How To Design A Compressed Air System For A Shop
When it comes to designing a
compressed air system for a new
or remodeled vehicle service
shop, there are several system
requirements to look into.
Depending on what kind of work a
24 Fleet Maintenance | JULY 2017
shop does, and how many people are
using equipment, there are numerous
compressed air system options
and design qualities that can make
a shop efficient and safe. So says
Jarrett Affolter, product specialist
team leader, Compression
Technologies & Services,
Ingersoll Rand (http://
company.ingersollrand.
com), a global leader in
compression technologies
and services.
“Shops should secure
baseline readings on an
air system’s load profile
before any renovation or
new build,” he advises.
“OEMs, such as Ingersoll
Rand, can easily conduct
one of these readings via
a telesurvey – a seven-day
assessment of an air
system with datalogging
equipment to determine
a system’s load profile.
The results of the readings
can help shops determine
the right compressed air
system to set up, based on
current shop needs and
conditions, as well as any
improvements that could
be beneficial to improving
a shop’s bottom line.”
COMPRESSOR
OPTIONS
When one is building a
shop from the ground-up
and looking to purchase
a new compressor, it’s
important to consider all
of the equipment options
and shop requirements
in order to make the
right purchase, Ingersoll
Rand’s Affolter says. Some
questions to ask are:
• What are you using the
compressor to power?
• How many people will
be using power from the
compressor at once?
• What is the power
supply at the shop?
Do you need a transformer
to support
the air compressor
you are evaluating?
These questions can help
you choose the right compressor
capacity, whether
it be a small reciprocating
unit or an oil-flooded
rotary screw compressor.
“Generally, small reciprocating
units are ideal
for small service shops
with intermittent tool
use, but they can also power large
equipment, such as a vehicle lift,”
says Affolter. “Rotary screw compressors
are designed for shops
that use compressed air continuously
and need more power than
a reciprocating unit can support.
“A rotary screw compressor is
ideal for larger shops with more
than three service technicians,
and can support several tools and
equipment running all at once.”
If upgrading equipment, Affolter
says it’s advisable to keep any old
compressor tanks for extra capacity
and back-up. Even an older, noisy
compressor can have a role in the
shop. The sound can be diffused by:
• Relocating the compressor to
a different area of the shop.
• Building an enclosure around the
compressor to muffle the sound.
• Remotely plumbing the intake.
PIPING CONFIGURATION
If expanding to more space in the
shop or building a larger shop, consider
installing or reconfiguring the
compressed air piping to make sure
all equipment is getting equal air
power, Affolter of Ingersoll Rand says.
“Using a loop formation rather than
one, single pipe that spans across the
entire shop will ensure that the same
pressure and flow is delivered to each
point of use,” he says. “This is a fundamental
detail, but often overlooked.”
If a shop needs new piping or
needs to reconfigure its current
structure, he says it’s important
to think about the following:
Consider installing a new
system regulator
“Not all systems need to run at the
maximum pressure an air compressor
is capable of at all times,”
Affolter notes. “A regulator will help
output only the pressure needed.
This ensures the system runs at
premium efficiency. Take advantage
of any piping reconfiguration to
add a system pressure regulator.
Do research on piping materials
Affolter points out aluminum is
recommended for vehicle service
applications, though there are
a number of other options.
“Some piping materials are more
susceptible to corrosion and higher
pressure loss,” he says. “For
example, polyvinyl chloride (PVC)
material is the lowest cost material,
but it can also result in a safety
hazard. The piping can shatter if
PVC lines are over pressurized.”
In addition, synthetic compressor
lubricant can make the glue on PVC
connections deteriorate, resulting
in the piping coming apart. Contact
an OEM that manufactures quick-fit
piping systems that are user-friendly
and easy to install, such as SimplAir
from Ingersoll Rand, recommends
Affolter. Shops that install piping
in-house save resources on labor.
OEM technicians are also available to
help install compressed air systems.
AIR QUALITY AND
CONDENSATE REMOVAL
Air cleanliness and filtration are
especially important in a shop
environment because of all of the
equipment that compressors power.
“Clean, dry air, free of debris and
moisture, keeps pneumatic shop
tools and equipment running reliably
for a long time,” Affolter says.
“Effective compressed air drying
also has a significant impact on the
quality and integrity of vehicle service
applications. It directly impacts
end results, including paint finishes,
where you can see issues such as
‘fish eyes’ and ‘orange peels.’”
Tire filling applications need clean
dry air with the use of tire pressure
monitoring systems, and
there are long-term benefits of
keeping the air dry and clean for
long rim and tire life, he adds.
“Consider adding dryer equipment
to a compressed air system to
ensure that the system is outputting
high-quality air,” he says. “While
much thought and calculation often
goes into the selection of an air
compressor to ensure the necessary
volume of air is generated, selecting
the proper dryer will have a significant
impact on the quality of the
air that is ultimately delivered.”
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