Air systems provide compressed air in an industrial setting. The air distribution network lies between the air compressor and the point of use. These pipes transport compressed air to pneumatic tools dependent on a steady flow, and throughout the plant to support other needs.
Using reliable compressed air piping systems is essential. Leaky or poorly designed pipe networks result in air pressure drops, increased energy consumption, and higher operational costs. Studies estimate that air leaks can account for 20–30% of total compressed air production losses in poorly maintained systems.
Therefore, effective piping systems are a vital component to ensure operational efficiency.
We begin our guide to compressed air piping systems below.
Understanding Compressed Air Piping Systems
A compressed air system comprises three basic components. These are as follows:
- The air compressor
- The distribution network
- The points of use
Air compressors – produce compressed air in the volume and at the pressure required.
Key Insight: Proper selection and maintenance of piping systems significantly influence a compressed air system’s efficiency, reliability, and longevity.
Distribution network – is the piping system that distributes the air. This piping system is essential for distributing compressed air to pneumatic tools.
Points of use – are where the compressed air is needed. Distribution systems must use the right compressed air piping to boost system efficiency. Air quality requirements are also a factor.
Air Flow Dynamics and Piping System Design 101
Air distribution systems must transport the compressed air without significant losses. Compressors produce air to a specified air pressure level and at a volume to readily support industrial needs.
Designing and dimensioning a compressed air system considers airflow dynamics and system design to meet all needs and requirements. High air quality standards must be maintained to ensure pneumatic equipment and other machinery are supported by appropriately pressured air, meeting quality and volume requirements.
Pipe systems must use appropriate dimensions to facilitate volume distribution needs rather than create a potential system bottleneck. Material selection alters air system outcomes. The types include plastic, aluminium, copper, and stainless steel.
It is easy to overlook the importance of a distribution network. However, a properly configured and carefully installed network of pipes is optimal. Otherwise, inefficiencies in design and implementation result in air loss, higher energy expenses to compensate, reduced pneumatic tool performance, and increased maintenance.
Key Factors in Design
- Pipe Sizing: under-dimensioned pipes create bottlenecks, while oversized pipes can lead to inefficiencies and unnecessary costs.
- Material Selection: the choice of material directly affects pressure retention and air quality.
- Air Quality Standards: ensuring clean, dry air reduces wear on pneumatic tools and equipment.
Properly configured distribution systems improve airflow, reduce energy waste, and enhance the overall performance of compressed air systems.
Choosing the Right Materials
The piping material for your compressed air system impacts efficiency, air quality, and reliability. At J Ll Leach, we help customers select materials that suit their requirements.
Aluminium Piping
Aluminium pipes have smooth interior surfaces that reduce pressure drops. They resist corrosion and are lighter than traditional materials, making installation quicker. While the initial cost may be higher, the reduced maintenance and energy efficiency often balance this out over time. Many of our West Midlands customers prefer aluminium for newer installations.
Stainless Steel Piping
Stainless steel resists corrosion both inside and out. It is particularly useful in pharmaceutical, food processing, and research facilities where air quality is critical. We have installed these systems in several Midlands breweries, and they have proven their worth despite the humid conditions. The pipes are heavier than aluminium, requiring proper support during installation.
Copper Pipes
Copper has antimicrobial properties and handles heat well. These pipes are familiar to most plumbers and engineers, with parts readily available from local suppliers. We maintain copper systems for several Birmingham medical facilities, which have been in service for over 15 years. They work reliably across many industrial applications.
Galvanised Steel Piping
Galvanised steel offers good value with moderate corrosion protection. The zinc coating helps but can wear down over time, especially at joints. We still service several galvanised systems in older Coventry factories, which have held up well in standard environments. These systems often show their age near condensate collection points.
Making Your Selection
When choosing your piping material, consider the following:
- Your operating pressure and air quality needs
- Workshop temperature and humidity levels
- Whether you might expand the system later
- Installation and maintenance costs
Factors Influencing Piping Material Choices
Below are the major factors to consider with pipe material selection:
Cost – Distribution network materials and installation costs are not insignificant. The choice of pipe materials affects ultimate costs. Different material choices may result in more complicated installations over longer timeframes. Conversely, some materials are more expensive but require less installation time. Therefore, the cost of supplying and installing the pipe network requires proper consideration.
Durability – How long the pipe network is expected to last matters. The quality of the steel or aluminium and how it withstands continual, high-pressure air flow is important, too. Potential pipe corrosion and necessary maintenance for durability should also be considered.
Environmental – Pipe materials handle hot and humid or bone-chilling environments differently. Aluminium and stainless steel handle humid environments adeptly. Steel pipes manage dampness better. Therefore, seasonable temperature variances and changing environmental conditions require prior planning.
