Sizing Compressed Air Mains The compressed air mains are the ali-importent link between the compressor and the point of usage. It is thoroughly bad to install mains which are too small and cause high pressure drop. If, for example, a compressor has to work at 8 bar 120 psi, to cater for pressure drop condi- tions, whereas 7 bar 100 psi would normally meet’ the case, it calls for an additional power input of as much as 10%. Mains, which are too small also cause high velocity, making it difficult to separate the water from the air because much of the conden- sed vapour running as a stream of water along the bottorn of the pipe, will be whipped up by and carried along with the fest moving air stream. Whilst watchful eye must be kept on the pressure drop, it is common practice to size compressed ait mains on velocity and a reason- able figure for all practical problems is 6-9 m/s 20-30 ft/sec which is sufficiently low to Prevent excessive pressure drop on most systems and will allow moisture to precipitate out without re-entrainment, Many compressed air systems are working inefficiently because the demand has outgrown the supply — new pneumatic plant has been added from time to time without addition to ‘the compressor plant or mains. In designing a new plant, therefore, some thought might be given to possible future demands and allowance made in the mains sizes Sizing by velocity presents an easy form of determining pipe size for a given duty, but it must be remembered that the duty of a compr- essor and the demand of the equipment is usu- ally expressed in dm?/s of free air cubic feet of free air per minute and that when compressed the volume will be less. Table 8 shows that ratio of compression and the actual volume occupied at any given pressure can be found by dividing the volume of free air by the ratio of compression. Example (Metric SI Units) At a gauge pressure of 8 bar, Table 8 shows the ratio of compression as 8:9 so if we have At 2 gauge pressure of 120 psi, Table 8 shows the ratio of compression as 9-16 so if we have 100 cubic feet of free air compressed to 120 psi, it will occupy a space of: 400 S76 7 43-66 cubic feet Table 9 shows the equivalent volume already worked out for some of the more everyday pressures. Table 10 shows the volume of air which can be carried by various sizes of pipes at given velocities, Pipe sizing is, therefore, reduced to simpli- city by using these tables. Example (Metric S! Units) To determine the size of 2 main to carry 100 dm/s of free air at a working pressure of 7-0 bar. From Table 8 it will be seen that at 7-0 bar the ratio of compression is 7:91 so the actual volume of 100 dm? of free air when compressed, to 7-0 bar is: 100 a1 Alternatively, because 7:0 bar is a pressure in everyday use Table 9 will give the answer direct without the bother of working it out. Having decided that the velocity shall not exceed 6 m/s, from Table 10 we can determine the size of pipe required to carry 12-64 dm°/s of air. Casting an eye along the line opposite 6 m/s in the left hand column (Table 10) we find that 2.50 mm pipe will carry 13-00 dm*/s and is the nearest commercial size to our requirements. 1264 Example (Imperial Units) To determine the size of a main to carry 200 cubic feet of free air per minute at a working pressure of 100 psi. From Table & it will be seen that at 100 psi the ratio of compression is 7-8 so the actual volume of 200 cubic feet of free air when compressed to 100 psi is: 190 dm” of free air compressed to 8 bar, it will 200 . i See FE 2 eH cubic feet 190 = 21.35 dm? 89 Table 8 Metric SI Units Ratio of Compression Gauge Pressure bar [0-5|1 [2 [3 [4 [5 [6 [7 [8 [10 [12 |i4 [is Ratio of Compression| 1-5 [1-99] 2-97 |3-96] 4-95] 5.94| 6-92|7-91| 8.9 |10-87] 12.85|1482|18-77 Table 8 Imperial Units Ratio of Compression Gauge Pressure pat 70 20 | 30 En) 50 50 