ESL-IE-05-05-10

Hank van Ormer AIRPOWER USA 11520 Woodbridge Lane

President 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

Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

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 won’t hold the
system pressure. You purchase another 200-hp unit– things get better but still seem to
be marginal?

What’s 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 it’s 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 isn’t the distance – it’s 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 post-
project 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
that’s way off base.

AirPower USA, Inc. 1 www.airpowerusainc.com

Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

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? It’s obvious which is cheaper, but
port size isn’t 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 can’t accommodate velocity- and flow-
induced 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.

AirPowerProceedings
USA, Inc. of the Twenty-Seventh Industrial Energy Technology
2 Conference, New Orleans, LA, www.airpowerusainc.com
May 10-13, 2005
 ESL-IE-05-05-10

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 outside-
mounted 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? Don’t 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 doesn’t 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.

AirPowerProceedings
USA, Inc. of the Twenty-Seventh Industrial Energy Technology
3 Conference, New Orleans, LA, www.airpowerusainc.com
May 10-13, 2005
 ESL-IE-05-05-10

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: Here’s 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 – don’t 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 FOUNDRY – LONG SMALL INLET PIPE

260-300 ft measured vacuum 18” 1040 gal

Hg = 9.5 psia inlet pressure 6” - 300 Ft of inlet pipe

assuming a normal 14.2 psia/inlet
pressure, this lowers the scfm
from 725 scfm at 60°F to 501
3”
scfm at 60° -- a loss of 31% Filter Separator
Filter Filter Separator
volume per unit. 2” 2”
Separator 2”

To supply required 1400 scfm, the SULLAIR SULLAIR SULLAIR

plant had to run one “extra” 150-
hp full load – estimated electrical 150L
20-
150L
20-
150L
20-

energy cost wasted -- $54,000

150 HP 150 HP 150 HP
/year for 26 years = $1,400,000 Zurn RA 1400
Refer Dryer
wasted energy!

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

AirPowerProceedings
USA, Inc. of the Twenty-Seventh Industrial Energy Technology
4 Conference, New Orleans, LA, www.airpowerusainc.com
May 10-13, 2005
 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 today’s 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.

Cfm Line Pressure -- psig

Nominal
Free
Pipe Size
Air 10 15 20 30 40 50 75 100 12 150 200 250 300 350
75 .19 .16 .13 .10
100 .28 .24 .20 .16 .13 .11
150 .69 .57 .49 .38 .31 .26 .19 .15 .12 .10
200 1.20 1.00 .85 .66 .54 .46 .33 .26 .21 .18 .14 .11
250 1.53 1.31 1.02 .83 .70 .51 .40 .33 .28 .21 .17 .15 .13
300 1.89 1.47 1.20 1.01 .73 .57 .47 .40 .31 .26 .21 .18
400 2.50 2.04 1.73 1.25 .98 .80 .68 .52 .42 .36 .31
2” 500 3.87 3.16 2.67 1.93 1.51 1.24 1.05 .81 .65 .55 .48
600 4.50 3.81 2.75 2.15 1.77 1.50 1.05 .93 .79 .68
Schedule 800 4.87 3.82 3.13 2.66 2.04 1.65 1.39 1.20
40 1000 7.55 5.90 4.85 4.12 3.16 2.56 2.16 1.86
1250 9.12 7.49 6.35 4.87 3.96 3.32 2.87
1500 10.8 9.17 7.02 5.70 4.80 4.14
1750 12.5 9.54 7.74 6.50 5.62
2000 16.3 12.5 10.1 8.50 7.35
2250 15.8 12.8 10.8 9.30
2500 19.4 15.8 13.3 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.

AirPowerProceedings
USA, Inc. of the Twenty-Seventh Industrial Energy Technology
5 Conference, New Orleans, LA, www.airpowerusainc.com
May 10-13, 2005
 ESL-IE-05-05-10

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.

The large reciprocating units were

6” Discharge Line installed in 1968 – 6” discharge to a
10” header with directional angle
entry. The velocities are 7.9 fps to
2” Discharge Line
8.4 fps.
The calculated pressure loss is less
than 1 psig by the standard
6”
pressure chart and the actual
2”
measured pressure loss is less than
1 psig. This system is done by the
3” Header
book and works fine.

