Compressed air distribution system

The objective of installing a compressed air distribution system id to provide a sufficient volume of air to
work location at pressure adequate for efficient tool operation. Any drop in pressure between the
compressor and the point of use is an irretrievable loss

General rules for designing a compressed air distribution system

 Pipe size should be large enough so that the pressure drop between the compressor and the
point of use does not exceed 10% of the initial pressure.
 Each header or main line should be provided with outlets as close as possible to the point of use.
This permits shorter hose length and avoids large pressure drops through the hose.
 Condensate drains should be located at appropriate low points along the header or main lines.

Air manifolds

An air manifold is a large diameter pipe used to transport compressed air from one or more air
compressors without a detrimental friction line loss.

Manifolds can be constructed of any durable pipe. Compressors are connected to the manifold with
flexible hoses. A one-way check valve must be installed between the compressor and the manifold. This
valve keeps manifold back pressure from possibly forcing air back into an individual compressor's
receiver tank. 'The compressors grouped to supply an air manifold may be of different capacities, but
the final discharge pressure of each should be coordinated at a specified pressure. In the case of
construction, this is usually 100 psi. Compressors of different types should not be used on the same
manifold.

Loss of Air Pressure in Pipe

The loss in pressure due to friction as air flows through a pipe or a hose is a factor that must be
considered in selecting the size of a pipe or hose. Failure to use a sufficiently large pipe may cause the
air pressure to drop so low that it will not satisfactorily operate the tool to which it is providing power.
Pipe size selection for an airline is a productivity (economics) problem. The efficiency of most equipment
operated by compressed air drops off rapidly as the pressure of the air is reduced.

Several formulas are used to determine the loss of pressure in a pipe due to friction. Equation (20.7] is a
general formula:

where:

𝐶𝐿 𝑄2
𝑓= × 5
𝑟 𝑑
f = pressure drop in psi

L = length of pipe in feet

Q = cubic feet of free air per second

r = ratio of compression

d = actual inside diameter (I.D.) of pipe in inches

C = experimental coefficient
For ordinary steel pipe, the value of C has been found to equal 0.1025/dQ31• If this value is substituted
in Eq. [20.7], the result is
0.1025𝐿 𝑄2
𝑓= × 5.31
𝑟 𝑑
Loss of Air Pressure in Hose

Air-line hose is a rubber-covered, pressure-type hose designed for transmitting compressed air. Hose is
usually furnished equipped with quick-acting fittings for attaching a tool, a compressor, or another hose.
Hose size is based on the amount of air that must be delivered to the tool. When transmitting
compressed air at 80 to 125 psi gauge, the Table 2.0.4 guidance is valid for short hose lengths (25 ft or
less). As the required hose length increases, the nominal size must also be increased. The loss of
pressure resulting from the flow of air through hose is given in Table 2.0.5. The Table 2.0.5 data can be
used to design hoses whose length will be greater than 25 ft.

DIVERSITY FACTOR

It is necessary to provide as much compressed air as required. However, to supply the needs of all
operating equipment and the many different tools that may be connected to one system (see Fig. 2.0.5)
would require more air capacity than is actually needed. It is probable that all equipment placed on a
project will not be in operation during the exact same time periods. An analysis of the job should be
made to determine the probable maximum actual need, prior to designing the compressed-air system.
As an example. if ten jackhammers are on a job, normally not more than five or six will be consuming air
at a given time. The others will be out of use temporarily for changes in bits or drill steel, or moving to
new locations. Thus, the actual amount of air demanded should be based on five or six drills instead of
ten. The same condition will apply to other pneumatic tools. The diversity factor is the ratio of the actual
load (cf'll) to the maximum calculated load (cfm) that would exist if all tools were operating at the same
time. For example. if a jackhammer required 9.0 cfm of air, ten would require 9.0.0 cfm if they were all
operated at the same time. However, with only five hammers operating at one time, the demand for air
would be 45.0 cfm. Thus, the diversity factor would be 45.0 + 9.0.0 = .0.5.

Pneumatic Tools

Pneumatic power tools can be hazardous when improperly used. Operators must perform a
preoperational check of all air hoses, couplings, and connections to determine if leakage or other
damage exists. However, it is the responsibility of management to train employees in the proper use of
all power tools. Safety requires that employees

 wear appropriate protective clothing and equipment (hearing and eye protection must be worn,
gloves and respirators are often appropriate). (OSHA Standard 1926.102, Personal Protective
and Life Saving Equipment)
 check that hoses are fastened securely and prevented from becoming accidentally
disconnected. A short wire or positive locking device attaching the air hose to the tool will serve
as an added safeguard.
 install a clip or retainer to prevent attachments, such as chisels on a chipping hammer, from
being unintentionally shot from the barrel.
 turn off the air and disconnect the tool when repairs or adjustments are being made or the tool
is not in use.
 inspect the hose to ensure it is in good condition and free from obstructions before connecting a
pneumatic tool.
 remove leaking or defective hoses from service. The air hose must be able to withstand the
pressure required for the tool.