The Complete Guide to Compressed Air System Design

 

1. Why System Design Matters 

 

Compressed air is a versatile and reliable source of energy used in a wide range of industrial applications. A properly designed compressed air system delivers efficient performance, reliable operation and lower operating costs throughout its service life.

Although the initial investment in equipment and piping typically represent only a small portion of a system's lifecycle cost, energy consumption accounts for the majority of long-term expenses. Maintenance, replacement components and air losses further increase operating costs over time.

Because energy represents the largest share of a compressed air system's lifecycle cost, decisions related to network design, pipe sizing, material selection and maintenance practices have a direct impact on system efficiency, reliability and long-term operating costs.

 

 

2. Design Considerations

 

Before designing a compressed air distribution system, several factors should be evaluated to ensure long-term performance, reliability and maintainability.

 

Air Quality Requirements

 

All compressed air applications require different levels of air quality. The required air quality will influence the selection of filters, dryers, separators and condensate treatment equipment.

Refer to the Air Quality section of this guide for additional information.

 

Compressor Room Planning

 

Compressors, receivers and air treatment equipment should be installed in a properly ventilated and accessible compressor room.

Adequate space should be provided to facilitate maintenance and future equipment additions.

 

Heat Recovery

 

Approximately 90% of the electrical energy consumed by an air compressor is converted into heat. When planning the compressor room, consider opportunities to recover this heat to improve overall facility energy efficiency.  Heat recovery systems are generally most effective when designed during the initial planning stage of the compressed air system. 

 

Future Expansion

 

When sizing the distribution network, future growth should be considered. Size up main distribution lines to accommodate future expansion (next 5-10 years) whenever possible.

 

Maintainability

 

System layouts should incorporate isolation (piloted) valves and bypass sections where appropriate to simplify maintenance and reduce downtime.

 

Vibration Management

 

Flexible anti-vibration connections should be incorporated between equipment and the piping system to reduce vibration transfer and facilitate maintenance.

 

Air Leaks

 

Minimizing leaks starts with proper system design and ongoing maintenance. Selecting a high-quality piping system and regularly inspecting components such as quick couplers, hoses, and FRL bowl seals can significantly reduce air losses.  Maintaining the lowest practical operating pressure also helps minimize leakage.

Comprehensive compressed air audit can identify leaks, prioritize repairs and improve energy efficiency. 

 

3. System Planning

 

3.1 Estimating Air Requirements

 

Every compressed air system project is unique because user requirements vary widely.

 

Before designing the system, determine:

1. Number of pneumatic tools and equipment
2. Total airflow required (SCFM)
3. Air quality requirements
4. Operating conditions of each workstation
5. Choice of compressor
   
   

 

3.2 Determining Facility Layout

 

A plant layout should be prepared to determine the system’s length in linear feet.

 

The following points should be taken into consideration:

• Building structure and available mounting locations
• Ceiling- or wall-mounted installation requirements
• Ceiling height and available clearance
• Compressor room location and temperature
• Workstation locations
• Equipment placement
• Accessibility for future maintenance  (at least 25% to 50% extra capacity should be added)

 

3.3 Choosing a Network Configuration

 

The optimal configuration of a compressed air network depends on the layout of the facility and the requirements of the application. The objective is to achieve a balance between airflow demand (SCFM) and the pressure required at the points of use (PSI), while minimizing pressure losses throughout the system.

It's also important to think about future requirements during the design phase. Planning for potential expansions can help ensure that the network is sized appropriately not only for current needs but also for future growth, reducing the need for costly modifications later.

The selected network configuration plays an important role in system performance, pressure stability and long-term flexibility.

To learn more about the different compressed air distribution layouts available, see our article:  The 5 Main Configurations of a Compressed Air System.

 

 

3.4 Choosing a Piping Material

 

The selection of piping material affects system performance, air quality, installation requirements and long-term operating costs.

Common materials used in compressed air systems include steel, galvanized steel, copper, aluminum and stainless steel. Each material offers advantages and limitations depending on the application, environment and performance requirements.