6” The other system constructed in

1978 (audited in 2001 & corrected)
2”
uses 2” lines to a 3” header with
Electric Cost of 18 psig @ .05 “crossing tee” connection.
kWh / 8760 hrs = over

6”
$60,000 /year wasted
• The velocities are 69.8 fps to
92.6 fps.
• The calculated pressure loss
Three 150-hp Class 750-
2” from standard charts is 8.0
cfm Reciprocating
Compressors
psig -- relatively high, but
Three 150-hp Class
1968 units 750-cfm Rotary Screw acceptable at the time.
Compressors
1978 units • Actual measured pressure
loss was 18 psig--10 psig of
implemented pressure loss
was turbulence-driven
caused by high velocities and
“crossing tees.”

AirPowerProceedings
USA, Inc. of the Twenty-Seventh Industrial Energy Technology
6 Conference, New Orleans, LA, www.airpowerusainc.com
May 10-13, 2005
 ESL-IE-05-05-10

Typical “Crossing Tee and Dead Head”

At higher velocities, these create significant turbulence-
driven 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 Guidelines for Interconnecting Piping from Compressor(s)
distinct guidelines for through Filters, Dryers, etc. to System
pipeline velocity, which we
56.8 scfm 220 scfm
have found to work very 20 fps 20 fps
1” Pipe
well in the “real world.” 2” Pipe

• Interconnecting piping 492 scfm

20 fps
838 scfm
20 fps
should never exceed 20 3” Pipe 4” Pipe
fps. There is no such All pipeline velocities to be
20 fps or less at 100 psig. 1901scfm 3295 scfm
thing as too low velocity For Example: 20 fps 20 fps
(or too large pipe) for 6” Pipe 8” Pipe
this application.
• Avoid all dead heads, 5191scfm 7368 scfm
crossing tees, “chokes” 20 fps 20 fps
for flow meter – use 10” Pipe 12” Pipe
large enough pipe and
“long ells.”
• At velocities below 20
Use Long Ell’s
fps, design is much less for turns.
critical.

90o Turns Crossing “T”

Dead Head

Use 45o directional (to flow)

connection for two conjoining
air lines.

AirPowerProceedings
USA, Inc. of the Twenty-Seventh Industrial Energy Technology
7 Conference, New Orleans, LA, www.airpowerusainc.com
May 10-13, 2005
 ESL-IE-05-05-10

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.

If the compressor is set

to full load at 100 psig
and unload at 110 psig
and pressure loss in the
4” Header interconnecting piping
2000 ft
176.5 cuft
and equipment reaches
4 psid
5 psid
4 psid 1321 gallons 10 psig at the afterfilter
Control Band 10 psig
as in the figure at left.
500
gallon The effective storage is
1 cuft 1 cuft 537 gals /71.84 cft. The
storage value of the
distribution piping is not
500 cfm 66.84 cuft 3 cuft being utilized. This is
100 hp much too small to allow
EFFECTIVE STORAGE
71.84 cuft / 537 gallons efficient operation of the
compressor at full range.

The example at right shows

the same system set up with
a special low pressure drop
coalescing filter, oversized 4” Header
2000 ft
heat sink-type refrigerated 176.5 cuft
dryer (and good piping). <2 psid 1321 gallons
Control Band 10 psig <1 psid
The operating pressure
500
band includes all the gallon Oversized Heat
headers throughout the Sink Cycling
Dryer
system. The system is
optimized with regard to
controls. The effective 500 cfm 66.84 cuft 2 cuft 3 cuft
100 hp
storage now is 1857 gallons
or 248.34 cft minimum EFFECTIVE STORAGE
248.34 cuft / 1857 gallons

AirPowerProceedings
USA, Inc. of the Twenty-Seventh Industrial Energy Technology
8 Conference, New Orleans, LA,www.airpowerusainc.com
May 10-13, 2005
 ESL-IE-05-05-10

Discharge Piping or Interconnecting Piping

Here we have more complex considerations:

Materials: The discharge air from the compressors can be at 250°F to 350°F (for centrifugal,
oil-free rotary screw and reciprocating types), or from 200°F to 220°F (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 100°F, 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 self-
contamination.

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 200°F 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 Victaulic-
type 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.

