Reducing Pressure Drops in Your System

Pressure drops reduce the performance of your compressed air system and cost you money!

 

There can be many reasons, for example a small leak in your pipework that gets worse over time. They may be tough to spot right away, but eventually you’ll notice a decline in the performance of your system. Pressure drops will lead to an increase in energy consumption and reduce your systems performance. 

Pressure drop in a compressed air system is due to airflow resistance caused by pipe friction and various components within the system (e.g., valves, bends). Inadequate pipe sizing also results in pressure drop. The compressor must produce air at a pressure high enough to overcome these pressure losses in the system and still meet the minimum operating pressure of the end use equipment or process. For a compressor delivering air at a pressure of 8 bar, if the pressure at the point of use is say 6.5 bar, this pressure drop of 1.5 bar through the system represents wasted energy and money.

In a properly designed and installed system, pressure drop should be less than 10% of the compressor’s discharge pressure, as measured from the compressor outlet to the point of use. So, at a pressure of 7 bar, the pressure drop should be less than 0.7 bar. The need to generate at a substantially higher pressure than required by the end use application is usually an indication of a pressure drop problem. If reducing the pressure, make sure the most critical process still has sufficient air to operate.

Check the required pressure and air purity levels with the equipment supplier. For example, blow guns should be regulated down to 2 bar to meet health and safety requirements.

If you suspect that the pressure has dropped on your compressor, there are actions that you can take to restore it to normal function. Also, you can always call an Air4u engineer to perform routine maintenance on your compressor.

Ways to Reduce Pressure Drop

Your air compressor and system consume energy to generate the compressed air and quality you require. If you notice it using more than normal, it could be due to a pressure drop.

Below are a few things to check for as you inspect your compressed air system:

Inspect Pipework & Tubing.

• It’s important to inspect it, to make sure that your distribution remain airtight. By listening to your pipework, you may be able to hear air leaks. So, try running your compressor, but do not use any air tools or equipment.
• A leak may be really quiet, so make sure there’s as little background noise as possible. It’s preferable to check outside working hours.
• Walk slowly around the system listening for hissing or rasping sounds – these are usually sure signs that there is a leak. Make sure you include all joints, flanges and valves in your inspection.

Check for Worn Hoses.

• Kinked or worn-down hoses can lead to air leaks. When you inspect hoses regularly to make sure they’re in prime working condition. You may be able to spot a leak earlier, before the problem worsens. Make sure that none of the hoses in your system are in a stressed position. All connection pieces should be properly sized and tight.

Check Regulators.

• The settings on the pressure regulators may be what is causing the pressure drop, and the increase in energy. You can try resetting it, and if you still experience the drop, it might need to be replaced. 

Pipework design.

• The layout of your pipework needs to be looked at. It may be time to reconfigure it and move your most used tools closer to your compressor, so that you can eliminate any extension pieces and reduce the amount of ground that needs to be covered. When you shorten the distance air needs to travel, you improve the efficiency of the system.

If you cannot find the source, it may be time to call for a repair. 

The Benefits of Reducing Pressure Drop- Saving money!

If you’re experiencing a pressure drop in the system, you may not notice the difference at first. It may not become apparent until your system is expending a significantly higher amount of energy than previously. 

But when you successfully address this problem, you will experience improved performance, reduced, maintenance, and lower operating cost. All of this leads to you being able to focus on core aspects of your business. 

Your Air Compressor is a Complex Machine.

It can be incredibly difficult to troubleshoot your compressor, and to know what needs to be fixed. If you’ve looked and cannot identify the source in order to reduce pressure drop, it may be time to contact an experienced Air4U engineer to help you with the problem. 

Please Remember

Compressed air can be dangerous and therefore we recommend that you consult an expert if you are in any doubt about how to proceed. Always ensure that the system is completely de-pressurised before attempting any repair.

If you wish to find out any further information or would like to book a service, please follow the link to send us an email at sales@air4ultd.co.uk