Many times when we provide the air consumption of an EXAIR product, we get a response like…. “I’ve got plenty of pressure, we run at around 100 PSIG”. While having the correct pressure available is important, it doesn’t make up for the volume requirement or SCFM (Standard Cubic Feet per Minute) needed to maintain that pressure. We commonly reference trying to supply water to a fire hose with a garden hose, it is the same principle, in regards to compressed air.
When looking to maintain an efficient compressed air system, it’s important that you use properly sized supply lines and fittings to support the air demand (SCFM) of the point-of-use device. The smaller the ID and the longer the length of air supply line, it becomes more difficult for the air to travel through the system. Undersized supply lines or piping can sometimes be the biggest culprit in a compressed air system as they can lead to severe pressure drops or the loss of pressure from the compressor to the end use product.
Take for example our 18″ Super Air Knife. An 18″ Super Air Knife will consume 52.2 SCFM at 80 PSIG. We recommend using 1/2″ Schedule 40 pipe up to 10′ or 3/4″ pipe up to 50′. The reason you need to increase the pipe size after 10′ of run is that 1/2″ pipe can flow close to 100 SCFM up to 10′ but for a 50′ length it can only flow 42 SCFM. On the other hand, 3/4″ pipe is able to flow 100 SCFM up to 50′ so this will allow you to carry the volume needed to the inlet of the knife, without losing pressure through the line.
Another problem area is using restrictive fittings, like quick disconnects. While this may be useful with common everyday pneumatic tools, like an impact wrench or nail gun, they can severely limit the volumetric flow to a device requiring more air , like a longer length air knife.
For example, looking at the above 1/4″ quick disconnect, the ID of the fitting is much smaller than the NPT connection size. In this case, it is measuring close to .192″. If you were using a device like our Super Air Knife that features 1/4″ FNPT inlets, even though you are providing the correct thread size, the small inside diameter of the quick disconnect causes too much of a restriction for the volume (SCFM) required to properly support the knife, resulting in a pressure drop through the line, reducing the overall performance.
If you have any questions about compressed air applications or supply lines, please contact one of our application engineers for assistance.
A question arises every now and then on whether or not PVC pipe, yes the stuff from your local hardware store that says it is rated for 200 psi, is safe to use as compressed air supply line. The answer is always the same, NO! OSHA agrees – see their statement here.
Schedule 40 PVC pipe is not designed nor rated for use with compressed air or other gases. PVC pipe will explode under pressure, it is impacted significantly by temperature and can be difficult to get airtight.
PVC pipe was originally designed and tested for conveyance of liquids or products that cannot be compressed, rather they can be pressurized. The largest concern is the failure method of the piping itself. When being used with a liquid that cannot be compressed, if there is a failure (crack or hole) then the piping will spring a leak and not shatter. When introducing a compressed gas, such as compressed air, if there is a failure the method ends up being shrapnel. This YouTube video does a good job of illustrating how the pipe shatters.
While it may seem that it takes a good amount of pressure to cause a failure in the pipe, that is often not the case. I have chatted with some local shop owners who decided to run PVC as a quick and cheap alternative to get their machines up and running.
They each experienced the same failures at different points in time as well. The worst one was a section of PVC pipe installed over a workbench failed where an operator would normally be standing. Luckily the failure happened at night when no one was there. Even though no one got injured this still caused a considerable expense to the company because the compressor ran overnight trying to pressurize a ruptured line.
Temperature will impact the PVC as well. Schedule 40 PVC is generally rated for use between 70°F and 140°F (21°-60°C). Pipes that are installed outside or in non temperature controlled buildings can freeze the pipes and make them brittle.
If you haven’t worked with PVC before or do not let the sealant set, it can be hard to get a good seal, leading to leaks and a weak spot in the system.
The point of this is the cheapest, quick, and easy solutions are more often , the ones that will cost the most in the long run.
If you would like to discuss proper compressed air piping and how to save compressed air on your systems, please contact us.
An important component of your compressed air system is the supply piping. The piping will be the middle man that connects your entire facility to the compressor. Before installing pipe, it is important to consider how the compressed air will be consumed at the point of use. You’ll also need to consider the types of fittings you’ll use, the size of the distribution piping, and whether you plan to add additional equipment in the next few years. If so, it is important that the system is designed to accommodate any potential expansion. This also helps to compensate for potential scale build-up (depending on the material of construction) that will restrict airflow through the pipe.
The first thing you’ll need to do is determine your air compressor’s maximum CFM and the necessary operating pressure for your point of use products. Keep in mind, operating at a lower pressure can dramatically reduce overall operating costs. Depending on a variety of factors (elevation, temperature, relative humidity) this can be different than what is listed on directly on the compressor. (For a discussion of how this impacts the capacity of your compressor, check out one of our previous blogs –Intelligent Compressed Air: SCFM, ACFM, ICFM, CFM – What do these terms mean?)
Once you’ve determined your compressor’s maximum CFM, draw a schematic of the necessary piping and list out the length of each straight pipe run. Determine the total length of pipe needed for the system. Using a graph or chart, such as this one from Engineering Toolbox. Locate your compressor’s capacity on the y-axis and the required operating pressure along the x-axis. The point at which these values meet will be the recommended MINIMUM pipe size. If you plan on future expansion, now is a good time to move up to the next pipe size to avoid any potential headache.
