Air Compressor Piping Installation and Maintenance Guide.

When installing air compressor piping, ensure slope design, minimize elbows, install drain valves, and conduct air pressure testing. Anti-corrosion and lightning protection measures are essential. Energy-saving piping design can significantly reduce pressure loss.

1. Air Compressor Piping Installation Specifications

When installing air compressor piping, a series of specifications and key points must be followed, covering layout, connections, and support, to ensure smooth system operation and long-term stability.

These requirements cover piping layout, connection methods, support structures, and other aspects, each of which is crucial. Following these requirements can effectively prevent pipeline leaks, blockages, and other problems, ensuring a stable air supply from the air compressor.

The air compressor unit’s air supply port is pre-installed with a threaded nipple for direct connection to your air supply line. Please refer to the manufacturer’s instructions for specific installation dimensions.

To ensure maintenance does not disrupt the operation of the entire station or other units, and to prevent backflow of compressed air during maintenance, it is recommended to install a shutoff valve between the unit and the air storage tank.

Considering the potential impact of filter maintenance on air usage, it is recommended to add equipment piping to each filter line.

Branch lines should be introduced from the top of the main line to prevent condensate from the main line from flowing into the air compressor.

When laying out piping, minimize its length and straightness, and minimize the use of elbows and valves to reduce pressure loss.

2. Pipeline Connection and Layout

Next, we will discuss the connection and layout of air lines. Pipeline design should include a slope and minimize elbows. Underground pipes crossing the road must meet the specified depth. After installation, pressure strength and air tightness tests are required to ensure system sealing.

The main line size for the air compressor is 4 inches, and branch lines should be connected using existing resources whenever possible.

When designing piping, ensure a certain slope, typically at least 2/1000, and install drain valves (or plugs) at low points to facilitate drainage. Furthermore, the use of elbows and valves should be minimized to reduce pressure loss.

When underground pipelines cross primary roads, the top of the pipe should be buried at a depth of at least 0.7 meters; on secondary roads, the required depth is 0.4 meters.

The installation location and dimensions of pressure and flow meters should ensure that the indicated pressure is clearly visible to operators, and the pressure scale range of the instrument should ensure that the operating pressure is between 1/2 and 2/3 of the dial scale.

After system installation, a pressure test and airtightness test should be conducted to ensure the system’s tightness. During the test, the pressure should be set at 1.2 to 1.5 times the pressure of the same gas, and the system is considered acceptable only if there is no leakage.

3. Anti-corrosion and Lightning Protection Measures

Next, we will discuss anti-corrosion measures for air pipelines. After installation and pressure testing, impurities such as dust, dirt, rust, and welding slag must be removed from the pipeline surface. Subsequently, anti-corrosion treatment is performed, typically including painting. Anti-corrosion involves removing impurities and painting, while lightning protection requires good grounding to prevent safety hazards caused by lightning induction.

Anti-corrosion paint not only extends the life of pipes but also enhances their aesthetics and identification. Generally, a layer of anti-rust paint is applied first, followed by a coating of the specified blended paint.

High voltage generated by lightning can be introduced into the workshop piping system and gas-using equipment, posing a safety risk to equipment and personnel. Therefore, before entering the workshop, pipelines must be properly grounded.

4. Pipeline Pressure Loss and Energy-Saving Measures

During gas flow, pipelines experience pressure loss due to friction and localized resistance. This loss is primarily caused by friction in straight sections, while additional localized resistance occurs at locations such as valves, tees, elbows, and reducers. Pipeline friction and localized resistance contribute to pressure loss. Special materials and designs, such as anodizing the inner layer of energy-saving pipes, can effectively reduce frictional resistance and pressure drop.

For example, energy-saving air compressor pipes offer excellent performance. Their inner layer undergoes anodizing, creating a smooth and dense Al₂O₃ protective layer that effectively reduces frictional resistance. The outer surface is coated with a special dry powder coating, making the pipes highly resistant to acids and alkalis, ensuring long-term stability.

In addition, the smooth inner surface of the piping system, seamless connections between pipes, and a special joint sealing design all keep pressure drop to an extremely low level, further reducing pressure loss.