™

Chapter 4
Compressed Air Distribution (Systems)

Air turbines may be used for starting gas turbines and for other purposes. Air
consumption of turbines may be calculated by the usual methods of thermodynam-
ics. For single-stage impulse turbines with converging nozzles, the air consumption
may be found by applying Fliegner’s equation to the nozzles. The air turbine
manufacturer can supply the needed data.
Other devices have an air flow condition approximating simple throttling. A
steady jet used for blowing chips from a tool would fall within this classification.
Another device with approximately the same flow characteristics is the vibrator
actuated by a steel ball propelled around a closed circular track by means of an air
jet. Table 4.4 may be used for estimating air flow through such devices. These data
are not intended for use in air measurements and should be used only for estimating
system air requirements.

Table 4.4 How to Determine Compressor Size Required

________________________________________________________________________
Load CFM required*
Factor _____________________________________
Number (per cent Per Tool Total if All Total Actually
of Tools of time When Tools Operated Used (A x B x
tools Operating Simultaneously C ÷ 100
actually
operated)
Type of Tool Location (A) (B) (C) (D) (E)
Blowguns,
chucks Machine Shop 4 25 25 100 25
and vises
8-in. grinders Cleaning 10 50 50 500 250
Chippers Cleaning 10 50 30 300 150
Hoists Cleaning 2 10 35 70 7
Small
Assembly 20 25 12 240 60
screwdrivers
Large
Assembly 2 25 30 60 15
nutsetters
Woodborer Shipping 1 25 30 30 7 1/2
Screwdriver Shipping 1 20 30 30 6
Hoist Shipping 1 20 40 40 8
___________________________________________________________________________________________________________
Total 47 1270 528 1/2
___________________________________________________________________________________________________________

*Cfm is cubic feet of free air per minute.

Note: Total of column (E) determines required compressor sizes.

Regenerative desiccant type compressed air dryers require purge air which
may be as much as 15% of the rated dryer capacity and this must be added to the
estimate of air required at points of use.
An often neglected consideration is system leaks. Theoretically, a new system
should have no leaks but experience shows that most systems have varying
amounts of leakage sources.
Electronic leak detectors are available and should be used on a regularly
scheduled basis. It also can be useful to determine how long an air compressor runs
to maintain system pressure during a shutdown period when there is no actual
usage of compressed air.

210 Compressed Air & Gas Institute • 1300 Sumner Avenue • Cleveland, OH 44115
Phone: 216/241-7333 • Fax: 216/241-0105 • E-mail: [email protected]
 ™

Compressed Air Distribution (Systems)

Air Pressure Requirements

This is one of the more critical factors in the design of an efficient compressed
air distribution system. One problem is that the variety of points of application may
require a variety of operating pressure requirements. Equipment manufacturers
should be consulted to determine the pressure requirement at the machine, air tool
or pneumatic device. If these operating pressure requirements vary by more than
20%, consideration should be given to separate systems. In a typical plant with an
air distribution system operating at a nominal 100 psig, an increase of one half per
cent in the air compressor energy costs is required for each additional 1 psi in sys-
tem pressure. Operating the complete system at 20% higher pressure to accommo-
date one point of use, would result in the air compressor(s) using 10% more energy
and an increase in work factor as previously noted. This, obviously, is to be
avoided.
Allowance also must be made for pressure drops through compressed air treat-
ment equipment, including air dryers and filters.
An inadequately sized piping distribution system will cause excessive pressure
drops between the air compressors and the points of use, requiring the compressor
to operate at a much higher pressure than at the points of use. This also requires
additional energy. For example, if the distribution piping size is only half of the
ideal, the cross-sectional area is only one fourth, resulting in velocities four times
the ideal and sixteen times the pressure drop. In an air distribution system where a
given pipe diameter piping may be sufficient, it should be remembered that the
installation labor cost will be the same for double the pipe diameter and only the
material cost will increase. The savings in energy costs from reduced pressure drop
will repay the difference in material costs in a very short time. and could provide
for future capacity.
Air velocity through the distribution piping should not exceed 1800 ft. per
minute (30 ft. per sec.). One recommendation, to avoid moisture being carried
beyond drainage drop legs in compressor room header upstream of dryer(s), is that
the velocity should not exceed 1200 ft. per minute (20 ft. per sec.). Branch lines
having an air velocity over 2000 ft. per minute, should not exceed 50 ft. in length.
The system should be designed so that the operating pressure drop between the air
compressor and the point(s) of use should not exceed 10% of the compressor dis-
charge pressure.
Pressure loss in piping due to friction at various operational pressures is tabu-
lated in Tables 4.5, 4.6, 4.7, 4.8 and 4.9 can be used to determine pipe sizes required
for the system being designed. These tables are based upon non-pulsating flow in
a clean, smooth pipe.

