Pressure loss in a compressed air system

Let's take a closer look at pressure losses in a compressed air system, the most common causes, and strategies for reducing them and improving efficiency.

What is pressure loss in compressed air? 

Pressure loss in a compressed air system occurs when  the force of the air decreases as it flows through various points in the system.

During its journey from the compressor to the point of final use, the air inevitably encounters resistance due to pipes, fittings, or impurities in the circuit. This resistance causes a pressure drop that reduces the amount of energy available.

A pressure loss is not just a technical-functional problem: it can lead to reduced production efficiency, increased energy consumption, and accelerated machinery wear.

To compensate for the pressure loss, compressors must operate at a higher pressure, resulting in system overload and higher operating costs. In the long run, this overload will lead to more frequent maintenance, costly repairs, and a reduced component lifespan.

Understanding how and why a pressure loss occurs is therefore essential to maintaining system efficiency and reducing energy waste.

Oil and Particulare Contamination

It's important to remember that the air produced by a compressor is never completely pure. During the compression process, it can contain contaminants that, over time, compromise the efficiency and lifespan of the system.

One of the most common causes of component wear is oil contamination, which particularly damages plastic seals, causing them to crack or fail prematurely.

Moisture, oil droplets, and solid particles also pose a serious danger:

They alter lubricants, reducing their effectiveness;

They clog valves and fittings;

They contaminate internal circuits, causing blockages and performance losses.

All of these factors lead to poor maintenance management and increased operating costs, as well as significantly reducing the reliability of the compressed air system.

Priver Industriale, Compressed Air & Gas Service Center 

How to Measure and Reduce Leaks 

One of the areas where efficiency losses are most frequently observed is the final segment of the system, with a reduction of 30-40% overall.

To reduce pressure drops, it is essential to use quality materials, both in the compressor room and in the distribution network. A well-designed and sized system minimizes future resistance and ensures constant pressure.

The point closest to the air consumption requires the most attention: from there, the most frequent problems can be identified, such as obstructions, worn fittings, or micro-leaks.

For the final sections of the system, it is advisable to choose materials that are corrosion-resistant, lighter, and easier to inspect.

In any distribution network, proper pipe sizing is essential to maintain uniform airflow and reduce energy losses. It's also important to account for expansion and vibration during operation, using quality threaded fittings, filters, and quick-release couplings, which help maintain the overall efficiency of the system.

To promptly address leaks, the most effective strategy is to implement a continuous monitoring system.

This allows for real-time leak detection and preventive maintenance planning, avoiding unexpected shutdowns or drops in performance.

At the same time, it's essential to invest in technical staff training: knowledgeable and well-trained operators can recognize the signs of a leak early on, reducing costs and potential inefficiencies.

Small measures like timely leak detection and proper reporting of interventions can make the difference between well-managed routine maintenance and a costly and unexpected breakdown.

Priver Industriale is the ideal partner to assist you in the design and construction of high-performance compressed air and technical gas treatment systems.

For years, we have provided complete solutions for production plants requiring pure, contaminant-free air, designed to ensure continuity, reliability, and uncompromising energy efficiency.

Contact us today for a free consultation and find out how we can help you optimize your systems with our customized solutions.