Planning a compressed air system that is both compact and future-proof
You will find some general information about how to determine the size of a compressor or the compressed air installation in our article on the basics of planning a compressed air system.
Since installation floor space in certain regions - Europe, for example - is more expensive than in other parts of the world, the compressed air system's footprint must be as compact as possible, but sufficiently large to be future-proof.
This can be quite difficult because the basic dimensions of compressors with comparable levels of performance differ from manufacturer to manufacturer. It is, therefore, worthwhile to compare the specific energy requirement of each compressor (in kilowatt-hours per liter or cubic meter of compressed air produced). For example, our latest generation of GA compressors starts from a footprint as small as that of a refrigerator thanks to the compact, vertical arrangement of components.
Why the compressor room should be as central as possible in the factory
If sufficient space is available, you should always allocate a separate room for the compressors and plan the installation at ground level. Depending on the size and weight of the required compressors, an appropriately reinforced foundation may be required.
Empirical evidence shows that a centralized location of the compressors makes more sense than a scattered installation of the machines across the factory. A dedicated machinery room has many advantages, for example:
- easier monitoring
- better installation design
- higher user and service friendliness
- better control of access
- improved sound insulation
- straightforward ventilation system
A fenced-off area of a workshop or a dedicated single room can equally well-suited locations for a central compressor station. However, the individual circumstances and requirements of the user also play a significant part here.
The following aspects should be considered when choosing the location of a compressed air installation:
- the noise produced by the compressors
- the options for ventilation of the area
- the heat dissipation from the compressors
- the manner in which condensate is disposed of
- the presence of potentially explosive or aggressive substances in the air or in the environment
- the space required for future expansions
- the access requirements for maintenance activities.
What are the environmental conditions that influence the planning of an air compressor system?
Environmental conditions vary by continent and region, as well as the location of the compressor installation on the respective site. Many compressors contain sensitive electronics and sometimes they have to be placed outdoors - for example as part of larger installations such as steelworks or tunnel boring machines. For long-term reliable operation, the compressors must, therefore, be able to withstand the extreme temperatures, dust, and moisture loads that can occur at the installation site. For particularly demanding environments, project engineers should specify sophisticated compressor technology with weatherproof design, whose components have a high IP protection class (with regard to the ingress of dust and splash or jet water) and are designed for high ambient temperatures.
The height above sea level also has an impact on the planning of a compressor installation. The higher the location, the lower the atmospheric pressure and temperature. This influences the pressure ratio and thus the power consumption and volume flow of the compressor. At the same time, the performance of electric and combustion engines deteriorates. Project engineers must take these factors into account.
For example, it must be determined whether the designed pressure of the compressed air system should be specified relative to absolute pressure or to gauge pressure and whether the compressed air temperature is significant. When in doubt, the manufacturer of the compressors should be consulted as well as the suppliers of the machines which use compressed air, whose operation can also be influenced by the ambient conditions.
What role does compressor room ventilation play in system design?
Industrial compressors pull in ambient air through the intake and then compress it to a fraction of its original volume. Depending on their size, they have to draw in anything between several hundred to several thousand cubic meters of air per hour, as is the case in turbo compressors. Ventilation must, therefore, be well planned and must be adjusted to these volume flows. Depending on the location of the installation, ventilation shafts must be provided. Inadequate ventilation, poor installation, the wrong intake location as well as incorrect or inadequate maintenance can lead to malfunctions of the compressor and the compressed air supply.