Compressed Air & Gas Institute • 1300 Sumner Avenue • Cleveland, OH 44115 211
Phone: 216/241-7333 • Fax: 216/241-0105 • E-mail: [email protected]
 ™
Chapter 4
Compressed Air Distribution (Systems)

Table 4.5 Loss of Air Pressure Due to Friction

Equivalent
Cu ft Cu ft Nominal Diameter, In.
Free Air Compressed
Per Min Air
Per Min /2
1 3/ 1 1 1/ 1 1/ 2 3 4 6 8 10 12
4 4 2

10 1.96 10.0 1.53 0.43 0.10

20 3.94 39.7 5.99 1.71 0.39 0.18
30 5.89 …. 13.85 3.86 0.88 0.40
40 7.86 …. 24.7 6.85 1.59 0.71 0.19
50 9.84 …. 38.6 10.7 2.48 1.10 0.30
60 11.81 …. 55.5 15.4 3.58 1.57 0.43
70 13.75 …. …. 21.0 4.87 2.15 0.57
80 15.72 …. …. 27.4 6.37 2.82 0.75
90 17.65 …. …. 34.7 8.05 3.57 0.57 0.37
100 19.60 …. …. 42.8 9.95 4.40 1.18
125 19.4 …. …. 46.2 12.4 6.90 1.83 0.14
150 29.45 …. …. …. 22.4 9.90 2.64 0.32
175 34.44 …. …. …. 30.8 13.40 3.64 0.43
200 39.40 …. …. …. 39.7 17.60 4.71 0.57
250 49.20 …. …. …. …. 27.5 7.37 0.89 0.21
300 58.90 …. …. …. …. 39.6 10.55 1.30 0.31
350 68.8 …. …. …. …. 54.0 14.4 1.76 0.42
400 78.8 …. …. …. …. …. 18.6 2.30 0.53
450 88.4 …. …. …. …. …. 23.7 2.90 0.70
500 98.4 …. …. …. …. …. 29.7 3.60 0.85
600 118.1 …. …. …. …. …. 42.3 5.17 1.22
700 137.5 …. …. …. …. …. 57.8 7.00 1.67
800 157.2 …. …. …. …. …. …. 9.16 2.18
900 176.5 …. …. …. …. …. …. 11.6 2.76
1,000 196.0 …. …. …. …. …. …. 14.3 3.40
1,500 294.5 …. …. …. …. …. …. 32.3 7.6 0.87 0.29
2,000 394.0 …. …. …. …. …. …. 57.5 13.6 1.53 0.36
2,500 492 …. …. …. …. …. …. …. 21.3 2.42 0.57 0.17
3,000 589 …. …. …. …. …. …. …. 30.7 3.48 0.81 0.24
3,500 688 …. …. …. …. …. …. …. 41.7 4.68 1.07 0.33
4,000 788 …. …. …. …. …. …. …. 54.5 6.17 1.44 0.44
4,500 884 …. …. …. …. …. …. …. …. 7.8 1.83 0.55 0.21
5,000 984 …. …. …. …. …. …. …. …. 9.7 2.26 0.67 0.27
6,000 1,181 …. …. …. …. …. …. …. …. 13.9 3.25 0.98 0.38
7,000 1,375 …. …. …. …. …. …. …. …. 18.7 4.43 1.34 0.51
8,000 1,572 …. …. …. …. …. …. …. …. 24.7 5.80 1.73 0.71
9,000 1,765 …. …. …. …. …. …. …. …. 31.3 7.33 2.20 0.87
10,000 1,960 …. …. …. …. …. …. …. …. 38.6 9.05 2.72 1.06
11,000 2,165 …. …. …. …. …. …. …. …. 46.7 10.9 3.29 1.28
12,000 2,362 …. …. …. …. …. …. …. …. 55.5 13.0 3.90 1.51
13,000 2,560 …. …. …. …. …. …. …. …. …. 15.2 4.58 1.77
14,000 2,750 …. …. …. …. …. …. …. …. …. 17.7 5.32 2.07
15,000 2,945 …. …. …. …. …. …. …. …. …. 20.3 6.10 2.36
16,000 3,144 …. …. …. …. …. …. …. …. …. 23.1 6.95 2.70
18,000 3,530 …. …. …. …. …. …. …. …. …. 29.2 8.80 3.42
20,000 3,940 …. …. …. …. …. …. …. …. …. 36.2 10.8 4.22
22,000 4,330 …. …. …. …. …. …. …. …. …. 43.7 13.2 5.12
24,000 4,724 …. …. …. …. …. …. …. …. …. 51.9 15.6 5.92
26,000 5,120 …. …. …. …. …. …. …. …. …. …. 18.3 7.15
28,000 5,500 …. …. …. …. …. …. …. …. …. …. 21.3 8.3
30,000 5,890 …. …. …. …. …. …. …. …. …. …. 24.4 9.5

