How To Properly Install Compressed Air Systems

A compressed air system is a vital utility for many businesses in machining, manufacturing, mechanical repair, and beyond. The system can help operations power equipment, inflate objects, clean surfaces, and more. But proper installation must back the system if it is to perform with the utmost efficiency, reliability, and safety. Otherwise, pressure drops, air leaks, and equipment damage all become potential risks that are costly and dangerous.

IQ Compression strives to support industries with the best air compression technology, maintenance, and advice. Here, we review the basics of how to properly install compressed air systems. Following these guidelines can help you set up a system that performs optimally and supports your facility’s needs over the years.

The Planning Stage

Before you buy or assemble components, you must know your facility’s demands for compressed air and its associated pressure requirements.

Assess Your Air Demand

First, determine the total air consumption of all tools and processes that will use the compressed air system. You can find the consumption rate, usually in cubic feet per minute (CFM), in the equipment manufacturer’s specifications. Sum these values to get a baseline for your total demand.

It is also important to consider the duty cycle of each piece of equipment. Not all tools will operate simultaneously. Calculating a diversity factor, which estimates the percentage of tools running at any given time, provides a more realistic picture of your peak air demand. This helps you avoid oversizing the compressor, which wastes energy and increases costs.

Determine Pressure Requirements

Different tools and processes have varying pressure requirements, which are measured in pounds per square inch (PSI). Identify the highest pressure any single piece of equipment requires in your facility, then make sure the system can supply this pressure consistently.

Keep in mind that pressure drops will occur throughout the piping network. The system’s design must account for these losses to deliver the necessary pressure at the point of use.

Factor in Future Expansion

Your business may grow, and when it does, so will your need for compressed air. Therefore, when planning your system, think about potential future expansions. Designing a system with scalability in mind should prevent you from spending huge amounts of time and money on emergency expansions in the future.

But how can you plan for growth? Two common methods are choosing a modular compressor or designing a piping layout that is easy to extend.

Component Selection

Once you have a solid plan, the next step is to choose the components that make up your compressed air system. The quality and compatibility of these parts are crucial for the system’s performance and longevity.

The Air Compressor Itself

The air compressor is the heart of the system. There are several types of air compressors, all of which fall into two main categories: positive displacement and dynamic.

Positive displacement air compressors (e.g., reciprocating, rotary screw, rotary vane, scroll, etc.) mechanically trap air in a chamber and reduce its volume to increase pressure. Dynamic air compressors (e.g., centrifugal and axial) use high-speed rotating impellers to impart velocity to the air, which is then converted into pressure.

We recommend discussing your options and needs with a professional. They have the industry knowledge to select a compressor that can meet your peak CFM demand at the required PSI.

Air Dryers and Filters

Compressed air contains moisture, oil, and particulates that can damage downstream equipment and compromise product quality. Air treatment components are essential for delivering clean, dry air.

An air dryer removes water vapor from the compressed air. Refrigerated dryers are common and suitable for most industrial applications. For applications requiring extremely dry air, a desiccant dryer may be necessary.

Filters remove solid particles and oil aerosols. A pre-filter placed before the dryer protects it from larger debris, while a coalescing filter after the dryer removes fine oil and water droplets. The level of filtration required depends on the sensitivity of your point-of-use equipment.

The Receiver Tank

An air receiver tank stores a volume of compressed air, providing a buffer that prevents the compressor from cycling too frequently. This reduces wear and tear on the compressor and saves energy. The tank also helps to cool the air and remove some moisture before it enters the dryer. The rule of thumb for sizing a receiver tank is 2 to 4 gallons for every CFM of compressor output.

Piping Installation

A poorly designed piping system can be a major source of inefficiency. Below are some tips to get it right.

Choose Reliable Piping Material

Common materials for compressed air piping include black iron, galvanized steel, copper, and aluminum. Black iron is traditional but prone to corrosion, which can introduce rust particles into the airstream. Likewise, galvanized pipe can flake and cause similar contamination issues.

Aluminum piping systems are today’s gold standard for new installations. They are lightweight, resist corrosion, and come at a relatively low cost. Copper is also an excellent, though more expensive, option due to its corrosion resistance.

Thoughtfully Lay Out and Design the Piping

The most common and effective piping layout is a closed-loop or ring main design. This configuration allows air to flow in two directions to any point of use, which helps to equalize pressure throughout the system and reduce pressure drop.

But as you decide on a layout, don’t forget to factor in pipe sizing. Pipes that are too small will cause significant pressure loss and starve equipment of air. Use pipe sizing charts (and consult professionals) to select the appropriate diameter based on the CFM flow rate, system pressure, and length of the pipe run.

System Startup and Maintenance

After the installation is complete, check everything before it goes into full operation.

Enforce Pre-Startup Checks

Before turning on the compressor, inspect all connections to make certain they are secure. Check that all valves are in their correct positions. Conduct a leak test by pressurizing the system and applying a soapy water solution to all joints and fittings. Any bubbles indicate a leak that you must fix.

Prioritize and Schedule Ongoing Maintenance

Proper installation is just the beginning of a well-functioning, long-lasting air compressor system. A regular maintenance schedule is also essential for keeping everything running efficiently. This includes regularly checking and changing filters, draining condensate from the receiver tank and drip legs, and monitoring the compressor for any signs of trouble. Make sure to have technicians come out to provide this equipment servicing at the manufacturer’s recommended intervals.

Call IQ Compression

In the end, better than learning to properly install compressed air systems is having professionals handle everything for you. At IQ Compression, we’re the team for the job. When you hire us for compressed air system installation, you’ll receive a system designed to uphold your facility’s operational and financial needs. We offer custom consultations and best-in-class design and installation practices. Call or email us today to discuss your needs and move your compressed air project forward with confidence.