 

3.5 Series 08: Aluminum Compressed Air Piping

 

 

Certifications

 

All fittings are registered under the Canadian Registration Number (CRN)

All products are registered with Technical Standard & Safety Authority (TSSA)

All products meet the requirements of ASME B31 / ASME B31.1 / ASME B31.3

All products are in compliance with the European Pressure Equipment Directive (PED) 2014/68 / EU

 

>Learn more about Series 08 piping

 

4. The 5 steps to calculate the right pipe diameter

 

4.1 Calculate the Linear Feet of the Main Line

 

The main distribution line must be sized to provide adequate airflow while minimizing pressure losses.  It is recommended that you draw a diagram of the system showing the route of the piping.

 

 Sizing depends on: 

• The location of the compressor room;
• The locations of the air consumption points;
• The chosen configuration for the network;
• The obstacles that need to be avoided when routing the main pipe;
  
  

4.2 Calculate the Equivalent Lengths (fittings)

 

Fittings can create additional resistance to airflow and contribute to pressure loss.  To account for this effect when sizing a compressed air network, each fitting is assigned an equivalent length of straight pipe (see below table).

The total equivalent length of all fittings should be added to the actual pipe length before determining the required pipe diameter.  

While accounting for equivalent lengths may not always result in a larger pipe diameter, it is considered a best practice and helps ensure a more accurate sizing calculation.

 

 

4.3 Calculate the Total Airflow Required in SCFM

 

The pipe diameter must be big enough to transport sufficient air at the required pressure to all points of use.         

The required number of SCFM is indicated by the manufacturer of the pneumatic tools or equipment. For reference, the table below provides the typical average flows for most used pneumatic tools.  The flow rate (SCFM) of each tool is multiplied by their percentage of usage time.

Use the average flow SCFM to complete the calculation and validate the actual SCFM for the equipment being used for your project.

 

 

4.4 Determine the Diameter of the Main Line

 

Use the tables below for the type of compressed air network being used.  Always round up to the higher factor in the table when the result is not a round number.  In addition, it is recommended to size up the main line diameter to cover the possibility of network expansion over the next 5-10 years.

 

 

4.5 Determine the Diameter of Each Drop

A drop is a branch line that connects the main distribution line to a point of use.

Using the linear network sizing table from step 3, calculate the required SCFM for each drop based on the combined air consumption of the connected tools and equipment. This process should be repeated for every drop in the system, taking into account the specific airflow requirements at each point of use.

 

Example of the 5-step calculation for main line diameter sizing

 

• Closed loop system with 9 drops

• Plant measures 100 ft x 30 ft
• Total length of the line in linear feet : (2 x 100 ft) + (2 x 30 ft) = 260 ft
  
  

• 10 unions (63 mm): 0.5 ft x 10 = 5 ft

• 4 elbow (90°) unions (63 mm): 1.8 ft x 4 = 7.2 ft

• EQUIVALENT TOTAL LENGTH : 12.20 ft + Main line: 260 ft

• NEW TOTAL LENGTH (linear ft) = 272.20 ft

Based on the sizing table for a closed loop system (above), a demand of 374.43 SCFM and a main line length of 260 ft require at least 50 mm pipe diameter.

 

• 12 reversible drills (1/2") : 33 SCFM x 12 x 50% usage time = 198 SCFM

• 9 belt sanders (10 mm) : 19 SCFM x 9 x 33% usage time = 56.43 SCFM

• 3 impact wrench (1/2") : 40 SCFM x 3 x 100% usage time = 120 SCFM

TOTAL REQUIRED AIRFLOW : 374.43 SCFM

 

Based on the sizing table for a closed loop system, a demand of 374.43 SCFM and a main line length of 260 ft require a 50 mm pipe diameter. To accommodate future expansion and maintain optimal system performance, it is recommended to select the next available size, 63 mm, for the main distribution line.

 

 

Step 5 - Determine the diameter of each drop

Referring to the sizing table below for a linear system, calculate the required SCFM for each drop based on the total air consumption of the connected tools and equipment.

