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DESIGNING AN EFFICIENT
COMPRESSED AIR
DISTRIBUTION NETWORK
The main source of inefficiencies and problems
affecting compressed air distribution systems is
often the distribution plan of the system itself.
The majority of problems therefore usually occur
somewhere between the compressor and the
application points.
Most systems are usually of either of two types:
Dead-end network
Octopus network
neither of which provides the best results

DEAD-END NETWORK
COMPRESSOR

In a dead-end network, air flow must be

sacrificed (quantity of air per minute) in
order to preserve a uniform pressure at the
point of use. The progressive reduction of
the central pipe while it moves away from
the compressor maintains pressure.
However, air tools and equipment must
be placed along the length of the circuit in
decreasing order of consumption (SCFM).

The equipment using the most air flow

must be located near the compressor, and
that using less, further away.
This generates major handling problems,
as production processes are not necessarily designed this way.
This is not the optimum network design.

CONVENTION AL
NET WORK

OCTOPUS NETWORK

TOPRING

COMPRESSOR

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A network where each additional line and

extension does not necessarily match the
initial configuration is often called an
octopus network. Dead-end networks
often evolve into octopus networks over
time.
The octopus network includes the
following anomalies:
Different airline materials
Curves, reductions and enlargements
without apparent reason
Inconsistent diameters of air lines

OCT OPUS
NET WORK

Installation done with no knowledge

of pneumatic standards

Predicting what flow and pressure are

available at any point is virtually
impossible. Air flow fluctuations from
varying usage of pneumatic equipment
and air tools makes it even more difficult
to get the right pressure and flow at any
given point.
This results in varying pressure and air
flow conditions through out the system,
creating many problems.
This type of network, while quite common,
is the worst possible situation.

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THE PROBLEM
More than 98% of factories using
compressed air started out with a
dead-end network.

At the very least, the dead-end network

they have has sacrificed air flow in order
to maintain point of use pressure.

Over the years, their systems have come

to resemble a giant octopus whose
growth reminds us of a monster escaping
our control.

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THE SOLUTION
The secret to planning an efficient,
problem-free distribution network is
actually quite simple. The goal is to
achieve a balance between flow and
pressure to maintain the ideal situation at
all points of use, while providing for future
expansion and remaining flexible in the
face of varying compressed air needs.

How is this balance achieved ?

The best solution remains the
CLOSED LOOP NETWORK design.

CLOSED LOOP NETWORK

COMPRESSOR

The equipment located

at point A demonstrates
that the air supply flows
through several lines at
a time, providing
balanced pressure and
air flow.

A closed loop network allows the air

supply to flow through several lines at a
time to any given point on the network.
The balance between pressure, air flow
and stability of supply is ensured by using
a single diameter for piping. This type of
system will also easily accommodate
modifications and can easily supply tools
and equipment with varying supply
requirements anywhere on the network.
Ball valves permit the isolation of a
particular portion of the air line network
to allow for easy:
Repairs
Connections
Enlargements
Periodic maintenance

The size of each loop does not need to be

uniform. The important thing is to have at
least two different supply routes available
simultaneously for each feeder pipe
descending toward a tool or piece of
equipment.
This type of network is the ideal situation
for compressed air distribution systems,
providing the balance between flow and
pressure required to provide the most
efficient distribution of compressed air.

A well-built closed loop network is

therefore most often the ideal situation
for the distribution of compressed air.
In addition to being easy to plan and to
modify when needed, this type of
distribution system becomes an immense
compressed air reservoir that:

Offers a constant air flow at all times

Guarantees a uniform pressure
through out
Contributes to the life of the
compressor by limiting functioning
time
Reduces the electrical consumption
of the compressor

TOPRING

OPTIMAL NETWORK EFFICIENCY

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COMPRESSED AIR DISTRIBUTION SYSTEMS

PROPER SYSTEM DESIGN CAN
INFLUENCE AIR TREATMENT NEEDS

A properly designed system can offer cleaner air of the

appropriate volume and pressure, translating to better tool
performance and worker productivity.

