Stage 01Compression: creating the air supply
The compressor takes in ambient air and raises its pressure so it can be delivered to equipment around the plant. The machine and its controls need to suit the way the plant uses air.
- Air delivery: The required flow depends on the equipment in use and how many users operate together.
- Working pressure: Pressure must meet the equipment’s needs after losses through treatment, piping and connections.
- Operating duty: Hours of use, demand variations, electrical supply and installation space guide the selection.
Stage 02Treatment: preparing air for the application
Compressed air may carry moisture, particles and oil, depending on the source and compressor type. Treatment is selected around the quality needed by the process.
- Filtration: Suitable filters help manage contaminants; the required filtration depends on the application.
- Drying: A dryer reduces moisture to the required level. Selection considers flow, pressure, temperature and the required pressure dew point.
- Condensate management: Collected condensate needs suitable drainage and handling. Filters and drains also need maintenance access.
Stage 03Storage: buffering changes in demand
An air receiver stores compressed air and helps the system accommodate changes in demand. It works with the compressor controls and the rest of the air system.
- Demand changes: Stored air can help respond to short-term peaks, subject to the system’s capacity and design.
- Design and placement: Receiver size and location are selected for the application. Wet and dry receiver arrangements can differ from this simplified illustration.
- Inspection and access: Pressure equipment, protective devices and drainage need appropriate specification, inspection and service access.
Stage 04Distribution: carrying air around the plant
The distribution network brings air from the supply equipment to the work areas. A ring main forms a loop; a header-and-branch arrangement serves users from a main route.
- Pipe sizing: Flow, operating pressure, route length and fittings influence pressure loss and the required pipe size.
- Material selection: GI, aluminium, MS, stainless steel and other rated systems are considered against the application and site requirements.
- Routing and isolation: Supports, valves, branch locations, maintenance access and future changes are considered during layout planning.
Stage 05Point of use: connecting each workstation
Branch drops take air from the main network to a machine or workstation. Local components help provide the connection and air conditions that the equipment needs.
- Local preparation: Filtration and regulation are added where required. Lubrication is used only when the connected equipment calls for it.
- Connections: Hoses, couplings and fittings need suitable pressure ratings and adequate flow capacity.
- Service access: Accessible isolation and connection points support maintenance; work follows the site’s safe isolation procedures.
Stage 06Useful work: matching supply to demand
Pneumatic tools and actuators use compressed air to perform work. Their operating cycles change the demand on the network, so supply and distribution must be considered together.
- Equipment demand: Air consumption, simultaneous use and duty cycle help establish the system requirement.
- Pressure at the equipment: The pressure available at a running machine matters alongside the pressure measured at the compressor.
- Ongoing care: Leak checks, filter and drain servicing, and reviewing changes in demand help keep the system working as intended.