Repeat this process for each drop in the system.

 

• Dop leg #1: 25 ft

• 2 reversible drills (3/8")  : 33 SCFM x 2 = 66 SCFM 

SIZE FOR DROP LEG #1 : 25 mm     

 

5. Thermal Expansion

 

5.1 Thermal Expansion Considerations

 

Aluminum compressed air pipes are subjected to temperature variations and expansion movements, which may be compensated by absorption devices on the system network. A flexible element (expansion loop, anti-vibration hose, or expansion fitting) must always be installed on any straight section longer than 150 m (500 ft) to absorb expansion and prevent stress on the piping system.  These solutions are explained in this section to counter this phenomenon.

When thermal movement is not properly managed, excessive stress can be transferred to fittings, valves and connected equipment, potentially affecting system performance and longevity. 

 

When evaluating thermal expansion requirements, consider:

• The length of the straight sections of piping
• Expected operating temperature range
• The space available for installation
  
  

Longer pipe runs and larger temperature variations generally require greater attention to thermal expansion management.

 

5.2 Effects of Expansion and Contraction

 

If thermal expansion and contraction are not properly considered during the design phase, the resulting stresses can affect the performance and longevity of the compressed air distribution system.

 

Potential consequences include:

• Excessive stress between fixed points
• Compression of clamps and supports
• Strain on connected equipment
• Pipe deformation or sagging
• Premature wear of components
• Increased risk of leaks or system failure

Proper expansion compensation helps protect the piping system and connected equipment while ensuring long-term reliability.

 

5.3 Expansion Loops : For Systems With a Pipe Diameter of 20 mm to 160 mm (3/4 to 6 in)

 

Expansion loops or lyres absorb thermal movement by allowing the piping to flex naturally as it expands and contracts.

This solution is commonly used on long straight pipe runs where sufficient installation space is available.

 

Benefits

• Fully CRN solution for all pipe sizes
• No moving parts
• Long service life
• Low maintenance requirements
• Effective for large temperature variations

 

 

5.4 Anti-Vibration Hoses: For Systems With a Pipe Diameter of 16 mm to 80 mm (1/2 to 3 in)

 

Anti-vibration hoses can also absorb expansion movements. The anti-vibration hose must not be overly bent (too squared or not rounded enough).

It is important to note that only sizes 16 mm (1/2 in.) - 50 mm (2 in.) rubber anti-vibration hoses are available with a  Canadian Registration Number (CRN).

Rubber anti-vibration hose can also be installed at the compressor to neutralize sources of vibration.

> Explore anti-vibration hoses

 

 

 

>Explore high temperature anti-vibration hoses

 

5.5 Expansion Fittings: For Systems With Pipe Diameter of 63 mm to 160 mm (2-1/2 to 6 in)

 

Expansion fittings are designed to absorb thermal movement when space limitations prevent the use of expansion loops.

These components provide controlled flexibility within the piping system and help reduce stresses caused by temperature changes.

 

Benefits

- Compact solution
- Suitable for confined spaces
- Easy integration into existing systems
- Effective absorption of thermal movement

 

>Explore expansion fittings

 

6. Network Design Components

 

The proper selection and placement of system components contribute to the efficiency, reliability and maintainability of a compressed air distribution network. These components should be considered during the design phase and incorporated into the system layout drawings. 

 

6.1 Main Line Slopes

 

Main distribution lines should be designed with a slope to promote the natural drainage of condensate toward designated collection points.

A properly sloped network helps prevent water accumulation within the piping system and improves the effectiveness of condensate management equipment.

As a general guideline, a slope of approximately 1% (10 mm per metre / 1⁄8 in. per foot) should be maintained. In practice it is usually necessary to break the slope in several peaks and valleys with a drainage drop at each low point.

 

6.2 Pipe Supports

 

The pipe fixing methods are defined according to the configuration of the building and must be carried out in such a way as to obtain perfect alignment and good solidity of the whole. 

