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Compressed air pipe pressure drop

Enter flow, pressure and pipe run to see the pressure drop at each size, what it costs in compressor energy and which size pays back.

Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.

Pre-sizing
Air and piping

Main header: up to 20 to 26 ft/s. Branches and drops: up to 50 ft/s.

Energy
Economic analysis
—Pressure drop at the current size
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Pressure drop and velocity by size

Green bars meet the allowed drop and the maximum velocity.

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Cost of pressure drop if demand grows

Pressure drop grows with the square of flow: a network at its limit today becomes expensive as the plant expands.

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Project payback

Cash flow of the improvement: investment in year 0 and annual savings escalated at the rate entered, discounted at the MARR.

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The report gathers this page's inputs, results, equations, assumptions and references, with fields for project, engineer and revision. In the print dialog, choose Save as PDF.

Method, assumptions and references

Equations used

Actual flow: Q = FAD × (p_atm ÷ p_abs) × (T ÷ 293.15 K); ρ = p_abs ÷ (287.05 · T)
Darcy–Weisbach: Δp = (f · L ÷ D + ΣK) · ρ v² ÷ 2; f from Colebrook–White; air μ from Sutherland
Extra energy: ΔW ÷ W = [((p + Δp) ÷ p0)^0.2857 − 1] ÷ [(p ÷ p0)^0.2857 − 1] − 1 (adiabatic compression)

Assumptions and limits

  • Isothermal flow with mean density over the run, valid for drops small compared with absolute pressure (under about 10%).
  • Approximate nominal inside diameters; check the piping system manufacturer for exact IDs.
  • Savings assume the compressor setpoint can be lowered after the change.

Standards and technical documents

  • ISO 11011:2013: Compressed air — Energy efficiency — Assessment
  • ISO 8573-1: Compressed air — Contaminants and purity classes
  • Compressed Air Challenge / U.S. DOE: Improving Compressed Air System Performance: A Sourcebook for Industry
  • Atlas Copco: Compressed Air Manual, 9th ed.

U.S. regulations

  • OSHA 29 CFR 1910.242(b): compressed air used for cleaning limited to 30 psi
  • ASME B31.1 / B31.3: piping codes

Frequently asked questions

What pressure drop is acceptable in compressed air piping?

Up to about 1.5 psi (0.1 bar) in the main header and 4 to 5 psi (0.3 bar) from compressor to point of use, including dryer and filters. More than that usually leads to raising compressor pressure, at 1% energy per 2 psi.

What velocity should I size for?

Main headers 20 to 30 ft/s; branches and drops up to 50 ft/s. High velocity increases pressure drop and carries condensate.

Is a loop header better?

Yes. In a loop, air reaches each user from two directions, flow per section halves and the drop falls to roughly a quarter.