AirPowerProceedings
USA, Inc. of the Twenty-Seventh Industrial Energy Technology
9 Conference, New Orleans, LA, www.airpowerusainc.com
May 10-13, 2005
 ESL-IE-05-05-10

Dead Head Old abandoned Orifice Plate

In this case, the header 6”
Flow meter – 3-5 psid

piping itself is acting as a Air from Compressor Air from Compressor

storage vessel for the Room 1 Room 2

process—sometimes a Drop at bottom of header –

should be top
1” 1”
supplemental storage 1”

vessel (air receiver) at the All processes total area fed

by 1 small 1” drop –
1” Air Line from
right location can be very subheader
Crossing Tee Compressor Room 2
effective if the headers High Pressure Loss

are too small. This type 2”

Tie in at bottom of drop
should be -
application has to be
evaluated on a case-by- 1”

case basis. D 1/2”

Sizing Distribution Pipe:

Modern thinking would Air Leak
call for 0 psig pressure
loss in the distribution by
design. The real trick is
estimating how much flow
1/2”
capacity is in any one
section at the highest
Common Compressed Air Distribution Piping Mistakes
possible load.

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.

AirPower USA, Inc. 10

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

72 PSIG
59 PSIG
AIR PEELER
AIR PEELER

72 PSIG
61 PSIG AIR PEELER
AIR PEELER

72 PSIG
64 PSIG AIR PEELER
AIR PEELER
72 PSIG 12”
65 PSIG 4” AIR PEELER HEADER
AIR PEELER HEADER

72 PSIG
AIR PEELER
68 PSIG
AIR PEELER
72 PSIG
AIR PEELER
71 PSIG
AIR PEELER

85 PSIG

3200 GAL

4” FROM
COMPRESSOR ROOM
MULTIPLE 90O TURNS

85-80 PSIG Figure 1

5” OR 6” STRAIGHT
FROM COMPPRESSOR
Figure 2
ROOM

90 PSIG

Sometimes It Doesn’t 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.

The main 2” feed from the air system is at

1 1/2” 105 psig. The regulators and piping were
installed by the contractor. Each time the
1 1/2” process runs, pressure quickly pulls down
Supply Air
CIP Solenoid
as low as 50 psig, which has very serious
negative impact on productivity, product
Regulator quality, and maintenance of the collector.

105 psig Cashco Regulators Check valve

Regulator and piping sized to surge
2” 1” 2” demands as this must be sized on rate of
flow:
Air to Pulsers
90-50 psig
1” Establish Rate of Flow: 8 cfm @ 0.75
Filter
seconds =
1/2”
Instrument Air
8 x 60 sec ÷ 0.75 = 640 cfm rate of flow
Regulator
Filter

Supply Feed from System

AirPower USA, Inc. 11
www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 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 V = 11.6 cft or 86 gallons

(0.75 sec) (640) (14.5)

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
1 1/2” drop:
Supply Air
CIP Solenoid 1 1/2”
Air to Pulsers 0.125 = 116x = 16 = 7.25 psig
90+ psig

Regulator 120 Establish new rate for 4-second refill:

Gallon
Metering
105+ psig Check valve
2” 2”
Valve
2” 0.06 min = (16) (7.25) = 0.966x =
(4 sec) x (14.5)

2” 116 = 120 cfm rate of flow

Filter
1/2”

Regulator Instrument Air

Filter Summary: the receiver, along with a
metered flow allowing the receiver to
Supply Feed from System 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.

AirPower USA, Inc. 12

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

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 can’t 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

All of these subheaders are fed by a 1”

line. It is always easier to tie in on the
1”
1” 1” end than “hot tap” or put another tap
1” into the main header. Often this can
lead to very high pressure loss at the
process.
2”
Tip: When you build the main header,
1” put in extra taps, valved off on top and
sides.
D7 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?

AirPower USA, Inc. 13

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

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 don’t 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 don’t 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, don’t 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.

AirPower USA, Inc. 14

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

Compressed Air Facts That Will Help to Keep the Process Air Clean and Dry

Use common sense: Typical application considerations that affect performance.

30+ Feet per Second Velocity:

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

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
DRY AIR flow. Don’t ignore leaks.

Water Liquid water always drains down by gravity regardless of

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

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 – Liquid condensate now drains from system
negatively affects operation and life. pipe and regulator to automatic drain.
Regulator gets no liquid.

Hose

C Regulator
o Pipe
n Regulator
d Pipe
e
n Floor
Support
s
a
t
e
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

AirPower USA, Inc. 15

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

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

AirPower USA, Inc. 16

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

AirPower USA, Inc. 17

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

AirPower USA, Inc. 18

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

AirPower USA, Inc. 19

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

AirPower USA, Inc. 20

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005
 ESL-IE-05-05-10

AirPower USA, Inc. 21

www.airpowerusainc.com
Proceedings of the Twenty-Seventh Industrial Energy Technology Conference, New Orleans, LA, May 10-13, 2005