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Compressed Air Distribution

A poorly designed and carelessly installed pneumatic distribution system will cause trouble and result in expensive repairs and costly down-time.
A well designed system, however, provides relatively clean air at the necessary pressure to efficiently operate the components at maximum production capabilities.

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Here are some things to consider when planning a pneumatic distribution system:

1. Both a general purpose pre-filter, an oil filter, and an oil removal filter should be installed just downstream of the compressor aftercooler to remove solid contaminants, water, and oil. (Water, of course, promotes corrosion, and in combination with other contaminants, forms sludge.) A dryer should be installed between the aftercooler and receiver.
2. Pressure drop between the receiver and the point of use should be kept at a minimum. The loss should be 3% or less of the line pressure.
3. Pipe sizing is an important factor. You must remember the relationship between pressure drop and air flow. For a given size of line, pressure losses increase as flow increases. Main lines should be sized with future requirements and the effects of aging in mind. As systems age, rust and corrosion affect the inside smoothness of pipe walls causing additional pressure loss. Specify pipe sizes so that pressure drop between the receiver and the farthest point of use in the system is less than 3% of the original line pressure. Branch mains and drop lines should be large enough to handle "peak" compressed air needs.
4. An additional accumulator of liberal size should be installed where distribution lines are long. This unit should be mounted at the farthest point from the main receiver. In many installations the demand for air comes in short, heavy bursts. This additional air supply at the end of the line will help to maintain system pressure.
5. Main filters, those with screens or coarse filter elements, should be mounted in the mail distribution line after the receiver. Element rating is 50 to 70 microns. Smaller branch or drop line filters should be used throughout the distribution system and be installed as close as possible to the equipment to be protected. These filters are rated 5 to 50 microns. As a general rule, the distance between a drop line filter and the equipment it is to protect should not exceed 20 feet.