 

• The maximum distance between each mounting clip must be 3 metres, regardless of the pipe diameter.

• It is strongly recommended to install a mounting clip between 20 and 30 cm from each side of the fitting.

• Mounting clips should be installed 20 cm from each side of a valve. 

 

Pipe clips should not be positioned directly against a fitting, as sufficient clearance is required to accommodate thermal expansion and contraction. Proper clip placement helps prevent excessive stress on fittings and valves while maintaining proper pipe alignment. 

 

6.3 Mounting Clips, Hangers, Pipe Clips and Valve Brackets

 

To securely fix the pipe to the wall, a combination of mounting clip and clip spacers may be necessary, depending on the diameters of the pipe and the space to be filled between the wall and the pipe (see drawings below). A spacer compensates for the height difference created when connecting pipes with different diameters. The spacer allows perfect alignment.

 

Wall and Ceiling Mounting

 

 

• With a 35 mm gap between the wall and the centre of the pipe, no spacers are required with a 16, 20, 25 or 32 mm mounting clip.

• With a 90 mm gap, no clip spacers are required with a 63, 80 or 100 mm mounting clip.

 

• Examples of installations requiring a combination of clip spacers and mounting clip with a 70 mm or 90 mm gap between the wall and the centre of the pipe.

 

Ceiling Mounting

 

 

>Explore ceiling mounting accessories

 

Other Ceiling and Wall Mounting Accessories

 

 

>Explore other ceiling and wall mounting accessories

 

Valve Brackets

 

It is important to install a mounting clip 20 cm on each side of a ball valve to avoid pipe distortion or vibrations during application, particularly in a drop.

There are also several models of brackets for ball valve depending on the diameter. If you are installing a ball valve equipped with a valve bracket, a mounting clip on each side of the valve is not required.

 

>Explore valve brackets

 

Bracket for Ball Valve
Bracket for Ball Valve with Flange

 

6.4 Manifold Considerations

 

At application points (drop legs), the manifold should be aligned with the centreline of the pipe to ensure proper installation and accessibility. 

When the distance between the wall and the centreline of the pipe exceeds 35 mm, a manifold spacer may be required to provide adequate clearance and maintain proper alignment. 

 

>Manifold Spacers   Used to provide additional clearance between the wall and the manifold assembly when the distance between the wall and the centreline of the pipe exceeds 35 mm.

 

6.5 Drop Legs:  Bypass Saddle Tees

 

Bypass saddle tees are used to create drops for supplying workstations on both new and existing compressed air systems. By drawing air from the upper portion of the main line, they help reduce the risk of condensate entering the drop and reaching downstream equipment.

In addition to improving condensate management, bypass saddle tees simplify system modifications and future expansions. They can be installed with or without pressure, eliminating the need to cut the main pipe and reducing the number of fittings, installation time and overall project costs.

When designing a drop, it is also recommended to incorporate a drain at the bottom of the drop leg to facilitate condensate removal. Automatic drains can further simplify maintenance and improve condensate management. >Explore bypass saddle tees

 

Bypass Saddle Tee Connection type : Compression	25 - 80 mm	100 mm
Bypass Saddle Tee Connection type: Threaded	Straight : 25 - 100 mm	Female: 25 - 100 mm
Bypass Saddle Tee for Pressurized Drilling Connection type: Threaded

 

6.6 Bypass Assemblies

 

Any component that may require maintenance or repair should be isolated through the use of a bypass assembly.

 

Typical applications include:

- Water separators
- Refrigerated dryers
- Filters
- Air treatment equipment

 

Bypass assemblies allow maintenance to be performed without shutting down the entire compressed air system, improving maintainability and reducing downtime.

 

6.7 Adapters and Flanged Fittings 

 

When upgrading or expanding an existing compressed air system, it is often necessary to connect new piping to equipment or infrastructure that uses different connection standards.

Adapters and flanged fittings simplify the integration of S08 aluminum piping with existing compressed air networks and equipment, making system upgrades and phased installations easier to implement.