06 SYSTEM DESIGN
07

System design should start with a layout of the

shop or plant. Designate where and what tools will
be used. Determine the placement of the mainline.
Try to keep the line as short as possible while
providing access to where tools are used. Try to
keep in mind any future needs or alterations. It is
much easier to make changes if they are planned for.
Drop supply lines at the point of use or at regular
intervals, to minimize hose length. Size the lines
appropriately for the equipment to be used.
Each supply line should be installed with at least a
filter and regulator. FRLs should be installed at the
point of use, allowing the air to be prepared properly
for the application. Designate appropriate supply lines
as clean air lines for use with paint guns, blow guns
or tire inflator gauges.
On lines operating air tools, install lubricators to
extend tool life.

PROPER SLOPES AND DROPS

Pre-formed Pipe

As for the slope of network pipes, either for lines

running along exterior walls or within a building,
there should be a minimum inclination of 1 inch
for every 10 feet of length. This will lead any
condensation toward water evacuation points.
It must be noted that the feeder pipe may perform
both functions : air flow and the elimination of
condensed liquids. Secondary pipes attached
below the main pipes should include a ball valve
and will help eliminate condensation at their feet
by the presence of evacuation valves.

Water
Trap Tee

Lowest Point of the

Main Line

Main line slope: 1 inch for

every 10 feet of run (always
in the same direction as the
air flow)

Pipe Clip

Ball Valve
Y Strainer
Automatic
Drain

TOPRING

PROPER DISTRIBUTION SYSTEM INSTALLATION

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Properly installed pipe minimizes the amount of moisture

at the point of use. Piping should slope in the direction of
the air flow to an accessible moisture drain point
Outlets should be taken from the top of the main
air lines to keep moisture out
Assemble and test for leaks one section at a time to avoid
major disassembly later
Pipe unions should be installed at regular intervals.
This makes future repairs and modifications easier
Sealant should always be used on threads to eliminate air leaks

Tapered threads should not be overtightened as this could

cause the fitting to crack
Air lines should be secured to a solid surface using
pipe clamps
All piping and fittings should be checked regularly to avoid
leaks in the system. An air leak will reduce the amount of
air at the tool, causing pressure drop. It will also cause the
compressor to work longer and harder, increasing energy
and maintenance costs. See Series 41 for an idea of air leak
costs (Page 185)

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COMPRESSED AIR DISTRIBUTION SYSTEMS

SIZING A COMPRESSED AIR LINE
Correct sizing of the air line is essential
to maximize the cost effectiveness of the
compressed air distribution system.
Network line size is determined by the
flow capacity required for the tools and
equipment to be supplied, as well as by
system design and length.
THINGS TO CONSIDER:
Pressure drops are totally unrecoverable
and waste energy; a drop in pressure
from 87 to 73 PSI will decrease machine
and tool capacity by up to 27%

Main line size is determined by total tool

consumption (SCFM) and total effective
line length
Branch line size should be determined
based on length and total consumption
of the tools on the branch
Main lines that are too small will cause
high air velocity, thus making water
separation more difficult
A larger main line is in fact advantageous,
acting as a reservoir for the air, reducing
the load on the compressor and providing
capacity for future demand and growth

Energy cost will rise by 10% if pressure

is increased by 15 PSI to compensate
for pressure drop
Pipe fittings are responsible for much
of the pressure drop in compressed air
systems
Pipe size should therefore be large
enough to keep pressure drop between
the reservoir and the point of use to a
minimum
Main line size should never be smaller
than the compressor outlet size

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NETWORK TYPES
Flow capacity is a function of total network length; longer lines require larger diameters to maintain the same flow and minimise
pressure drop.
The type of network used will also have an impact on line size. There are two basic types of network designs: closed loop and
linear/dead-end. Both are commonly used for compressed air networks.

CLOSED LOOP NETWORK

LINEAR/DEAD-END NETWORK

EFFECTIVE LENGTH
= ABC

EFFECTIVE LENGTH
= 1/2 x ABCDA
= ABC

For a closed loop system, the fact that there are always at least two
paths to any point on the loop means that only half of the total length
must be considered when sizing the main air line

For a linear/dead-end system, the total length of line must be

considered when sizing the main air line

BEFORE EVALUATING TOTAL NETWORK LENGTH

In order to calculate an effective length of the total network, fittings used must also be taken into account. Every direction change,
cross manifold, T connection or reduction in line size within the network will cause pressure loss equivalent to adding additional line
length.
The table below indicates effective lengths added to the network by each of these restrictions and/or connections.

