In general, the pipeline selection, layout, and accessories for a compressor owner are among the lesser significant sections of their air compressor. However, these components support the optimum air supply, pressure, volume, and, eventually, output quality in the compressed air system.

Impact of faulty component selection

A faulty layout, design, and selection of pipe material will cut down profits by:

•  Increase in energy consumed by the air compressor
•  Equipment failure
•  Reduction in production efficiency
•  Increase in maintenance costs

What should be the key focus points in a pipe layout and design?

Fixing leaks is the first thought that pops up in the customer's mind! But there is a lot more to the compressed air system. Here is a list of additional components to be considered for efficient transmission and better quality of the compressed air:

1. Air-receiver: It is the primary storage for compressed air to balance the output pressure and application need. The selection of an air-receiver is crucial to meet the plant's demands, along with the effective operation of the compressor (load / unload).
2. Size: Appropriate selection of the size of the pipe, based on CFM of the compressor, will minimize the pressure drop, thereby reducing energy consumption. The larger the size of the pipe, the lower is the pressure drop.
3. Bends: A straight path for the air is the most efficient choice. When it comes to bends, a large radius bend is the most preferred choice. It reduces turbulence, thereby reducing the pressure drop. Note: Avoid short bends as much as possible.
4. Dropline: Dropline tapping should always be from the top of the main header line, curved down to the application point.
5. Moisture drain points: At the right place with the auto drain valve, moisture drain points will drain the water from the system.
6. Closed-loop design: It is the most efficient piping layout. There is no beginning or end for the header line, just a continuous loop.

Planning for the long-term is always crucial for the continuity of the business. Hence, following structure, recommendations, and timely upgrades in the expansion plans will keep the customers better, avoiding any expensive modifications.

What compressor piping systems are available for businesses?

Following types of compressor piping systems are available:

• Aluminium pipes: The latest technology, Aluminium, is lightweight, making it easy to handle, and is highly recommended for clean air applications. It is non-corrosive and remains leak-free.
• Galvanized pipes: Galvanized steel pipes are widely used in compressed air systems. However, over time, the galvanizing coating flakes off and affects the application equipment in the line.
• PVC pipes: PVC pipes are commonly used in compressed air systems, mostly because they are readily available, inexpensive, and easy to install.

Air accessories for the effective operation of your plant

Building a complete compressed air system will need analyses of the equipment requirements and selection of the accessories that deliver the best quality and quantity of compressed air for effective plant operations. 

• Line filters: Compressed air will contain dirt, moisture, scales, and other impurities. Air purity plays a significant role in the sterility of processes, especially in sensitive industries, including food, beverage, and pharma. Installation of filters will ensure that the application remains oil and dirt free. It is also necessary to replace the cartridges at recommended intervals to maintain air quality.
• Dryer: The moisture in the compressed air system will damage pipelines, tools, and equipment that use compressed air. A dryer must be selected based on the moisture tolerance level of the equipment. Dryers are effective in removing moisture and delivering moisture free air for further processes within the system.
• Drain valves: Zero loss drain valves are highly efficient and reliable. The condensate level is sensed, and the moisture/condensate is drained completely with no air loss. 
• Condensate treatment: A mix of oil-water (condensate) is bound to be present in the system. It is always recommended to treat this mixture before releasing it to the sewage-disposal phase. A Condensate treatment unit (Oil-water separator) will help carry out this activity to dispose of the condensate.
• Measure the effectiveness of your compressed air system periodically: This can be done by simple visual checks for leakage, monitoring the condition of filters for a pressure drop, analysing the application pressure, and finally, adjusting and adapting to the changing needs.

Air audit data is the most reliable source of information for reducing operating costs. Depending on the demand pattern, one can decide on using VFD or sizing of the air compressor.

About the author:

Dilip Visvesvaran is the Deputy Manager - Product Management (Global After Market) at Elgi Equipments Ltd.

Delta Electronics supports states in fight against Covid 19 pandemic 

On the 50th Global Anniversary, Delta Electronics support various state governments in India for relief work in fighting against Covid-19. Over the years, Delta has devoted itself to environmental protection and energy saving. Delta’s contributions to sustainable development includes energy-efficient products, the use of alternative energy sources, recycling, life cycle thinking, process development, green manufacturing processes, personnel training, waste management programs and taking environmental issues into account when building facilities. The company also uses a green product management system that takes into account not only its environmental performance but also that of its suppliers.

For every company, the most important asset is its people, and currently, people are facing challenges that require everyone to unite and fight against Covid-19 pandemic together. Delta Electronics understands the need for ICU beds and oxygen cylinders in the hospitals. To supplement this shortage and ensure its availability in fighting the pandemic, Delta Electronics India recently took the initiative of donating ICU beds and oxygen concentrators (10 litre capacity), strengthening India’s fight against COVID 19. 

On this occasion, Niranjan S Nayak, Managing Director, Delta Electronics India, said, “At Delta Electronics India, we thrive on exploring such opportunities where we can contribute to the welfare of the society. We are happy to make a difference with our support for Uttarakhand and Tamil Nadu governments. For the relief work that ensures our commitment to be there with the people and the country in such challenging times. The government is taking various steps, and as a responsible corporate social citizen, Delta is doing its part, caring for the safety of people. We believe business can grow when community flourishes and our new manufacturing plant in Krishnagiri and new R&D Lab in Bengaluru are a testimony to our commitment in leading with a vision of Delta Powering Green India.”

Delta’s core competence in high-efficiency power electronics and expertise in the integration of energy-saving solutions have also been demonstrated in the green data center segment. Moreover, Delta’s own eco-friendly data center at its R&D center facility became the world’s first to receive the LEED v4 ID+C Gold certification in 2018, while its Taipei headquarters’ data center obtained a LEED Platinum green data center in 2019.

Delta, a global leader in power and thermal management solutions, is celebrating its 50th global anniversary this year under the theme “Influencing 50, Embracing 50” to express gratitude to employees, customers and all stakeholders worldwide for decades of loyal support.  Since its foundation in 1971, Delta has leveraged its core competence in high-efficiency power electronics as well as its focus on corporate citizenship to nurture sustainable development through lower carbon emissions. Its corporate mission, ‘To provide innovative, clean and energy-efficient solutions for a better tomorrow’ will guide Delta’s commitment to ‘sustainable conservation, nurturing life’ for the next 50 years, in which the company expects not only to advance lower carbon emissions that help mitigate global warming, but also to spark public awareness on the protection of marine ecology.