The piping system for compressed air takes compressed air from the air compressor rooms to all tools and machines. The size, type, and configuration of the piping system determine the pressure drop along the route, amount of water reaching the destination, and leakage of air. A well-sized compressor on badly designed pipework still delivers poor air.
Air compressor pipe is a rising search in the UAE as plants expand and add lines. The guide will describe how to size compressed air piping, select appropriate pipe materials, design ring mains, prevent water entering the system and the role that GENAVCO plays in designing Denair compressed air systems.
Importance of Pipework Equally to the Compressor
- Pressure drop: every bend, valve, and undersized pipework will cause a loss of pressure. The standard solution to this problem is to increase the compressor pressure, consuming energy during all hours of operation.
- Water: compressed air contains water. Pipework which retains water delivers it to machinery and products.
- Leaks: leaks from joints and fittings accumulate over time, wasting air regardless of production activity. Our guide to industrial air compressor running costs shows how leaks add up.
- Future growth: a network sized only for today's demand becomes a bottleneck when new machines arrive.
Sizing the Air Compressor Pipe
The pipe size is determined by the flow to be conveyed, the distance covered, the pressure at which work will be done, and the amount of pressure drop allowed. Large plants, even those using centrifugal compressors, require larger headers, capable of handling the entire compressor capacity.
- Step 1 - Add up the air demand of every user on each branch, allowing for how many run at once.
- Step 2 - Measure the length of all the mains and branches, and the equivalent lengths of any bends and valves.
- Step 3 - Decide on a satisfactory pressure drop between the compressor house and the furthest point of use, keeping it low.
- Step 4 - Select the pipe diameter that satisfies the requirement at full flow, then size for future growth.
- Step 5 - Look at drops and hoses at the point of use, where the fittings may cause the greatest loss.
Choosing an Air Compressor Pipe Material
| Material | Strengths | Points to check |
| Aluminium modular systems | Smooth bore, light, quick to install and modify, corrosion resistant | Fittings must be rated for the pressure and temperature |
| Stainless steel | Corrosion resistant, clean air, long life | Higher material and installation cost |
| Galvanised steel | Strong and widely available | Internal corrosion over time can shed particles; threaded joints can leak |
| Copper | Clean and corrosion resistant for smaller lines | Cost rises quickly with size |
Plastic tubing should not be used when it is not designed to handle compressed air. If there is an explosion, injuries may result. Check the pressure and temperature rating of every component, especially in hot UAE plant rooms.
Designing the Network Layout
- Ring main system: the loop around the building will allow supply to users from both directions, resulting in reduced pressure loss and more consistent pressure than a single dead end pipeline.
- Pipework fall: the main pipework needs to have some fall in the direction of flow for drainage of condensate.
- Takes off the top: takes should come off the top of the main pipework, looping downward in order to prevent water from going to drops but staying in the main pipe.
- Valves for isolation: install valves in order to isolate the section being serviced.
- Storage near large users: an air receiver tank close to a high, short demand can steady pressure in the line.
Draining Water From the Pipework
Despite the dryer, water may come up in case of a dryer failure or even in downstream pipes beyond untreated branches. Drains should be fitted at low spots and the ends of the main line. Ensure that the drains in the receiver and filters are working. Treatment comes first: see our guides to air dryers and choosing a compressed air filter.
Denair Compressed Air Systems From GENAVCO
1. Denair Full Feature Screw Compressors
- Confirmed range: installed motor power from 5.5 kW to 37 kW and free air delivery from 0.59 to 6.32 m3/min, in fixed speed configuration.
- Confirmed package: factory fitted with a refrigerated air dryer, air receiver tank, water separator filter, pre-filter and post-filter.
- Confirmed installation benefit: reduces installation space by up to 50% and saves installation cost, because the piping connections are already made.
View Denair full feature compressors
2. Denair Electric Screw Air Compressors
- Confirmed range: 5.5 kW to 400 kW and 0.36 to 74.49 m3/min, in fixed speed and variable speed configurations, with stainless steel internal piping and air pipe.
- Application fit: larger plants where the compressor room feeds a full distribution network.
View Denair electric screw compressors
Adding lines or losing pressure at the far end of the plant?
Send us your air demand by area and the pressure each user needs. We will review the compressor, dryer and filter selection for your demand.
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Compressed Air Piping in UAE Conditions
- Warm plant rooms and roof piping: pipe heated by the sun means that hot air is fed into the filters and users while fittings are put under pressure, and also moist air will give off water wherever the pipe is cooled. It is advisable to avoid exposing pipes to direct sunlight.
- High moisture at coast areas: more moisture gets into the system, thus it becomes more important to have dryers, drains, and the slope of the pipes.
- Dust: cover pipe ends when installing to prevent sand from getting into the system.
- Expansion: long runs move with temperature, so allow for expansion and support the pipe properly.
Reasons for Selecting GENAVCO for Compressed Air Solutions
- The whole system: GENAVCO helps customers combine compressors, dryers and filters from the Denair compressors range.
- After sales service: spare parts are genuine, preventive maintenance and service at site.
- Member of Juma Al Majid Group since 1967: a renowned UAE Company certified to ISO 9001.
Common Air Compressor Pipe Mistakes
- Small diameter mains: the compressor operates under higher pressure to compensate for this loss.
- End mains serving major customers: pressure drops on the downstream side during peak demand period.
- Branches taken from the bottom of the main: water flows straight into tools.
- Mixing materials and fittings: joints between different systems are common leak points.
- Ignoring leaks: small leaks across a plant add up to a large share of compressor output.
Frequently Asked Questions
What pipe size should I use for my air compressor?
This depends on the flow, the distance and the pressure drop that can be accepted. The main piping should be sized for the whole compressor capacity and future expansion, while the branch pipings should be sized based on their load.
What type of piping is good for compressed air?
Aluminum modular systems and stainless steel are among the most common types due to their cleanliness and corrosion resistance properties. It all depends on your budget and air quality.
Is a ring main better than a straight line?
Usually yes. A ring main feeds each user from two directions, which reduces pressure drop and steadies pressure across the plant.
Can I use PVC pipe for compressed air?
Only pipe rated for compressed air should be used. Unrated plastic pipe can fail under pressure and shatter.
Ready to Improve Your Air Distribution?
Good air compressor pipe design delivers the pressure and air quality your process paid for. GENAVCO plans Denair screw compressor systems with the treatment and storage around them. For the full picture, read our guide to air compressors in the UAE.
Tell us your air demand and pressure. We will recommend the right compressor and treatment and price them properly.
Serving Dubai, Abu Dhabi, Sharjah, Al Ain and the wider UAE.
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