Compressed air pipe system

History of compressed air pipe systems, compare alternatives, system examples, control operating
costs, guidelines, condensation.

Purpose of a compressed air pipe system

The purpose of the compressed air piping system is to deliver compressed air to the points of
use. The compressed air needs to be delivered with enough volume, appropriate quality and
pressure to properly power the components that use the compressed air. Compressed air is
costly to manufacture. A poorly designed compressed air system can increase energy costs,
promote equipment failure, reduce production efficiencies, and increase maintenance
requirements.

It is generally considered true that any additional costs spent improving the compressed air
piping system will pay for themselves many times over the life of the system. Compressed air is
utilized in many commercial industrial facilities and is considered a utility that is essential to
production. Transair’s aluminium compressed air pipe system provides airtight fittings with full
bore flow creating a more energy efficient system.

Transair compressed air pipe systems are quick to install and ready for immediate pressurization.
Components are removable and interchangeable and allow immediate and easy layout
modifications reducing production downtime. Unlike the performance of steel pipe, which
degrades over time due to corrosion, air quality is clean with optimum flow rate performance
with the use of a Transair pipe system.

Thanks to its large choice of sizes in 100mm (4") , 76mm (3"), 63mm (2 1/2") , 40mm (1 1/2"),
25mm (1"), 16.5mm (1/2") and an extensive range of accessories, the Transair system meets
the requirements of numerous industrial and garage workshop installations. Furthermore, you
can't beat the simple installation, energy savings, and layout flexibility of Transair compressed
air piping solutions.

History of a compressed air pipe system

Example of a compressed air pipe system

 View the Flash animation

 Controlling operating cost

Pressure Drop Costs: To compensate for pressure drops, the compressor must work harder,
which implies more energy consumption and additional costs.

• Cost of pressure drops over a 10-year period:

Technologies offering smooth bore pipe work (aluminium, plastic) provide a high reduction in
pressure drop and thus also operating costs. Conversely galvanized steel systems, affected by
rust and pitted interior surfaces after several years of use, cause higher operating costs.

Annual costs: In terms of overall performance versus costs, the choice should not only depend
on technology and purchasing price. The exact cost of a system also includes annual operating
costs (such as installation and commissioning of a system).

• Example of Annual Costs for a 200m system:

Operating: addition of drops, pressure drop, leaks, maintenance

Commissioning: leak detection, painting
Installation: materials, labour

Guidelines for optimizing an air pipe system

The installation of an air pipe system should be completed in accordance with certain guidelines.
These pages include various recommendations to be observed in order to obtain the expected
performance, reliability and security of your air pipe system.

• Bends and bypasses involve pressure drops. To avoid them, use assemblies: they allow
modification of a system and the bypass of obstacles.
• Limit excessive reductions in pipe diameters, which also involve pressure drops.

• Threaded components create ever increasing leaks over time, choose materials that do not
corrode.

• Ensure consistent quality clean air.

• The size of a system has direct influence on the good performance of tools: choose the
appropriate diameter according to the required flow rate and acceptable pressure drop.

• To facilitate access for maintenance, do not position a system underground.

• Install drops as close as possible to areas of operation, therefore where tools require maximum
energy for optimal working.
• Install pipe supports as follows: two supports per 3m & 6m pipe length.

The problem of condensation

The temperature variance between the outside air and the air within the pipe system will create
a drop in the temperature of the pipe network air and cause condensation in the system.

Condensate collects within the pipeline and circulates throughout the system:
Condensate matter adversely affects pneumatic applications. Therefore we must ensure that it
does not reach the workstation, if we want to prevent breakdowns.

The traditional method is to install an upward loop:

Condensate water thus remains in the main system and the workstation is not affected by poor
quality air.

Equipping compressed air pipe systems with brackets that incorporate an upward loop is
essential-even when a dryer is used. Dryers remove only a proportion of the water that is
present in compressed air since condensation continues to occur due to variations in temperature
levels.

Furthermore, such brackets increase the safety and protection of pneumatic tools and equipment
should the dryer break down or malfunction. For example, 11 litres of water per hour can be
produced by a compressor generating 294 cfm (500 m3/h) at 20°C.

To create this upward loop using traditional materials takes time and many fittings must be
used, thus increasing the risk of leakage.
A modern and faster solution is to use a bracket with an integrated upward loop (see below).
An oil flow system that eliminates the need for an oil circulating pump. COMPRESSED-
AIR DISTRIBUTION Compressed air is a powerful energy source which is very useful in
military and industrial applications. It is of particular advantage in applications that
require intermittent power at some distance from its source, as the air pressure can be
maintained nearly constant at work intervals. The rest of this chapter will pertain to
proper installation techniques of compressed-air systems. When you are assigned
a project that includes compressed air lines, follow the prints and specifications.
Pressures and Uses Compressed air usually falls into one of three categories-power
service, process service, or control purposes. Power service is when compressed air
either moves something or exerts a force. Examples of power service uses are
pneumatic tool operation, air lifts, clamps, and cylinders. Process service is when
compressed air is used as part of the process itself. An example is the use of
compressed air in a combustion process. Compressed air provides oxygen for the
combustion, and, in turn, it becomes a part of the combustion products and is no longer
identifiable as air. Control purpose is when compressed air is used to govern and/or
regulate various equipment by monitoring pressure or flow rates of some substance.
A pneumatically controlled combustion system is an example of such an application.
Compressed air is distributed at low, medium, or high pressure. A low-pressure system
delivers air up to 125 psig. When several different pressures are required within
that range, the plant is usually designed for the highest pressure. Typical low-
pressure systems include the following: air motors, crane drives, starting motors for
combustion engines, shops, laundry and dry-cleaning plants, and general service (tools,
cleaning, painting, and soot blowing for HTW generators and steam boilers). Medium-
pressure systems deliver air from 126 to 399 psig. Normally, this type of system
provides an individual compressor located near the load. Typical applications are
starting diesel engines, hydraulic lifts, and retread tire molds. High-pressure
compressed air systems range from 400 to 6,000 psig. To minimize the hazard that
exists with higher pressures and capacities, you can use separate compressors for
each required pressure. Some applications are torpedo workshop, ammunitions
depot, catapults, wind tunnel, and testing laboratories. Piping Distribution piping is
either aboveground or underground. Both aboveground and underground piping
systems have advantages and disadvantages. The advantages of each system are
as follows: Aboveground Initial cost is lower Less maintenance Underground Less
vulnerable target Less obstruction to traffic Easy detection of failure Less unsightly
Higher continuous Freeze protected when operating efficiency buried Longer life
Some other factors considered are permanent versus temporary use, existence of high
water table, annual ownership, operation and maintenance costs, and degree of hazard
(example, potential danger that overhead piping may cause to aircraft operations). Low-
pressure and medium-pressure systems use black steel pipe. Preferably the joints are
welded. Special conditions may require stainless steel and copper tubing with
 appropriate fittings. Connections to removable equipment are always flange
fittings, except when using small threaded pipe. High-pressure systems use seamless
steel pipe with butt welded fittings. Screwed fittings, when used, have their ends sealed
by fillet welds and exposed pipe threads covered with weld. Piping supports are held in
place by U-shaped or similar types of hangers firmly secured to support structures.
Support hangers must fit closely around the pipe, but may allow for slight
movement. Aboveground pipe is pitched downward a minimum of 3 inches per
100 feet of length, in the direction of the airflow, to low points where the condensate
is collected and drained through drip legs. The drip legs are at all low points, bottom of
all risers, and every 200 to 300 feet from horizontally pitched pipe. 6-49