Compressed air systems commonly use piping to move air through the system. It is important to properly maintain this piping to ensure performance and efficiency of the system as well as the equipment or machines of which it may be a part.
Like any other component, compressed air piping is susceptible to wear and tear over its lifespan. And the average service life of the piping can vary widely, anywhere from as few as 15 years to as many as 50 years depending on the material from which it is made.
At a certain point, it will likely be necessary to upgrade the piping to ensure the longevity of the compressed air system and any associated machinery. Performance issues can otherwise occur if left unattended, eventually leading to costly unplanned downtime. It can also hinder the efficiency of the system which can cause a business to have higher energy costs.
According to Unipipe Solutions — a provider of aluminum piping systems — there are five key signs to look for when determining if it is time to upgrade a compressed air system’s piping which are outlined in this article.
1. Excessive Pressure Drop
Pressure drop is commonly defined as the difference between the pressure released at the start of a system, such as an air compressor, and the amount of pressure which reaches the end point where it will be used, such as moving a pneumatic actuator.
Small amounts of pressure drop are common in most compressed air systems, but noticeable drops in pressure can negatively impact the performance and efficiency of a system as well as be an indication of a maintenance issue.
Blockages within the piping or other lines in the compressed air system can lead to excessive pressure drop. Corrosion of components in the system can be a factor as well.
If consistently experiencing excessive pressure drop, it could be a sign the piping is not sized correctly and therefore unable to handle compressed air system’s pressure requirements, and thus an upgrade to the piping may be necessary.
2. High Leak Rate
A compressed air system which is frequently leaking can be another indication it is time to replace the piping. Leaks hinder the efficiency of a system and waste valuable compressed air.
Continually having to fix leaks wastes time and money as well. Unipipe Solutions says constant repair of leaks in a compressed air system is a clear sign an overhaul is likely required.
In the article “Air-System Leak Assessment in 12 Steps” author Kelly Paffel notes three of the most commonly used methods for detecting a leak in a compressed air system:
- The human ear – Although it can be difficult to hear small leaks and determine their source, some can be detected by the human ear and thus a clear indicator of a leak which needs to be addressed.
- Liquids – Liquid detectors such as soapy water can be sprayed onto system components to help determine if a leak is present. A benefit of this method is that the size of the bubbles created after spraying the leak site can offer insight into the severity of the leak.
- Ultrasound – An ultrasound device can be used to detect high-pitched noises that can be associated with a leak and outside of the human threshold for hearing them.
3. Visible Corrosion
Rust and corrosion are known to cause issues for a number of components, including piping, and can occur over time depending upon the environment in which a compressed air system is being used and the materials from which piping is constructed.
If either is present in the piping structure, there is a greater potential for leaks system failures. Unipipe Solutions states that corrosion is especially common in older iron piping systems and can severely impact air quality.
The company says that if corrosion or pitting can be seen on the outside of the pipes or there is corrosion buildup within them, pipes should be replaced as soon as possible.
4. Blocked Filters
Filtration is an important part of any compressed air system as it prevents entry of contaminants that can cause performance issues.
Inline filters are among the many types used in these systems and are typically placed after the air compressor to remove any potential contaminants which may be in the compressed air. As Robert Horneman, Product Manager at ELGi Industrial, explained in an interview with Power & Motion, air itself contains small contaminants which need to be filtered out as anything the compressor takes in will be compressed and sent through the piping.
Over time, filters become full of all the contaminants they’ve collected and need to be replaced. Routine filter replacement ensures systems continue to perform as desired and in an efficient manner. However, if frequently replacing the inline filters it could be a sign of a larger problem.
Unipipe Solutions says internal corrosion or flaking in the compressed air pipes can cause blockages in the inline filters, leading to performance and efficiency issues and the need to replace these filters more often which can be both costly and time consuming.
5. Higher Energy and Maintenance Costs
Any business utilizing a compressed air system is going to have costs associated with its operation including those for routine maintenance and the energy required to run it. However, if these costs start to rise without a discernable reason, issues with the compressed air system’s piping could be the cause.
As previously noted, a compressed air system can become inefficient if its components are corroded or filters become blocked. The less efficient a system is, the more energy it uses to be able to do its work, which drives up operational costs.
Inefficiency could be due to the age of the system as well because of the wear and tear that can occur over the years causing leaks, pressure drops and other issues. Additions and changes throughout the life of a system can create messy piping with long pipe runs, dead ends, and poorly placed or designed drops, all of which can negatively impact system efficiency.
Unipipe Solutions notes that some of these design issues can be corrected, but often it is better to Upgrading the piping system can help overcome these issues, reducing energy use and costs.
Frequently performing maintenance on a system can also be costly not only in terms of the money spent on parts and labor but also the downtime required to complete the work. Routine maintenance is of course necessary to get the most out of a system during its life, but more repairs than what is typically required is often a sign of a larger problem, including the system nearing the end of its useful life and appropriate measures should be taken to address the issue.
Recognizing when compressed air piping needs to be replaced enables an operation to be proactive about doing so, helping to prevent costly maintenance and downtime issues from occurring.
This article is adapted from a piece written and provided by Unipipe Solutions entitled “10 Signs It’s Time to Upgrade Your Compressed Air Piping System” which originally appeared on the company’s website.
