A compressed air system works as a whole, and designing it piecemeal causes mismatches that waste energy. The design process moves from demand, through compression and treatment, to storage and distribution.
The design sequence
- Measure and calculate the air demand and load profile
- Select compressor type, size and control strategy
- Add aftercooling, drying and filtration to reach the required purity
- Size wet and dry receiver storage
- Design the pipework loop and point-of-use connections
Matching components
Each stage must be sized for the same flow and pressure, with correction for temperature and altitude. A mismatch, such as an under-sized dryer or thin pipe, becomes the bottleneck that limits the whole system.
Planning for growth
Design the compressor room, pipework and electrical supply for future capacity even if the first compressor is smaller. A little extra pipe diameter and floor space at the start saves a complete rebuild later.