How to Design an Air-Compressed System?

Compressed air is a crucial factor in the success of every industrial facility. Without it, the production process halts, and customer expectations are not met. Therefore, compressed air system design is essential for ensuring reliability and meeting peak demand. The right design of this system can save energy, reduce costs, and ensure a consistent supply of clean, dry air.

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Compressed Air System Design Considerations

There are a number of important considerations in compressed air system design, such as energy efficiency, piping system layout, compressed air quality, and maintenance costs. Here is a compressed air system design guide to help you make the right decisions.

Demand for Compressed Air

To determine the demand for new systems, the operating pressure requirements and duty cycle of individual equipment must be considered. The manufacturer rates compressed air consumers for optimal performance at a specific pressure and air flow rate.

In order to ensure that all tools operate effectively within a narrow pressure range, a system that delivers uniform pressure must be designed. If this is not possible, the system can function at a greater pressure, and users can adjust the regulators to lower the pressure as needed.

For any particular application that calls for higher pressures, a booster can also be used to raise the pressure. Finally, the last viable option is the design of two independent compressed air systems running at various pressures.

Compressed Air Supply

The compressed air supply must correspond to the compressed air demand. If the storage, supply, or distribution system is not optimized, excessive pressure fluctuations can lead to increased operating costs and decreased productivity.

A lot of compressors are controlled by the line pressure. Demand increases cause a drop in line pressure, which is then made up for by the compressor(s) producing more output. Thus, a decrease in downstream demand reduces compressor output, which is shown by a rise in line pressure. There are two common types of compressor control that can be used to manage such system operating conditions.

Smaller compressed air installations, where the compressor may run at maximum capacity, are typically better suited for single compressor setups.

Multiple compressor installations offer flexibility, adaptability to changing usage patterns, floor space flexibility, centralization or de-centralization.

Compressed Air Distribution System

The design of a compressed air distribution system is crucial for its efficiency and effectiveness. Poor design can lead to excess pressure drop, increasing operational costs. This is extremely inefficient and significantly raises operating expenses.

On the other hand, efficient design involves a loop-style system, proper pipe sizing, and minimizing pressure drop. Typically, this refers to a loop-style distribution system that permits air to flow in any direction and find the path with the least resistance. It is also important to have proper compressed air pipe sizing in the main distribution loop and connections between the compressor, loop, and endpoints.

To minimize pressure, drop, limit the use of elbows and tees, and avoid the use of quick couplings and hoses.

Also, using high-quality aluminium compressed air piping material can prolong the system lifespan, reduce air leaks, and lower overall system lifecycle costs. Similarly, the application of internal pipe coating to the piping can improve durability by reducing friction.