 

>Explore S08 fittings

 

Adapters NPT - Straight: 3/8 - 3 in. - Elbow: 3/8 - 1 1/2 in.
ISO 7005/ANSI 150# Flange Fittings 50 - 160 mm

 

6.8 Compact Connection Fittings

 

Compact connection fittings simplify the integration of equipment within compressed air systems while minimizing the overall installation footprint and simplifying installation and maintenance.

 

Their modular design makes them particularly useful in:   Compressor room layouts Air treatment systems Bypass assemblies Equipment replacement projects System expansion and modernization projects Equipment isolation assemblies   Two connection options are available depending on the application requirements: ISO 7005/ANSI 150# general-purpose flange and V-Clamp

 

V-Clamp Connection

 

 

ISO 7005/ANSI 150# Flange Connection

 

Configuration "A" with Regular Fittings	Configuration "A" with Compact Connection Fittings
Configuration "B" with Regular Fittings	Configuration "B" with Compact Connection Fittings

 

6.9 Condensate Drainage Points  

 

When a bypass saddle tee is not used, the drop should be designed to facilitate condensate collection and drainage. Depending on the application, this may include:

 

• A drip leg
• A condensate collection point
• A drain

>Explore series 08 condensate drains

 

Manual Drain Unit 20 to 25 mm	Automatic Drain Unit 20 to 25 mm	Automatic Drain Unit 20 to 25 mm

 

6.10 Isolation Valves

 

Isolation valves allow individual sections of a compressed air distribution network to be shut off independently for maintenance, repairs or future modifications.

Incorporating isolation valves throughout the system improves operational flexibility and helps minimize downtime by allowing work to be performed on specific sections of the network without interrupting the entire compressed air supply.

As a general guideline, isolation valves should be installed approximately every 30 m (100 ft) to simplify maintenance operations and facilitate the isolation of individual network sections when required. The exact location and frequency of isolation valves should be determined based on the size, layout and complexity of the system.

 

Ball Valves

• Recommended by CAGI

• Install ball valves to isolate sections of the compressed air network

• Topring is the only manufacturer offering CRN-certified ball valves specifically designed for compressed air networks.
  
  

>Explore Ball Valves

 

16 to 40 mm	50 to 100 mm	160 mm

 

Lockable Valves

• With safety exhaust valve

• Recommended by OSHA (91910.147)

• Allows safe maintenance of equipment

• Certified CRN

>Explore lockable valves

Ball Valve with Locking Handle 20, 25, and 32 mm	NPT Lockout Valve 1/2 - 2 in	Lockout Valve 16, 20, and 25 mm

 

Piloted Valves

• Isolate sections of the air network

• Open and close the network supply quickly and safely from the ground

• Eliminates risks associated with working at height

 

>Explore piloted valves and switches

 

Threaded Piloted Valve 16 - 25 mm	Piloted Valve 40 - 80 mm	Piloted Valve 100 mm

 

Switches for Piloted Valves

 

Programmable/110 VAC: Memorizes up to 16 programs
Button Switch	Key Switch

* Also available: Several kits including the necessary components (piloted valve/tube /mini flow control valve/control unit) are offered with a choice of valve and control unit

 

7. Air Quality

 

Compressed air is an efficient energy source used for many applications and processes. Its optimal use—and better air quality—depend on the removal of all condensates. Products in the Compressor Air Treatment category provide solutions for removing and treating condensates and contaminants.

 

7.1 Moisture in Compressed Air

 

Ambient air contains moisture in the form of water vapour. A compressor converts 7 volumes of ambient air into 1 volume of compressed air. This compression process concentrates water vapour and increases air temperature.

 As a result, exhaust air is warm and moisture-laden. As it flows through the system pipes, the compressed air cools and the water vapour condenses into liquid. The dew point is the temperature to which the air must be exposed for it to continue condensing water droplets. The dryer the air, the lower its dew point.

For information purposes, this table shows that a 25 HP compressor can generate close to 200 L of water over an 8-hour operating period, depending on the temperature.

