Pressure analysis of undersized air pipework
A pressure analysis at a toolmaking company revealed that its compressed air pipework was significantly undersized.
Using a pressure analysis at a toolmaking company, we identified significantly undersized compressed air distribution system. We measured average air consumption of 300 Nm3/h. A 37 kW compressor supplied the equipment through DN25×2.5 plastic fusion-welded pipework. Pressure analysis revealed a 3 bar drop between the compressor and end users. To avoid production interruptions and ensure the minimum required 6 bar at the equipment, operators had set the compressor to 9 bar.
The company’s annual electricity costs for compressed air production were almost CZK 300,000. Pressurising the entire network 3 bar above the necessary level increased electricity consumption. Potential energy savings were nearly CZK 65,000 per year, since 3 extra bar represent 21% of annual energy costs. We proposed new DN42×1.5 galvanised pipework costing CZK 69,000, with an estimated payback of around one year.
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