In psi in 1000 ft of pipe, 60 lb gage initial pressure. For longer or shorter lengths
of pipe the friction loss is proportional to the length, i.e., for 500 ft, one-half of
the above; for 4,000 ft, four times the above, etc.

212 Compressed Air & Gas Institute • 1300 Sumner Avenue • Cleveland, OH 44115
Phone: 216/241-7333 • Fax: 216/241-0105 • E-mail: [email protected]
 ™

Compressed Air Distribution (Systems)

Table 4.6 Loss of Air Pressure Due to Friction

Equivalent
Cu ft Cu ft Nominal Diameter, In.
Free Air Compressed
Per Min Air
Per Min /2
1 3/ 1 1 1/4 1 1/2 2 3 4 6 8 10 12
4
_________________________________________________________________________________
10 1.55 7.90 1.21 0.34
20 3.10 31.4 4.72 1.35 0.31
30 4.65 70.8 10.9 3.04 0.69 0.31
40 6.20 …. 19.5 5.40 1.25 0.56
50 7.74 …. 30.5 8.45 1.96 0.87
60 9.29 …. 43.8 12.16 2.82 1.24 0.34
70 10.82 …. 59.8 16.6 3.84 1.70 0.45
80 12.40 …. 78.2 21.6 5.03 2.22 0.59
90 13.95 …. …. 27.4 6.35 2.82 0.75
100 15.5 …. …. 33.8 7.85 3.74 0.93
125 19.4 …. …. 46.2 12.4 5.45 1.44
150 23.2 …. …. 76.2 17.7 7.82 2.08
175 27.2 …. …. …. 24.8 10.6 2.87
200 31.0 …. …. …. 31.4 13.9 3.72 0.45
250 38.7 …. …. …. 49.0 21.7 5.82 0.70
300 46.5 …. …. …. 70.6 31.2 8.35 1.03
350 54.2 …. …. …. …. 42.5 11.4 1.39 0.33
400 62.0 …. …. …. …. 55.5 14.7 1.82 0.42
450 69.7 …. …. …. …. …. 18.7 2.29 0.55
500 77.4 …. …. …. …. …. 23.3 2.84 0.67
600 92.9 …. …. …. …. …. 33.4 4.08 0.96
700 108.2 …. …. …. …. …. 45.7 5.52 1.32
800 124.0 …. …. …. …. …. 59.3 7.15 1.72
900 139.5 …. …. …. …. …. …. 9.17 2.18
1,000 155 …. …. …. …. …. …. 11.3 2.68
1,500 232 …. …. …. …. …. …. 25.5 6.0 0.69
2,000 310 …. …. …. …. …. …. 45.3 10.7 1.21 0.29
2,500 387 …. …. …. …. …. …. 70.9 16.8 1.91 0.45
3,000 465 …. …. …. …. …. …. …. 24.2 2.74 0.64 0.19
3,500 542 …. …. …. …. …. …. …. 32.8 3.70 0.85 0.26
4,000 620 …. …. …. …. …. …. …. 43.0 4.87 1.14 0.34
4,500 697 …. …. …. …. …. …. …. 54.8 6.15 1.44 0.43
5,000 774 …. …. …. …. …. …. …. 67.4 7.65 1.78 0.53 0.21
6,000 929 …. …. …. …. …. …. …. …. 11.0 2.57 0.77 0.29
7,000 1,082 …. …. …. …. …. …. …. …. 14.8 3.40 1.06 0.40
8,000 1,240 …. …. …. …. …. …. …. …. 19.5 4.57 1.36 0.54
9,000 1,395 …. …. …. …. …. …. …. …. 24.7 5.78 1.74 0.69
10,000 1,550 …. …. …. …. …. …. …. …. 30.5 7.15 2.14 0.84
11,000 1,710 …. …. …. …. …. …. …. …. 36.8 8.61 2.60 1.01
12,000 1,860 …. …. …. …. …. …. …. …. 43.8 10.3 3.08 1.19
13,000 2,020 …. …. …. …. …. …. …. …. 51.7 12.0 3.62 1.40
14,000 2,170 …. …. …. …. …. …. …. …. 60.2 14.0 4.20 1.63
15,000 2,320 …. …. …. …. …. …. …. …. 68.5 16.0 4.82 1.84
16,000 2,480 …. …. …. …. …. …. …. …. 78.2 18.2 5.48 2.13
18,000 2,790 …. …. …. …. …. …. …. …. …. 23.0 6.95 2.70
20,000 3,100 …. …. …. …. …. …. …. …. …. 28.6 8.55 3.33
22,000 3,410 …. …. …. …. …. …. …. …. …. 34.5 10.4 4.04
24,000 3,720 …. …. …. …. …. …. …. …. …. 41.0 12.3 4.69
26,000 4,030 …. …. …. …. …. …. …. …. …. 48.2 14.4 5.6
28,000 4,350 …. …. …. …. …. …. …. …. …. 55.9 16.8 6.3
30,000 4,650 …. …. …. …. …. …. …. …. …. 64.2 19.3 7.5