(IN LENGTH OF EQUIVALENT TUBE)

INTERNAL DIAMETER OF FITTINGS

15 mm

22 mm

28 mm

40 mm

63 mm

Ball Valve

+4"

+12"

+16"

+20"

+28"

Reducer

+16"

+20"

+24"

+28"

+39"

90 Elbow

+28"

+51"

+59"

+79"

+138"

T Fitting

+32"

+59"

+79"

+98"

+158"

TOPRING

EQUIVALENT LENGTHS FOR VARIOUS FITTINGS

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COMPRESSED AIR DISTRIBUTION SYSTEMS

LINE SIZING FOR A
CLOSED LOOP NETWORK
QUICK LINE & AIR LINE

PIPE DIAMETERS
63 mm - 2-1/2"

40 mm - 1-1/2"

28 mm - 1"

See
page 78 for
Series 06

22 mm - 3/4"

15 mm - 1/2"

NOTE: Equivalent fractional diameters are approximate

TOTAL LENGTH OF LINE (FEET)

25

SCFM
5
10
20

TOTAL FLOW REQUIRED

30
40
60
80
100
125
160
200

TOPRING

300

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400
500
600
800

15
15
15
15
15
22
22
22
22
28
28
40
40
40
40
63

50

15
15
15
22
22
22
22
28
28
28
28
40
40
40
63
63

100

200

15
15

15
15

22
22

22
22

22
22

22
28

28
28

28
28

28
40

40
40

40
40

40
63

40
63

63
63

63
63

63
63

300

15
15
22
22
28
28
40
40
40
40
40
63
63
63
63

400

15
22
22
22
28
28
40
40
40
40
63
63
63
63
63

500

15
22
22
28
28
40
40
40
40
40
63
63
63
63

600

15
22
22
28
28
40
40
40
40
63
63
63
63
63

700

15
22
22
28
28
40
40
40
40
63
63
63
63

800

15
22
22
28
28
40
40
40
40
63
63
63
63

900 1000

15
22
22
28
28
40
40
40
63
63
63
63
63

15
22
28
28
28
40
40
40
63
63
63
63
63

( P) PRESSURE DROP OVER 3 PSIG

Calculations based on total maximum pressure drop ( P) of no more than 3 PSIG for entire network, at 100 PSIG @ 60 F
Total flow required is the sum of all flows for all compressed air powered tools and equipment
Note that a typical compressor will produce approximately 4 SCFM per HP

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COMPRESSED AIR DISTRIBUTION SYSTEMS

LINE SIZING FOR A
DEAD-END NETWORK
QUICK LINE & AIR LINE

07

PIPE DIAMETERS
63 mm - 2-1/2"

40 mm - 1-1/2"

28 mm - 1"

See
page 79 for
Series 06

22 mm - 3/4"

15 mm - 1/2"

NOTE: Equivalent fractional diameters are approximate

TOTAL LENGTH OF LINE (FEET)

25

SCFM
5
10
20
30

TOTAL FLOW REQUIRED

40
60
80
100
125
160
200
300
500
600
800

100

200

300

400

500

600

700

800

900 1000

15
15

15
15

15
15

15
22

15
22

15
22

15
22

15
22

22
22

22
22

22
22

15
22

22
22

22
22

22
22

22
28

22
28

28
28

28
28

28
28

28
28

28
40

22
22

22
22

22
28

28
28

28
40

28
40

28
40

40
40

40
40

40
40

40
40

22
28

28
28

28
40

40
40

40
40

40
40

40
40

40
40

40
63

40
63

63
63

28
28

28
40

40
40

40
40

40
63

40
63

63
63

63
63

63
63

63
63

63
63

28
40

40
40

40
63

63
63

63
63

63
63

63
63

63
63

63
63

63
63

63
63

40
40

40
63

63
63

63
63

63
63

63

63

63
63

63
63

63
63

63

22
22
28
40
40
40
63
63
63
63
63

( P) PRESSURE DROP OVER 3 PSIG

Calculations based on total maximum pressure drop ( P) of no more than 3 PSIG for entire network, at 100 PSIG @ 60 F
Total flow required is the sum of all flows for all compressed air powered tools and equipment
Note that a typical compressor will produce approximately 4 SCFM per HP

TOPRING

400

50

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eries 050607
COMPRESSED AIR
DISTRIBUTION
SYSTEMS
Series 05
AIR LINE Nylon

46

Series 06
Aluminium and Nylon

74

Series 07

40

58

w w w . T O P R I N G . c o m

TOPRING

QUICK LINE Aluminium and Brass

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COMPRESSED AIR DISTRIBUTION SYSTEMS

WHY USE
TOPRING

COMPRESSED AIR
SYSTEMS ?
TOPRING compressed air piping

systems are put together using

non-traditional means, such as
push-in fittings or compression
fittings, as opposed to the usual
threading and welding methods
required by traditional pipe.