70 80 Ratio of Compression | 168 | 296 | 304 | 372 | 440 | 508 | 576 | 6-44 Gauge Pressure ps 30 700 _[ 110 | 120 | 130 | 140 750] 200 Ratio of Compression | 712 | 78 | 848 | 916 | 984 | 1052 | 112 | 146 7Alternatively, because 100 psi is 2 pressure in everyday use, Table 9 will give this answer Girect without the bother of working it out. Having decided that the velocity shali not exceed 20 feet/second, from Table 10 we cen determine the size of pipe required to carry 25-64 cubic feet of air per minute at this velocity. Casting an 20 feet/sec in the | we find that 2 2” pipe eye slong the fine opposite hand column, (Table 10}, vill carry 28 cubic feet and is the nearest commercial size to our requirements. For long runs the pressure loss through mains sized by the velocity method may be higher than desirable and it is as well to check what the actual pressure drop will be. It is of course only possible to obtain rough estimates es so much depends on the type and condition of the pipe and on the resistance of the various fittings. In calculations it is usual to allow for fittings by considering them in terms of straight lenth of pipe and Table 11 shows the equivalent lengths in metres feet for typical fittings. Table 9 Metric SI Units Equivalent Volume of Compressed Air at Common Pressures By adding the equivalent lengths to the actual length of pipe, the loss in each section of a system can be easily found by reference to the chart. The nomogram in Table 12 gives a ready means for determining pressure drops through pipes often found in industry (this information for smaller bore pipes is set out in Table 15). It is based on the following formula which can also be used for pipe sizes outside those shown in the table. Pressure Drop in bar = KLO2 _ Rees Where K= 800 Length of pipe in metres The volume of free air in dm?/s passing through the pipe. R= The ratio of compression at the beginn- ing of the pipe The internal pipe diameter in mm d= Table 9 Imperial Units Equivalent Volume of Compressed Air at Common Pressures Equivalent Volume (dm? ) Equivalent Volume (cu ft} Volume of when compressed to Cubic Feet when compressed to Free Air gauge pressures of Free Air pressures of den? 4 bar 5 bar 7 bar 60 psi 20 psi__ 100 psi 5 101 084 063 10 1-96 1-55 1-28 10 2.02 168 1-26 20 3.94 3-10 2:56 15 3.03 252 1.90 30 5-69 465 3.84 20 4.04 3:37 2-53 40 7-86 6-20 5412 25 5.05 421 3-16 50 9-84 774 6-41 30 6-06 5-05 3-79 60 18 9.23 768 35 707 5-69 442 70 13-8 10-8 896 40 8.08 6-73 5-08 80 18-7 12-4 10-2 50 10-4 8-42 632 90 17-7 14.0 115 60 124 10-1 758 100 196 155 128 70 14-4 18 8-85 125 246 19-4 158 80 16-2 13-5 10-4 150 29-5 23-5 19-2 20 18-2 15-4 114 178 34.4 27-2 22-4 100 202 168 126 200 39-4 31.0 256 125 25-2 210 158 250 49-2 38-7 316 150 303 252 19.0 300 58.9 46-5 384 175 353 295 22-4 350 688 542 448 200 40-4 33-7 253 400 786 62.0 51-2 225 45-4 379 28-4 450 ge4 63-7 87-7 250 50-5 42-1 316 500 284 774 63.3 275 555 463 348 00 4180 929 769 300 606 50-5 379 700 138-0 108-0 89-6 350 70-7 ee eae 800 1570 1244 103-0 400 80-8 673 506 900 177-0 140.0 115-0 500 101-0 84-2 63-2 1000 196-0 155-0 127-0 780 151-0 126-0 95:0 1500 295-0 232.0 192-0 1000 202.0 168-0 126-0 2000 394-0 3100 256.0 1250 252.0 210-0 158-0 2500 432-0 3870 316.0 8Table 10 Metric SI Units Volume of Compressed Air (dim Carried by Grade Stee! Pipes, of Minimum Bore, to BS 1387, at Given Velocities Velocity _ Volume of air through medium grade steel pipe, to BS 1387, minimum bore (mm) mis 15 201-25 32 40 506580100125 150200 3-0 O06 17 17 30 41 65 109 157 257 392 562 O85 35 07 13 20 35 47 76 127 176 300 45:7 655 115.0 4.0 08 14 23 40 54 87 146 20-1 34.2 52:2 749 131.0 45 09 16 26 45 61 98 164 226 385 58:8 842 147.0 5-0 10 18 28 50 68 108 182 25-1 428 654 936 164.0 55 11 20 34 55 74 119 200 276 47:1 71:9 103-0 181-0 60 12 27 34 60 814 130 218 30-1 513 785 1120 