How to Minimize Pressure Drop in a Compressed Air (pneumatic) Supply System

Compressed air is used in virtually every industrial or manufacturing environment due to the effectiveness and low-cost of pneumatic operations. When a compressed air system is designed, it is important to take certain measures to reduce pressure drop throughout the delivery system to ensure maximum efficiency. Did you know that for each 2psig of pressure drop in a system, it costs 1% of the total horsepower of the compressor just to compensate? That means in a 100hp system, a 10psig drop will result in a 5%, or 5hp loss! This guide will show you the steps to take to minimize this pressure drop.

Difficulty: Moderate

Instructions

1. Reduce losses due to friction in the pipes. Use smooth-walled piping, such as aluminum, instead of the traditional black-iron pipe. Although the smooth-walled piping will cost more initially, it will save money over time by offering a low-friction supply line to minimize pressure drop.

2. Another step to reduce loss is to remove restrictions to flow. This can be done by increasing the pipe size (larger pipes allow larger flowrates). Ensure that any valves (manual ball valves, solenoid valves, etc) are properly sized in order to minimize flow restriction.

3. Reduce the velocity or flowrate of the air traveling through the pipes by using receiver tanks (also called accumulators). A receiver tank will also act as a buffer, accommodating spikes in compressed air demand in the system.

4. Reduce the distance the air has to flow by using a loop system. Using a loop layout (or a series of loops, like a "ladder" layout) will allow for even distribution of pressure, which means minimal pressure drops.