping were
installed by the contractor. Each time the
process runs, pressure quickly pulls down
as low as 50 psig, which has very serious
negative impact on productivity, product
quality, and maintenance of the collector.
Regulator and piping sized to surge
demands as this must be sized on rate of
flow:
Establish Rate of Flow: 8 cfm @ 0.75
seconds =
8 x 60 sec 0.75 = 640 cfm rate of flow

Supply Feed from System

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HEADER

ESL-IE-05-05-10

Trying to use the pipe volume 2 and a quick response regulator did not work out:
No regulator has quick enough response to handle this 640-scfm rate of flow in 0.75 seconds,
so we will supply the demand with storage and allow a metering valve to refill the receiver over
a longer time frame (4 seconds), which will reduce the rate of flow from the air system
significantly.
Calculating maximum air receiver pressure loss 8 cfm demand in 0.75 seconds:
TDecay =

(Storage Vol) (P2 P1) .

(Net rate of flow) (14.5 psig)

0.0125 min = (V) (10 psig) = 10 V = 116

(0.75 sec)
(640) (14.5)

V = 11.6 cft or 86 gallons

Recommended action to deliver a consistent minimum pressure of 90 psig to the process during
pulsing (see figure below):

Remove 1 piping and both contractor-supplied regulators.

Install 2 piping to a metering valve (gate valve); adjust valve to refill the receiver in four
seconds after the pulser closes. Once set, remove handle to eliminate possibility of
inappropriate adjustment.

Install 120-gallon vertical air receiver to store at 100 psig or more.

Using a standard 120-gallon vertical
receiver (16 cu ft), we have the following
drop:

1 1/2
Supply Air
CIP Solenoid

1 1/2

Air to Pulsers
90+ psig

Regulator
105+ psig
2

Metering
Valve

120
Gallon
Check valve
2

2
1/2

0.125 = 116x = 16 = 7.25 psig

Establish new rate for 4-second refill:
0.06 min = (16) (7.25) = 0.966x =
(4 sec)
x (14.5)
116 = 120 cfm rate of flow

Filter

Filter

Regulator

Supply Feed from System

Instrument Air

Summary: the receiver, along with a

metered flow allowing the receiver to
refill over four seconds, will reduce the
rate of flow from 640 cfm to 120 cfm.

There is not a regulator, which can react in the short amount of time in which the pulsers hit at
the required rate of flow. The receiver and metering valve will cushion the distribution piping
from this high rate of flow experienced by the system and the 2 main feed, thus allowing it to
operate correctly.

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Our piping modification shows a new metering valve sized to handle the new flow at 120 cfm.
The bypass is piped with angle entry and exit around the metering valve. The process now
operates correctly.
What we have had here are two downstream processes that require a little special attention.
Until you get into the details, you cant be sure what the answer is. However, any surge
demand should be reviewed as to what effect it is having on the rest of the system and what
type of piping design it needs.
If the header is sized to 20 fps, not to exceed 30 fps, it will generally not have problems except
from these type demands or over very long runs.
Loop design systems are always a good idea and often a system that has become restrictive
over time may be corrected by creating loops AFTER PROPER INVESTIGATION. There are
many other considerations, which are always discussed which we will not cover here
centralized or decentralized system, top or side header connections, pipe slope, etc.
Be careful of subheader:
WATCH THE SUB-HEADERS

6 Header

1
1

1
D7

All of these subheaders are fed by a 1

line. It is always easier to tie in on the
end than hot tap or put another tap
into the main header. Often this can
lead to very high pressure loss at the
process.
Tip: When you build the main header,
put in extra taps, valved off on top and
sides.

1/2

Like all things, the header system

seems simple until you start looking at
what it has to do, what may be required
in a Preliminary Investigation before
actual design.
1/2

All of these processes fed by ONE 1 Feed

How Did Your Header Sizing Or Design Get Selected?

Drops to Process/Process Feeds
Again, this one seems simple feed to the process. Just attach to the top or side of the header
or subheader oops! where does the subheader get its air?

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Size the line size by -- ?? certainly not opening size! Who in the plant knew the average
demand in flow rate? Who knew in rate of flow? What is the minimum required pressure?
Why? If you dont know most of these answers, you are shooting blind.
Again, there is no such thing as too big a pipe or hose, unless the size interferes with
productivity. Most of the time when we have a low pressure problem because of being too far
from the compressors, we dont find the problem in the main headers it is usually in the
subheader, feeds, or connections.
You must know or estimate the flow demand (and the pressure), then check sizing on all feed
lines, hoses, tubes, filter, quick disconnects, regulators, etc.
The Book talks about allowing from 35 fps to 50 fps. Common sense says run it as large as
you can and when you have to go to smaller line, hose, etc., make it as short as possible. Look
for condensate control at all low and drop points.
Some general guidelines to evaluate feeds:

Know the flow and the optimum entry pressure required

When required, dont be afraid to use a needle gauge

Always measure pressures at load and at rest to accurately see the results

Know the performance data on all valves, regulators, quick disconnects on the feed lines
what effect on pressure drop the anticipated rate of flow will have.

Some Common Sense Tips on System Piping

20 or Less Feet per Second Velocity:
Rust, scale, water and oil will not carry down stream and into the element

Correct pipe sizing can

improve performance and
extend filter life. Large water
and oil drops and scale will
generally travel with the air
stream at flow velocities above
30 fps. At velocities lower than
20 fps, they will generally fall out.

Recommendation: Pipe to all filters and dryers with pipe sizing to handle the expected
maximum flow at less than 20 fps at pipeline conditions. At these conditions, a drain leg
ahead of the filter is always a good idea to extend it full performance life and remove any gross
load before it reaches the element. Twenty-five to 35 pipe diameters in length of the correct
size pipe will effectively slow the air down before it reaches the filter (drain leg). This may
improve filter performance and will extend element life.

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Compressed Air Facts That Will Help to Keep the Process Air Clean and Dry
Use common sense: Typical application considerations that affect performance.
Many air systems we review with
poor air quality problems have
ignored some common sense rules
that always apply. Keeping these
in mind will assure proper
performance over a longer period
of time at a lower operating cost.

30+ Feet per Second Velocity:

Virtually everything such as rust, scale, water and oil will carry down stream and into the element

Three basic rules on controlling

water contaminants before and
after the dryer, but ahead of a main
line filter:
Water vapor will always move from an area of high relative
humidity to low relative humidity regardless of the direction of air
flow. Dont ignore leaks.

DRY AIR

Liquid water always drains down by gravity regardless of

air flow -- remember when piping and draining. Automatic
condensate drains on all risers with undried air.

Water
Vapor

Liquid water left to stand in air receiver, filter housing, separators, low spots,
etc., will evaporate into the dry air raising the relative humidity and pressure
dewpoint within the system. Drain condensate immediately and continuously.
Example -- Piping to Bagging Unit Regulator:
Original System Connection

Corrected Connection

Liquid condensate drains into regulator

negatively affects operation and life.

Liquid condensate now drains from system

pipe and regulator to automatic drain.
Regulator gets no liquid.

Hose
C
o
n
d
e
n
s
a
t
e

Regulator

Pipe

Regulator

Pipe
Support

Floor

Drain Point

No changes to the compressed air system should be made without permission from the Compressed Air
Czar. No equipment ordered unless the central air utility can handle or has plans to handle.

COMPRESSED AIR IS YOUR MOST EXPENSIVE UTILITY

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APPENDIX
OTHER GENERAL PIPING & SYSTEM DESIGN GUIDELINES
NOT SPECIFICALLY COVERED IN MAIN PAPER

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