In psi in 1000 ft of pipe, 80 lb gage initial pressure. For longer or shorter lengths
of pipe the friction loss is proportional to the length, i.e., for 500 ft, one-half of
the above; for 4,000 ft, four times the above, etc.

Compressed Air & Gas Institute • 1300 Sumner Avenue • Cleveland, OH 44115 213
Phone: 216/241-7333 • Fax: 216/241-0105 • E-mail: [email protected]
 ™
Chapter 4
Compressed Air Distribution (Systems)

Table 4.7 Loss of Air Pressure Due to Friction

Equivalent
Cu ft Cu ft Nominal Diameter, In.
Free Air Compressed
Per Min Air
Per Min /2
1 3/ 1 1 1/4 1 1/2 2 3 4 6 8 10 12
4
_________________________________________________________________________________
10 1.28 6.50 .99 0.28
20 2.56 25.9 3.90 1.11 0.25 0.11
30 3.84 58.5 9.01 2.51 0.57 0.26
40 5.12 …. 16.0 4.45 1.03 0.46
50 6.41 …. 25.1 9.96 1.61 0.71 0.19
60 7.68 …. 36.2 10.0 2.32 1.02 0.28
70 8.96 …. 49.3 13.7 3.16 1.40 0.37
80 10.24 …. 64.5. 17.8 4.14 1.83 0.49
90 11.52 …. 82.8 22.6 5.23 2.32 0.62
100 12.81 …. …. 27.9 6.47 2.86 0.77
125 15.82 …. …. 48.6 10.2 4.49 1.19
150 19.23 …. …. 62.8 14.6 6.43 1.72 0.21
175 22.40 …. …. …. 19.8 8.72 2.36 0.28
200 25.62 …. …. …. 25.9 11.4 3.06 0.37
250 31.64 …. …. …. 40.4 17.9 4.78 0.58
300 38.44 …. …. …. 58.2 25.8 6.85 0.84 0.20
350 44.80 …. …. …. …. 35.1 9.36 1.14 0.27
400 51.24 …. …. …. …. 45.8 12.1 1.50 0.35
450 57.65 …. …. …. …. 58.0 15.4 1.89 0.46
500 63.28 …. …. …. …. 71.6 19.2 2.34 0.55
600 76.88 …. …. …. …. …. 27.6 3.36 0.79
700 89.60 …. …. …. …. …. 37.7 4.55 1.09
800 102.5 …. …. …. …. …. 49.0 5.89 1.42
900 115.3 …. …. …. …. …. 62.3 7.6 1.80
1,000 128.1 …. …. …. …. …. 76.9 9.3 2.21
1,500 192.3 …. …. …. …. …. …. 21.0 4.9 0.57
2,000 256.2 …. …. …. …. …. …. 37.4 8.8 0.99 0.24
