Jindal Composite Pipeline

• Locate each process, workstation, or piece of equipment that uses compressed air. They should be positioned on a layout plan, and a complete list should be prepared to simplify record-keeping. This initial step will serve as the foundation for your piping layout.
• Determine the volume of air and required pressure range at each location. Flow and pressure data can typically be obtained from the equipment manufacturer. If such values are not available, use estimated figures until actual values are provided.
• Define system conditioning requirements for each equipment unit. This includes permissible levels of moisture content, particulate matter, and oil. You may need air treatment components like dryers, filters, lubricators, and pressure regulators.

• Calculate the actual usage time of each tool or process per minute. This is called the duty cycle. In most industrial setups, similar tools and processes are grouped together for efficiency.

• Identify the maximum number of simultaneous users across all lines and the entire project. This is known as the use factor, and it helps in accurately sizing the system.
• Determine the allowable leakage in the system. Leakage can result from the number of joints, type of fittings, and the initial quality of assembly. More components typically mean more leakage. A well-maintained system usually exhibits 2–5% allowable leakage.
• Establish any allowance for future expansion. Thought should be given to over sizing some components (i.e., main supply lines) to avoid the cost of replacement
  at a later date.

• Select the air compressor layout and assign a preliminary pressure drop for the system.

• Select the air compressor type, conditioning equipment, equipment location, and air inlet, making sure that scfm (L/min) is used consistently for both the system and compressor capacity rating.
• Note: This allowable leakage rate applies only to compressed air made on site. All other inert gas systems must be designed with the strictest health and safety considerations in mind including preventing leakage of any pipe contents.

TO START, THE FOLLOWING INFORMATION MUST BE AVAILABLE:

• Total connected flow rate cfm (L/min) of all air-using devices, including flow to the air dryer system, if Applicable.

• Maximum pressure (psi) of all air using devices.

• Duty cycle and use factors for these devices giving maximum expected use of air.

• Leakage and future expansion allowance, cfm (L/min).

• Allowable pressure drops for the entire system, including piping and conditioning equipment.

• Altitude, temperature, and contaminant removal corrections.

• Location where adequate space is available for air compressor and all ancillary equipment.

• Produce a final piping layout and size the piping Network.

• To use pressure drop charts, it is necessary to find the equivalent length of run from the compressor to the farthest point in the step. In addition to the actual measured pipe length, the effect of fittings must be considered. This is because fittings create an obstruction to the flow of air. This degree of obstruction has been converted to an equivalent length of pipe in order to make calculations easy.
• Determine the actual pressure drop that will occur only in the piping system. Since the air compressor has not been selected yet, this figure is variable. A smaller pipe size may lead to higher compressor horsepower. It is considered good practice to oversize distribution mains to allow for future growth and the addition of condition equipment that may add a pressure drop not anticipated at the time of original design. It should be noted that this practice may result in a higher initial cost for the piping system.

• Size the piping using the appropriate charts, having first calculated the flow rate at the operating pressure and operating temperature, scfm, and the allowable friction loss in each section of the piping being sized. Since all pipe sizing charts are calculated using loss of pressure per some length of piping (100 ft {30.5m}), it is necessary to arrive at the required value for the chart you are using.