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These assembly methods speed

up the installation process by as
much as a factor of 4, saving on
installation costs that often include
more labour than materials.
TOPRING compressed air distribution

systems are also made of corrosion

proof materials such as Brass,
Aluminium and Thermoplastics.
These modern materials provide great
improvements over traditional
conventional materials, such as Iron,
Galvanized Steel and Copper, by doing
away with the corrosion problems that
plague traditional systems. This ensures
much longer useful life, definite
improvements in flow and reductions
in operating costs.
TOPRING systems are also very light,

reducing the time and effort required to

complete installations and reducing
strain on workers.

TOPRING
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COMPRESSED AIR DISTRIBUTION SYSTEMS

COMPRESSED AIR SYSTEM COSTS
Analyses of compressed air system costs are often limited to the
initial cost of the piping and fittings.
There are many other cost elements beyond these that should be
considered when planning a compressed air system.

Choosing low cost piping and fittings may lower installed costs
slightly, but will lead to additional costs over the years of system
operation that will far surpass any initial savings.

FITTINGS AND PIPING COSTS

Air system decisions should not be made solely based on the
purchase price of the components.
While the cost of AIR LINE, QUICK LINE and SicoAIR components may be higher than traditional black pipe or galvanized
systems, the savings in installation costs make up the difference.

TOPRING air system components

are easy to assemble

INSTALLATION COSTS
Labour costs for a TOPRING air distribution system can be as
low as one quarter of the cost of installing a conventional system.
The combination of lightweight materials with easy to use
push-to-connect fittings means that installations can be done in
as little as 25% of the time required for comparable black pipe or
galvanised Steel installations.
TOPRING systems also require less specialized labour, and can
often be installed by the user without outside help.
TOPRING air system components are lightweight and
easy to handle, reducing installation time and costs

OPERATING COSTS

CORROSION IN AIR PIPING:

NEW TUBING
OR PIPING

TUBING OR PIPING
OVER TIME

PRESSURE DROP

TOPRING

Pressure drop occurs when the air system cannot keep up with
consumption, reducing tool efficiency and therefore reducing
productivity.

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Rough, porous Steel (black) and galvanized piping causes

resistance to the passage of air and reduces the air flow available
for supplying tools and applications.

ALUMINIUM

NYLON

Smooth bore Nylon or Aluminium piping provides better flow and

reduced pressure drop, and therefore lower costs.

STEEL

COMPRESSOR ENERGY CONSUMPTION

To compensate for the pressure drop that can be caused by rough,
porous conventional piping, especially once it is corroded, the
compressor must work harder, using more energy and adding cost.

RUST

Steel tubing is subject to rust and will deteriorate over

time, unlike Aluminium and Nylon, which remain
essentially unchanged

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COMPRESSED AIR DISTRIBUTION SYSTEMS

CORROSION
Steel and galvanized steel pipes are affected by rust, and
interior surfaces pitted after several years of use cause
greater pressure loss and therefore higher operating costs.

06
07

This does not happen with TOPRING Nylon or Aluminium

piping, as this corrosion-proof piping will be as good as new
for many years to come.
Traditional piping corrodes and
allows contaminant build-up

TOPRING piping resists corrosion

and stays clean over time

LEAKS
TOPRING compressed air distribution systems use leakproof push-to-connect type fittings, eliminating the risk of
leaks from faulty welds or badly sealed threads.

Air leaks cost money

MAINTENANCE COSTS
Maintenance costs for conventional systems will increase
over time as the components deteriorate. TOPRING air
distribution components will not deteriorate.
TOPRING systems remain leak free, eliminating the need
for leak audits to limit compressed air loss.
High quality QUALICOAT paint prevents scratching and,
combined with the absence of corrosion, TOPRING piping
systems do not need to be repainted over time.
TOPRING piping is painted blue for easy identification

OVERALL SYSTEM COSTS ARE THEREFORE

LOWER WITH TOPRING COMPRESSED AIR
DISTRIBUTION SYSTEMS
While TOPRING air distribution system components may
make up a greater proportion of total initial cost than in a
conventional system, total system cost is reduced over the
life of the compressed air system.