2,500 316.4 …. …. …. …. …. …. 58.4 13.8 1.57 0.37
3,000 384.6 …. …. …. …. …. …. 84.1 20.0 2.26 0.53
3,500 447.8 …. …. …. …. …. …. …. 27.2 3.04 0.70 0.22
4,000 512.4 …. …. …. …. …. …. …. 35.5 4.01 0.94 0.28
4,500 576.5 …. …. …. …. …. …. …. 45.0 5.10 1.19 0.36
5,000 632.8 …. …. …. …. …. …. …. 55.6 6.3 1.47 0.44 0.17
6,000 768.8 …. …. …. …. …. …. …. 80.0 9.1 2.11 0.64 0.24
7,000 896.0 …. …. …. …. …. …. …. …. 12.2 2.88 0.87 0.33
8,000 1,025 …. …. …. …. …. …. …. …. 16.1 3.77 1.12 0.46
9,000 1,153 …. …. …. …. …. …. …. …. 20.4 4.77 1.43 0.57
10,000 1,280 …. …. …. …. …. …. …. …. 25.1 5.88 1.77 0.69
11,000 1,410 …. …. …. …. …. …. …. …. 30.4 7.10 2.14 0.83
12,000 1,540 …. …. …. …. …. …. …. …. 36.2 8.5 2.54 0.98
13,000 1,668 …. …. …. …. …. …. …. …. 42.6 9.8 2.98 1.15
14,000 1,795 …. …. …. …. …. …. …. …. 49.2 11.5 3.46 1.35
15,000 1,923 …. …. …. …. …. …. …. …. 56.6 13.2 3.97 1.53
16,000 2,050 …. …. …. …. …. …. …. …. 64.5 15.0 4.52 1.75
18,000 2,310 …. …. …. …. …. …. …. …. 81.5 19.0 5.72 2.22
20,000 2,560 …. …. …. …. …. …. …. …. …. 23.6 7.0 2.74
22,000 2,820 …. …. …. …. …. …. …. …. …. 28.5 8.5 3.33
24,000 3,080 …. …. …. …. …. …. …. …. …. 33.8 10.0 3.85
26,000 3,338 …. …. …. …. …. …. …. …. …. 39.7 11.9 4.65
28,000 3,590 …. …. …. …. …. …. …. …. …. 46.2 13.8 5.40
30,000 3,850 …. …. …. …. …. …. …. …. …. 53.0 15.9 6.17

In psi in 1000 ft of pipe, 100 lb gage initial pressure. For longer or shorter lengths
of pipe the friction loss is proportional to the length, i.e., for 500 ft,
one-half of the above; for 4,000 ft, four times the above, etc.

214 Compressed Air & Gas Institute • 1300 Sumner Avenue • Cleveland, OH 44115
Phone: 216/241-7333 • Fax: 216/241-0105 • E-mail: [email protected]
 ™

Compressed Air Distribution (Systems)