After determining the appropriate pipe size, you’ll need to consider how everything will begin to fit together. According to the “Best Practices for Compressed Air Systems” from the Compressed Air Challenge, the air should enter the compressed air header at a 45° angle, in the direction of flow and always through wide-radius elbows. A sharp angle anywhere in the piping system will result in an unnecessary pressure drop. When the air must make a sharp turn, it is forced to slow down. This causes turbulence within the pipe as the air slams into the insides of the pipe and wastes energy. A 90° bend can cause as much as 3-5 psi of pressure loss. Replacing 90° bends with 45° bends instead eliminates unnecessary pressure loss across the system.
Pressure drop through the pipe is caused by the friction of the air mass making contact with the inside walls of the pipe. This is a function of the volume of flow through the pipe. Larger diameter pipes will result in a lower pressure drop, and vice versa for smaller diameter pipes. The chart below from the “Compressed Air and Gas Institute Handbook” provides the pressure drop that can be expected at varying CFM for 2”, 3”, and 4” ID pipe.
Compressed air is used to operate pneumatic systems in a facility, and it can be segregated into three sections; the supply side, the demand side, and the distribution system. The supply side is the air compressor, after-cooler, dryer, and receiver tank that produce and treat the compressed air. They are generally located in a compressor room somewhere in the corner of the plant. The demand side are the collection of end-use devices that will use the compressed air to do “work”. These pneumatic components are generally scattered throughout the facility. To connect the supply side to the demand side, a compressed air distribution system is required. Distribution systems are pipes which carry the compressed air from the compressor to the pneumatic devices. For a sound compressed air system, the three sections have to work together to make an effective and efficient system.
An analogy, I like to compare to the compressed air system, is an electrical system. The air compressor will be considered the voltage source, and the pneumatic devices will be marked as light bulbs. To connect the light bulbs to the voltage source, electrical wires are needed. The distribution system will represent the electrical wires. If the wire gauge is too small to supply the light bulbs, the wire will heat up and the voltage will drop. This heat is given off as wasted energy, and the light bulbs will dim.
The same thing happens within a compressed air system. If the piping size is too small, a pressure drop will occur. This is also wasted energy. In both types of systems, wasted energy is wasted money. One of the largest systematic problems with compressed air systems is pressure drop. If too large of a pressure loss occurs, the pneumatic equipment will not have enough power to operate effectively. As shown in the illustration below, you can see how the pressure decreases from the supply side to the demand side. With a properly designed distribution system, energy can be saved, and in reference to my analogy, it will keep the lights on.
To optimize the compressed air system, we need to reduce the amount of wasted energy; pressure drop. Pressure drop is based on restrictions, obstructions, and piping surface. If we evaluate each one, a properly designed distribution system can limit the unnecessary problems that can rob the “power” from your pneumatic equipment.
Restriction: This is the most common type of pressure drop. The air flow is forced into small areas, causing high velocities. The high velocity creates turbulent flow which increases the losses in air pressure. Flow within the pipe is directly related to the velocity times the square of the diameter. So, if you cut the I.D. of the pipe by one-half, the flow rating will be reduced to 25% of the original rating; or the velocity will increase by four times. Restriction can come in different forms like small diameter pipes or tubing; restrictive fittings like quick disconnects and needle valves, and undersized filters and regulators.
Obstruction: This is generally caused by the type of fittings that are used. To help reduce additional pressure drops use sweeping elbows and 45-degree fittings instead of 90 deg. elbows. Another option is to use full flow ball valves and butterfly valves instead of seated valves and needle valves. If a blocking valve or cap is used for future expansion, try and extend the pipe an additional 10 times the diameter of the pipe to help remove any turbulence caused from air flow disruptions. Removing sharp turns and abrupt stops will keep the velocity in a more laminar state.
Roughness: With long runs of pipe, the piping surface can affect the compressed air stream. As an example, carbon steel piping has a relative rough texture. But, over time, the surface will start to rust creating even a rougher surface. This roughness will restrain the flow, creating the pressure to drop. Aluminum and stainless steel tubing have much smoother surfaces and are not as susceptible to pressure drops caused by roughness or corrosion.
As a rule, air velocities will determine the correct pipe size. It is beneficial to oversize the pipe to accommodate for any expansions in the future. For header pipes, the velocities should not be more than 20 feet/min (6 meter/min). For the distribution lines, the velocities should not exceed 30 feet/min (9 meter/min). In following these simple rules, the distribution system can effectively supply the necessary compressed air from the supply side to the demand side.
To have a properly designed distribution system, the pressure drop should be less than 10% from the reservoir tank to the point-of-use. By following the tips above, you can reach that goal and have the supply side, demand side, and distribution system working at peak efficiency. If you would like to reduce waste even more, EXAIR offers a variety of efficient, safe, and effective compressed air products to fit within the demand side. This would be the pneumatic equivalent of changing those light bulbs at the point-of-use into LEDs.