Total cost comparison between the TOPRING compressed

air distribution systems and conventional systems

$$$$

TRADITIONAL STEEL OR
COPPER SYSTEMS

TOPRING
Maintenance costs

This is due to the unique advantages of TOPRING systems:

Lower installation costs
Fewer leaks
Lower pressure drop and therefore lower compressor costs
No corrosion or deterioration
Lower maintenance costs

Operating costs

TOPRING COMPRESSED AIR DISTRIBUTION

SYSTEMS ARE THEREFORE THE IDEAL CHOICE

Installation costs

COMPRESSED AIR
DISTRIBUTION SYSTEMS

$$$$

Maintenance costs
Operating costs

Fittings and
piping costs

Fittings and
piping costs

TOPRING

Installation costs

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COMPRESSED AIR DISTRIBUTION SYSTEMS

THE IDEAL COMPRESSED AIR DISTRIBUTION SYSTEM

07

FEATURES AND BENEFITS

A complete solution from the
compressor to the workstation

Significant savings on installation,

maintenance and operating costs

Good quality clean compressed air

for equipment protection

TOPRING compressed air distribution

systems are designed for both primary
and secondary distribution systems,
used for compressed air and vacuum,
from the smallest workshops to the
largest factories

TOPRING compressed air distribution

systems are easy to install and easy to
reconfigure at any time. They are also
ready for immediate pressurization

The materials used for manufacturing

TOPRING pipes and pipe fittings
ensure excellent corrosion resistance.
This guarantees the life of the product
for many years under normal use
The inside surface of the pipe and pipe
fittings allows high flow capacities with
very little flow resistance

Maximum flexibility and

modularity

Optimal machine and tool

efficiency

TOPRING compressed air distribution

systems can be expanded and moved or
reconfigured easily since all
components are reusable

TOPRING

Installations that would take

days/weeks with conventional systems
are accomplished in hours

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No need for specialists or special

equipment
Eliminates expensive preparation time
required for threaded Steel pipe and
drying time for glued plastic systems.
Push-in connection provides a strong
and permanent seal
Lightweight rigid Aluminium or Nylon
piping is easy to lift and maneuver. It
does not require expensive support
structures
Virtually maintenance free

The full flow design of TOPRING

components, the low friction coefficient
of Aluminium/Nylon pipe, and the
sealing characteristics of the systems
ensure optimal and constant flow
through out

Tried and tested reliability

Not subject to corrosion damage
Compatible with most lubrication oils
Excellent mechanical resistance and
pressure handling
Aluminium pipes are able to withstand
impact and shock without danger
Aluminium and Brass components are
virtually flame proof

These systems will adapt to ever

changing requirements
A wide range of parts are available
for 5 different piping sizes

Leak-free system
Designed with reliable O-ring seals,
TOPRING compressed air distribution
systems ensure virtually leak-proof
operation

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COMPRESSED AIR DISTRIBUTION SYSTEMS

TOPRING offers several compressed
air distribution systems :

TOPRING
COMPRESSED AIR
SYSTEMS
ARE COMPATIBLE

Series 05 AIR LINE

Series 07 QUICK LINE
Series 06 SicoAIR

AIR LINE and QUIK LINE components

are compatible with each other and offer
several system options for various needs.

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05
07

Actual dimensions

PIPING
15

22

S05 AIR LINE & S07 QUICK LINE

28

FITTINGS
15

28 mm

22

28

22 mm
15 mm

Series 05 AIR LINE

Series 05 AIR LINE

175
PSI

Calibrated Nylon

175

Composite Push-In

PSI

175

Series 07 QUICK LINE

PSI

Series 07 QUICK LINE

220
PSI

Calibrated Aluminium

Brass Push-In

Actual dimensions
Series 07 QUICK LINE

PIPING
40

63 mm

63

40

40 mm

63

Series 07 QUICK LINE

220
PSI

Calibrated Aluminium

Brass Compression

TOPRING

Series 07 QUICK LINE

FITTINGS

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