Beyond the compressor: Why filtration and piping matter
Air compressors get the most attention, but filtration and piping can have a dramatic impact on performance.
Compressed air systems can only be as good as their weakest link. That’s why filtration and piping need to be heavily considered when assessing performance. They are crucial elements of the system, responsible for cleaning and distributing compressed air throughout a facility. The quality of filtration and piping in a facility can affect production quality and operating costs. They also have a substantial impact on a system’s efficiency and reliability. “If an air compressor is a system’s heart, then the piping and filtration are its veins and arteries,” said Justin Beckett, field technician and support specialist with ELGi. “Choosing the right components can make the difference between a system that runs smoothly or bleeds money and risks breakdowns.
The right piping
Piping needs to be sized correctly for the system. When it’s too small, the undersized piping increases air velocity, which leads to greater friction loss within the pipe. This restricts airflow and causes a drop in pressure. When the piping is too large, the compressor must work harder to maintain pressure. Both scenarios cause the air compressor to burn more energy, inflating costs and reducing the life of the system.
Pipes must be sized for the amount of air you’re pushing through. If you’re running a 200 hp compressor through a half-inch pipe, you’re going to have major pressure drop — and that puts a lot of extra work on the compressor,” Beckett explained.
To properly size a system, look to these key measurements:
- CFM (cubic feet per minute)
- Pressure requirements measured in hp (horsepower)
- Distance from compressor to use point
Improper layout can also create problems. Long pipe runs, sharp bends or complex routing add unnecessary resistance to airflow. These design flaws can result in uneven pressure across the system, increased wear on equipment and higher chances of leaks at connection points. “Working with a compressed air expert can help you avoid common design issues,” Beckett said, Pattons and its partners can look at your facility’s layout, recommend proper pipe sizing and make sure the system delivers consistent pressure without wasting energy.
Filter strategies
Filters also need to be sized correctly for both the system and their intended use. Using the wrong filter type or rating can lead to over-filtering, which wastes money, or under-filtering, which can lead to clogged filters, pressure drops, and system damage.
If filters are too small for the system, they restrict airflow and force the compressor to work harder than it should. It’s like putting a kink in your hose. Everything downstream suffers,” Beckett said. “But if they’re oversized for the application, you’re just spending more money than necessary — on equipment, maintenance, and replacement parts — without any real performance benefit.
Higher-efficiency filters can remove smaller particles but often create more resistance, which may reduce overall system performance. That’s why it’s important to understand what contaminants need to be removed and select a filter that meets those requirements without adding unnecessary pressure drops.
Filters aren’t always just at the compressor. Point-of-use filters are commonly used in sensitive areas and are found throughout an air compression system. They are employed just before the air is distributed for an application.
For example, a food production facility might be running many machines on an air compression system and utilize a higher-class filter only on a machine that handles food. Another type of plant might only need ISO Class 1 purity from a filter for one machine, not the whole facility. Localized filtration can:
- Save cost vs. purifying all compressed air
- Reduce filter replacement intervals
- Allow flexibility for different purity needs in the same facility
A qualified expert can help companies choose the right filters and piping with air audits, leak detection studies and technical evaluations,” Beckett said. “We assess a variety of factors to make sure the components match a company’s actual needs.
Diagnosing issues
In many systems, common issues are misdiagnosed as compressor problems. It’s often the pipes or filters. Examples include:
- Leaks causing pressure drops
- Clogged filters reducing flow
- Undersized piping choking off performance
Leaks are the most common and costly problem. They account for 20% –30% of energy use in many facilities. Because leaks often develop slowly, they can go unnoticed for long periods. Over time, these leaks lead to pressure drops, reduced system performance and increased energy consumption. Common sources of leaks include:
- Corroded fittings
- Worn thread sealants
- Aging drains
- Loose connections
Leaks are easy to overlook, but they add up quickly,” Beckett said. “That’s why we recommend performing a routine air audit and leak assessment. It can uncover hidden inefficiencies that are often missed during routine checks.
Piping and filters have their own maintenance needs and schedules to prevent problems. Filters should be replaced annually (or more), depending on usage. Piping doesn’t need frequent replacement but should be assessed via leak studies every few years. Assessing these can be built into service contracts with Pattons to ensure regular replacement.
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