 

 

The water that builds up in the compressor tank and in the piping is a source of oxidation that can cause significant damage, like:

• Corrosion or rust in the compressed air system

• Malfunction or premature wear of tools and equipment

• Premature wear and frequent maintenance of FRLs (Air treatment at point of use)

• Blocked valves and openings

• Contaminated finished goods (contaminated paint, proliferation of bacteria and microorganisms)

• Higher maintenance and downtime costs

• More compressed air leaks (less efficient and higher electricity costs)

• Diminished productivity from pressure drops

7.2 Sources of Contamination

 

Ambient air is a mixture of gases and millions of solid particles. These particles can be harmful to a compressed air system and to the quality of finished goods, especially at high concentrations and high speeds. Lubricated compressors also contribute to air contamination. Oil that makes its way into the system combines with water and other contaminants to form a thick, viscous substance that leads to even more damage at the point of use.

 

 

7.3 ISO 8573 Air Quality Standards

 

Certain applications and processes require very high air quality standards. This is true in food processing industries, where compressed air may come into contact with food (during processing, curing, packaging, and other steps). Water or contaminants in the air can lead to pneumatic equipment failing and bacteria proliferating in compressed air lines.

The International Organization for Standardization (ISO) established the ISO 8573 Series of standards to make it easier to select, design and measure air treatment components. ISO 8573.1 identifies three main types of contaminants in a compressed air system: solid particles, water, and oil (in the form of aerosols and vapour).
Each is categorized and assigned a purity class ranging from Class 0 (the most stringent) to Class 9 (the least stringent). Air use determines the required purity level based on industry standards and applications.

 

 

7.4 Selecting the Appropriate Air Quality Level

 

While ISO 8573.1 defines air quality according to particle, water and oil content, the required class will vary depending on the application.

The examples below illustrate typical ISO 8573.1 air quality classes commonly associated with different industrial applications.

 

 

8. Condensate Management

 

8.1 Multiple Layers of Air Treatment

 

Water is the primary contaminant found in compressed air systems, and no single component can remove or manage it under every operating condition.

A properly designed compressed air distribution system incorporates multiple layers of protection throughout the network. Each component performs a specific function to remove moisture and contaminants at different stages of the air treatment process.

For example, refrigerated or regenerative dryers remove the majority of water vapour, but they cannot compensate for every operating condition. Cooler sections of the distribution network may still allow moisture to condense. Likewise, filters require periodic maintenance, drains can become obstructed, and air treatment equipment may malfunction over time.

By combining water separators, dryers, filters, condensate drains and point-of-use air treatment, the system provides multiple safeguards that help maintain clean, dry compressed air throughout the network, even when individual components require maintenance or operating conditions change.

The products presented in this section can be applied to safely and efficiently remove and treat condensates while maintaining clean, dry air.

 

8.2 Water Separators

 

Water separators are typically the first stage of condensate removal and are installed at the compressor outlet. They use centrifugal force to remove bulk liquid water and solid contaminants from the compressed air stream.

Because compressed air continues to cool throughout the system, water separators should be used in combination with other air treatment components. >Explore water separators

 

 

8.3 Filters

 

Compressed air filters deliver the required level of air quality according to the needs of each application. Proper filtration protects downstream equipment from oil, particulate contamination, and other contaminants while helping maintain the required air quality throughout the system.

Most applications require a controlled level of air quality to ensure reliable operation and long service life. >Explore filters

 

8.4 Refrigerant Air Dryers

 

Refrigerated air dryers remove moisture from compressed air by cooling the air and condensing water vapour into liquid form.

They are commonly used in industrial applications and can achieve pressure dew points as low as 3°C (37°F). >Discover refrigerant air dryers

 

 

 

8.5 Regenerative Dryers

 

Regenerative desiccant air dryers remove moisture from compressed air by passing it through a desiccant material that adsorbs water vapour. They are used in applications requiring very low-pressure dew points, typically −40°C or lower.

Unlike refrigerated dryers, regenerative desiccant dryers periodically regenerate the desiccant material to restore its drying capacity. Depending on the technology, regeneration may use a portion of the dried compressed air or an external heat source.