197-0 6-5 13°23 37 65 88 141 237 326 556 85:0 1220 213-0 7-0 14° 25 40 70 95 151 255 35-1 599 91:5 131-0 230-0 75 15 27 43 75 101 162 273 376 642 98:0 140-0 246-0 80 16 28 45 80 108 17:3 29-1 40-1 685 105-0 150-0 263-0 85 17 30 48 85 115 184 31:0 426 728 111-0 159-0 278-0 2-0 18 3:2 51 90 122 195 328 45-1 77-1 118-0 169-0 296-0 Table 10 Imperial Units Volume of Compr Steel Pipes, of Minimum Bore, to BS 1387, at Given Velocities sed Air (cfm) Carried by Medium Grade Velocity Volume of air t mn grade steel Dip jinimum bor ftlsec "a a pt 6 10 73 23 36 14 3584127 12 1528 44 16 28 «39° 86101145 14 1B 3:20 54 19 33 45° «77 «4118169 16 20 37 59 103 140 22 38 52 88 135 193 18 23 41 66 116 160 25 42 58 99 152 217 20 25 46 73 128 17:0 28 47 65 110 168 242 22 28 51 81 1417 190 31 52 71 121 185 266 24 30 55 88 154 21:0 34 56 78 132 202 290 26 33°59 96 167 230 36 61 84 144 219 314 28 35 64 103 179 240 39 66 91 154 236 338 30 38 69 41.0 193 26.0 42 71 97 166 _253 362 Table 11 Metric SI Units Resistance of Pipe Fittings (Equivalent Length in m) Nominal Pipe Size (mm) Type of Fitting 15: __ 201 25_32._40'_50_65_80_100._ 125 Elbow 0-26 037 049 067 076 107 1-37 183 244 32 90°Bend (long) 0-15 0-18 024 038 046 061 0-76 091 1:2 1:52 Return Bend 0-46 061 0-76 107 1-2 168 198 26 366 488 Globe Valve 0-76 107 1:37 198 2.44 3.36 396 518 7:32 9.45 Gate Valve 0-107 0-14 048 0:27 032 040 049 064 091 1.20 Run of Standard Tee 0-12 0-18 0-24 038 040 052 067 085 1:2 152 Through Side Outlet of Tee 0-52 0-70 0-91 1.37 1:58 214 2.74 366 4-88 6-40 Table 11 imperial Units Resistance of Pipe Fittings (Equivalent Le ngth in feet) Nominal Pipe Size (inches) Type of Fitting Pie ah Med 2 OE OS 45 Elbow 09 12 16 22 25 35 45 60 80 105 90°Bend (long) 05 06 08 147 «15 20 2 40 50 Return Bend 15 20 25 35 40 55 65 85 120 160 Globe Valve 25 35 45 65 80 110 130 170 240 310 Gate Valve 04 05 06 09 10 13 16 24 30 -40 Run of Standard Tee 04 06 08 11 13 17 22 22 28 50 Through Side Outlet of Tee 17 23 3:0 45 52 70 90 120 160 21.0= The volume of free air in cu ft/minute passing through the pipe Table 12 Metric SI Units Pressure Drop in Internal die of Pipe in mm Flow of Free Air in drm3/s 5000 2000 20 Medium Weight Steel Pipe to BS 1387 Example (Metric SI Units) To determine size of pipe needed to pass 300 dm3/s free air with a pressure drop of not more than 300 mbar in 125 m of pipe. Air pressure is 9 ber. 300 300 mbar.in 125 m is equivalent to —— 125 = 2-4 mbar/m. Join 9 ber on the air pressure line to 2-4 20 The length of pipe in feet The ratio of compression at the beginn- ing of the pipe @ = The internal pipe diemeter in inches Steel Pipes (15 mm to 100 mm) Pressure Drop Through Pipe Air Pressure in mbar/m in bar Reference Line 30 2 20 3 4 10 5 6 5.0 7 40 8 9. 30 16 18 mbar/m on the pressure drop line and project to cut reference line at X. Join X to 300 dm Vs and project to cut pipe size line at approxi mately 61 mm. Therefore choose pipe having @ minimum bore of at least 61 mm (a 65 mm nominal bore pipe to BS 1387 has 2 bore of 69 mm and would therefore meet the case and give some margin}.Table 12 Imperial Units Pressure Drop in Steel Pipes (14 to 4”) Internal dia of Pipein Flowof Free inches Air in cfm 40 a le 3000 @ NT F 2000 @) S gf 15° 1000 @Q-120 & 15 @) © 1.0 @) Or1os Pressure drop in Reference psi through 100 ft Air pressure Line of steel pipe in psi ae 20 12 10 3 9 8 7 gi 50 5 4 75 100 125 Example ({mperial Units) To determine the pipe size to pass 1000 cu ft free eir per minute with a pressure drop of not more then 5 psi in 500 ft of pipe and @ line pressure of 150 psi. 5 psi in 500 ftis equivalent to 1 psi in 100 ft. Therefore join 150 psi on the pressure scale to 1 psi on the pressure drop scale to cut the reference line at X. Join the point X tp the 1000 cfm point, and project it to cut the pipe diameter line at point Y. So choose @ 3” pipe. a