The pipework is the part of a compressed air system most often under-specified. Undersized pipe creates pressure drop that forces the compressor to run at a higher pressure, wasting energy and starving the tools at the end of the line.
Why pressure drop costs money
Every 1 bar of excess system pressure adds about 7% to compressor energy consumption. If the network loses 1 bar between the compressor room and the point of use, the compressor must be set 1 bar higher just to deliver the required working pressure.
Sizing rules
- Keep velocity below about 6 m/s in main headers
- Size pipe for total potential flow, not current demand
- Use a looped header so air reaches each point from two directions
- Take branch lines from the top of the header and slope them to drains
Pipe material
Aluminium, stainless steel and engineered polymer systems offer smooth bores and corrosion resistance, which keeps pressure drop low over the life of the system. Avoid threaded black-iron joints that rust and leak. A clean, correctly sized network often delivers more savings than a new compressor.