>Discover regenerative air dryers

 

8.6 Condensate Drains

 

Condensate drains automatically remove accumulated water from compressors, receivers, water separators, filters and dryers.

The selection of a drain depends on the operating environment, pressure and condensate volume. >Discover condensate drains

 

 

 

Common Drain Types

• Zero Air Loss Drains - Open only when condensate is present, maximizing energy efficiency.
• Programmable Drains - Open at predetermined intervals: can operate against gravity (discharge water at a higher level)
• Mechanical Drains - Operate using a float mechanism with no electricity needed.
• Manual Drains - Best for mobile equipment that may be exposed to freezing temperatures.

 

>Learn more about what drain is best for your installation 

 

8.7 Water-Oil Separators

 

Water-oil separators treat condensate before disposal by separating oil from water, reducing oil content to less than 5 mg/L.

They help facilities comply with environmental requirements by reducing the oil content of condensate before disposal, while also reducing the cost and complexity of condensate management. In many cities or municipalities, condensate discharged into the sanitary sewer system must contain less than 15 mg/L (15 ppm) of oil. >Discover water-oil separators

 

 

9. Point-of-Use Equipment & Accessories 

 

Treating the air at the point-of-use helps improve compressed air quality, regulate pressure and extend the service life of pneumatic tools and equipment.

 

9.1 Filtration

 

Filters remove solid particles, water and other contaminants that may remain in the compressed air system after central air treatment. Proper filtration helps protect downstream equipment and maintain system performance.

 

Best Practices

• Install filters as close to the point of use as possible.
• Install filters upstream of regulators and lubricators.
• Replace filter elements regularly to minimize pressure losses

 

9.2 Pressure Regulation

 

Regulators control downstream pressure to ensure pneumatic tools and equipment receive a constant and accurate pressure, even if there are variations in upstream pressure or flow rate through the valve.

When air tools and equipment are used at pressure beyond the recommended level, energy is wasted, safety is jeopardized, and equipment is subject to premature wear. When a system operates at pressures below the recommended levels, it will not deliver the performance it is designed for.

 

Best Practices

• Install regulators where the required operating pressure differs from the main system pressure.
• Install regulators downstream of filters.
• Follow the airflow direction indicated by the regulator.

 

9.4 Lubrication

 

Lubricators introduce a controlled amount of lubricant into the compressed air stream to reduce wear on pneumatic tools and equipment.

The amount of lubrication should be adjusted according to the manufacturer's recommendations, as both under- and over-lubrication can negatively affect performance and equipment life. 

A typically recommended lubrication rate is 2 drops per minute while air is in demand. 

 

9.5 FRL Combination Units 

 

Filters, regulators and lubricators are usually installed in combination, near the application. Filter and regulator can be combined into one unit and proceed either a lubricator (for air tools) or a coalescing filter (for paint applications).

These combinations are designed to provide the exact level of air treatment required, in a compact format. Combined units simplify installation while providing the required level of air preparation for the application. >Discover filters, regulators and lubricators

 

 

9.6 Exclusive Integrated Air Preparation Assemblies 

 

Point-of-use safety stations combine several compressed air components into a single pre-engineered assembly, providing a convenient and standardized solution for supplying compressed air at workstations.

 

These assemblies can typically incorporate:

• Filter regulators and/or lubricators

• Exhaust shut-off valve with high efficiency silencer

• Wall manifold with drain

• Quick couplers

• Pipe connection fittings and wall brackets

• Semi-automatic drain and pressure gauge

Designed for direct integration into the compressed air network, they simplify installation while helping improve safety, accessibility and air quality at the point of use.

 

3 Port	2 Couplers (2 Ports)	1 Coupler (1 Port)

>Discover air preparation assemblies

 

9.7 Hose Reels and Air Hoses

 

Hose reels improve hose management at the point of use while helping reduce hose damage and workplace hazards.