Table 4.8 Loss of Air Pressure Due to Friction

Equivalent
Cu ft Cu ft Nominal Diameter, In.
Free Air Compressed
Per Min Air
Per Min /2
1 3/ 1 1 1/4 1 1/2 2 3 4 6 8 10 12
4
_________________________________________________________________________________
10 1.05 5.35 0.82 0.23
20 2.11 21.3 3.21 0.92 0.21
30 3.16 48.0 7.42 2.07 0.47 0.21
40 4.21 …. 13.2 3.67 0.85 0.38
50 5.26 …. 20.6 5.72 1.33 0.59
60 6.32 …. 29.7 8.25 1.86 0.84 0.23
70 7.38 …. 40.5 11.2 2.61 1.15 0.31
80 8.42 …. 53.0 14.7 3.41 1.51 0.40
90 9.47 …. 68.0 18.6 4.30 1.91 0.51
100 10.50 …. …. 22.9 5.32 2.36 0.63
125 13.15 …. …. 39.9 8.4 3.70 0.98
150 15.79 …. …. 51.6 12.0 5.30 1.41 0.17
175 18.41 …. …. …. 16.3 7.2 1.95 0.24
200 21.05 …. …. …. 21.3 9.4 2.52 0.31
250 26.30 …. …. …. 33.2 14.7 3.94 0.48
300 31.60 …. …. …. 47.3 21.2 5.62 0.70
350 36.80 …. …. …. …. 28.8 7.7 0.94 0.22
400 42.10 …. …. …. …. 37.6 10.0 1.23 0.28
450 47.30 …. …. …. …. 47.7 12.7 1.55 0.37
500 52.60 …. …. …. …. 58.8 15.7 1.93 0.46
600 63.20 …. …. …. …. …. 22.6 2.76 0.65
700 73.80 …. …. …. …. …. 30.0 3.74 0.89
800 84.20 …. …. …. …. …. 40.2 4.85 1.17
900 94.70 …. …. …. …. …. 51.2 6.2 1.48
1,000 105.1 …. …. …. …. …. 63.2 7.7 1.82
1,500 157.9 …. …. …. …. …. …. 17.2 4.1 0.47
2,000 210.5 …. …. …. …. …. …. 30.7 7.3 0.82 0.19
2,500 263.0 …. …. …. …. …. …. 48.0 11.4 1.30 0.31
3,000 316 …. …. …. …. …. …. 69.2 16.4 1.86 0.43
3,500 368 …. …. …. …. …. …. …. 22.3 2.51 0.57 0.18
4,000 421 …. …. …. …. …. …. …. 29.2 3.30 0.77 0.23
4,500 473 …. …. …. …. …. …. …. 37.0 4.2 0.98 0.24
5,000 526 …. …. …. …. …. …. …. 45.7 5.2 1.21 0.36
6,000 632 …. …. …. …. …. …. …. 65.7 7.5 1.74 0.52 0.20
7,000 738 …. …. …. …. …. …. …. …. 10.0 2.37 0.72 0.27
8,000 842 …. …. …. …. …. …. …. …. 13.2 3.10 0.93 0.38
9,000 947 …. …. …. …. …. …. …. …. 16.7 3.93 1.18 0.47
10,000 1,051 …. …. …. …. …. …. …. …. 20.6 4.85 1.46 0.57
11,000 1,156 …. …. …. …. …. …. …. …. 25.0 5.8 1.76 0.68
12,000 1,262 …. …. …. …. …. …. …. …. 29.7 7.0 2.09 0.81
13,000 1,368 …. …. …. …. …. …. …. …. 35.0 8.1 2.44 0.95
14,000 1,473 …. …. …. …. …. …. …. …. 40.3 9.7 2.85 1.11
15,000 1,579 …. …. …. …. …. …. …. …. 46.5 10.9 3.26 1.26
16,000 1,683 …. …. …. …. …. …. …. …. 53.0 12.4 3.72 1.45
18,000 1,893 …. …. …. …. …. …. …. …. 66.9 15.6 4.71 1.83
20,000 2,150 …. …. …. …. …. …. …. …. …. 19.4 5.8 2.20
22,000 2,315 …. …. …. …. …. …. …. …. …. 23.4 7.1 2.74
24,000 2,525 …. …. …. …. …. …. …. …. …. 27.8 8.4 3.17
26,000 2,735 …. …. …. …. …. …. …. …. …. 32.8 9.8 3.83
28,000 2,946 …. …. …. …. …. …. …. …. …. 37.9 16.4 4.4
30,000 3,158 …. …. …. …. …. …. …. …. …. 43.5 13.1 5.1

In psi in 1000 ft of pipe, 125 lb gage initial pressure. For longer or shorter lengths
of pipe the friction loss is proportional to the length, i.e., for 500 ft, one-half of
the above; for 4,000 ft, four times the above, etc.

Compressed Air & Gas Institute • 1300 Sumner Avenue • Cleveland, OH 44115 215
Phone: 216/241-7333 • Fax: 216/241-0105 • E-mail: [email protected]