Pro Tip: Conduct an operational assessment to balance cost, durability, and environmental suitability for the chosen material.
Design Considerations
Appropriate pipe sizing is crucial to network design.
Pipe Sizing and Layout
- Ensure pipes are properly sized to accommodate required airflow without creating bottlenecks or excessive velocity.
- Minimise sharp bends and long runs, which can lead to turbulence and pressure losses.
Future-Proofing the System
- Plan for future expansions by including additional capacity in the design.
- Advanced piping systems like Atlas Copco’s AIRnet are modular and scalable, enabling easy upgrades without disrupting operations.
Installation Tips
Follow these best practices for successful installation:
- Design for Flow and Pressure: base system layout on expected airflow and pressure requirements, considering potential expansion needs.
- Avoid Sharp Bends: reduce turbulence by minimising the number of sharp bends and fittings in the system.
- Use Proper Joint Techniques: deburr pipe ends and use high-quality fittings to ensure airtight connections.
- Test for Leaks: conduct comprehensive leak tests after installation to identify and resolve any issues before full operation.
Pro Tip: Professional installation ensures accurate alignment, tight connections, and system integrity, reducing maintenance requirements over time.
Experienced air system installers help to reduce future maintenance needs. J LL Leach has decades of experience installing robust compressed air systems for its customers.
Maintenance and Safety Practices
Regular maintenance of compressed air piping systems ensures reliable operation and reduces energy costs. Proper upkeep helps deliver clean air at consistent pressure throughout your facility.
Essential Maintenance Tasks
- Filters and Air Treatment: change filters and maintain desiccant dryers according to manufacturer schedules. This keeps contaminants from damaging pneumatic tools and components.
- Finding Leaks: use ultrasonic equipment to identify leaks at connections and pipes. Even small leaks waste significant energy – a 3 mm hole can cost £2,000 annually in wasted electricity.
- Pressure Checks: monitor pressure at strategic points in your system. Most industrial systems operate at 7–8 bar. Low pressure at endpoints often indicates blocked filters or leaks in the distribution network.
- Connection Inspection: check and tighten fittings quarterly. Vibration naturally loosens connections over time, particularly near equipment with reciprocating motion.
- Moisture Management: drain condensate from receivers and separators. Birmingham facilities often see higher moisture levels from October through March, requiring more frequent draining during winter months.
Safety Requirements
- Appropriate Materials: never use standard PVC for compressed air. Aluminium, steel, or specially rated composite pipes comply with HSE guidelines.
- Proper Mounting: secure pipes at 2–3 metre intervals with appropriate brackets. Allow for thermal expansion, particularly in outdoor installations.
- Safety Devices: test pressure relief valves twice yearly and log results. Ensure they are sized correctly for your receiver volume.
Conclusion
The distribution network supporting an air system is easy to overlook. However, high-quality customised piping systems lower energy costs, reduce air leaks and pressure losses, and moderate maintenance issues.
A professional assessment of your air distribution network is the first step toward achieving greater efficiency and reliability. Contact our team at J LL Leach to discuss your system requirements and ensure a robust solution tailored to your needs.
An assessment to determine the best type of pipe network is essential in any complete air system. Talk with our professionals at J LL Leach to arrange one today.
FAQ
What maintenance does a compressed air piping system require?
Compressed air systems need regular maintenance to work properly. Replace filters every 1,000 operating hours or quarterly, whichever comes first. Check desiccant dryers and change desiccant material according to the manufacturer’s schedule – typically every 2–5 years, depending on air quality.
Inspect joints and connections for leaks using soapy water or ultrasonic detection equipment. Drain moisture from air receivers weekly in summer and twice weekly in winter. Most workshop managers in the Midlands keep a maintenance log hanging near the main compressor unit.
Why is pipe material important in a compressed air system?
Pipe material affects both safety and efficiency. Steel pipes last decades but are heavy and can rust internally. Aluminium pipes resist corrosion but cost more initially. Copper offers good corrosion resistance but requires skilled installation.
BSI-approved composite pipes provide a balance of durability and ease of installation. Standard PVC is unsafe for compressed air and can shatter under pressure. The local council building inspector will reject installations using unapproved materials during the annual certificate inspection.
How do I ensure that clean, dry air reaches my equipment?
Install proper filtration between the compressor and your tools. A typical setup includes a particle filter (5–10 microns), an oil removal filter (0.01 microns) and a suitable dryer. Refrigerated dryers work for most general applications, while desiccant types are needed for outdoor lines during winter months.
Check pressure drop across filters with simple gauges – more than 0.3 bar difference means the filter needs changing. Many workshops in Coventry and Leicester find that installing drain taps at low points in the system reduces moisture problems substantially.