 

When specifying hose reels and hoses, consider:

• Required hose length
• Internal diameter
• Working pressure
• Airflow requirements
• Environmental conditions
• Compatibility with the application

Proper hose sizing is important because undersized hoses can create excessive pressure drops and reduce tool performance.

Hose reels should be located to provide convenient access while minimizing hose travel distance and unnecessary pressure losses. >Discover hose reels and hoses

 

9.8 Manifolds and Quick Coupler Kits

 

Manifolds provide a convenient connection point at workstations and drop legs, allowing multiple tools or equipment to be supplied from a single compressed air outlet.

These assemblies simplify installation, improve accessibility and help standardize compressed air distribution at the point of use. >Discover wall Mounted Manifolds and Kits

 

Manifold kits include: - Manual drain - 1, 2 or 3 outlets

Manifold kits include: - Manual drain - Ball valve - 1, 2 or 3 quick couplers

10. Engineering Support

 

Whether you're designing a new compressed air distribution network, expanding an existing system or evaluating future capacity requirements, our team can assist with system planning and component selection.

 

Available services include:

• Network layout recommendations

• Pipe sizing assistance

• Product selection support

• System expansion planning

• Integration with existing infrastructure

• For more complex projects, conceptual layout drawings can be prepared to help visualize the proposed installation.

• Compressed air audits with our technical team help identify leaks, optimize operating pressure and improve system efficiency. 

 

10.1 Installation Resources 

 

Once the design phase is complete, consult the S08 Installation Guide for detailed information on:

• Pipe preparation

• Assembly procedures

• Expansion considerations

• Mounting requirements

• Installation best practices

• The guide is intended to support installers and maintenance personnel during system implementation.

 

>View the S08 Installation Guide 

 

10.2 Compressed Air System Design Checklist

 

Use this checklist throughout the design process to verify that all essential design considerations have been addressed before finalizing the design of a compressed air system. 

 

10.3 How to Design a Compressed Air System Video

 

Watch our video to learn key principles of compressed air system design. For organizations looking to deepen their knowledge, Topring also offers virtual and in-person training sessions tailored to engineers, consultants, and industrial teams.

 

>Contact us to learn more about our training programs.

 

 

10.4 Additional Resources

 

Explore additional resources to help plan, design and maintain compressed air systems:

 

National Masters Specification for Compressed Air	Product Catalogue No. 19
Compressed Air Audit Services	Energy Efficiency
Compressed Air System Blog Articles

 

11. Liability of all Buyers and/or Users

 

Anyone who purchases and/or uses a Topring product and/or system (hereinafter “Topring Product(s)”) must
carefully read the user instructions for that Topring Product and, where the product relates to compressed air, must be familiar with the associated health and safety risks prior to use.

By purchasing and using a Topring Product, the buyer and/or user acknowledges that he or she understands and accepts his or her sole liability for installation, identification, maintenance, and use of the Topring Product as well as for configuration of any system that uses a Topring Product. Subject to the limits of public policy as expressed in the law, the buyer and/or user assumes the risk and liability that may arise from loss, damage, or injury caused by improper installation, identification, maintenance, and/or use of a Topring Product, or by misconfiguration of any system using a Topring Product, to the extent to completely and entirely exonerate Topring and its subsidiaries and affiliated corporations (hereinafter “Topring”). The buyer and/or user must consider, among other factors, current regulations, the user instructions for the TOPRING Product, safety measures, the specifics of the premises or location, and the activities or operations conducted there.

By purchasing a Topring Product, and subject to the limits of public policy expressed in the law, the buyer and/or user hereby acknowledges and agrees that Topring cannot be held liable for any damages whatsoever (including damages caused by loss of profits, business interruption, loss of information, or any other loss) arising from improper installation, identification, maintenance, and/or user of a Topring Product, misconfiguration of a system that uses a Topring Product, or the impossibility of such a configuration, installation, identification, maintenance, and/or use.

The buyer and/or user of a Topring Product is responsible for informing any people concerned of the risks,
warnings and safety measures for Topring Products, including but not limited to employees using one or more
Topring Products.