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GENERAL TERMS CONTINUED DETERMINING YOUR

AIR REQUIREMENTS
PISTON DISPLACEMENT:
Is the volume swept by the piston, generally expressed in cubic feet per A relatively simple procedure to see if additional compressor capacity
minute (CFM). For multi-stage compressors, the piston displacement (CFM) is required can be performed in any plant or compressed
of the first stage only is commonly stated as that of the entire machine. air-using operation.
Most general compressor air operations supply 100 PSIG at the
ACTUAL CAPACITY: compressor and deliver a minimum of 90 PSIG to the using air tool. For
Is the quantity of gas actually compressed and delivered to the lowest possible power cost, this means compressor has a cut out
discharge system by the compressor at rated speed and under rated pressure or unloads at 100 PSIG and cut-in or loads at 90 PSIG
receiver or system pressure. With these known figures (or whatever
pressure conditions. Actual capacity is expressed in cubic feet per unload and load figures a particular system utilizes), we can determine
minute at the temperature and pressure conditions existing at the inlet the following:
to the first stage.
If the receiver is below the normal cut-in point (90 PSIG) or does not
gradually rise to the cut-out point (100 PSIG), more air is probably
VOLUMETRIC EFFICIENCY: needed. Always check, of course, that there are no significant leaks
Is the ratio of actual capacity to piston displacement, generally stated and that the unloading and control system on the compressor are
as percentage. functioning correctly.
NOTE: If the compressor must operate at more than 100 PSIG to get
FREE AIR: 90 PSIG at the tools, check the distribution system for piping size or
Generally describes air at room or ambient temperatures and pressures, check points. The pipe may be too small or a single choke point too
that is, normal atmospheric conditions. In other words, the term free air small for the systems total demand (flow) or length.
describes the air actually taken into the suction of a compressor which
takes air from the surrounding atmosphere. CHECKING EXISTING
COMPRESSOR CAPACITY
STANDARD CONDITIONS:
Are not universally defined; therefore, since compressor capacities are
Running a timed pump-up test is a relatively accurate way to check
sometimes expressed in standard cubic feet per minute (SCFM), it is your existing air compressors capacity or output. This will confirm that
necessary to identify, before the compressor can be sized, (1) the your shortage of compressed air is not due to a worn unit or a
standard pressure condition; (2) the standard temperature condition; malfunction.
(3) the compressor suction pressure condition, and; (4) the Check the receiver volume in cubic feet. Check the pipe volume
compressor suction temperature condition. The most popular between the compressor and receiver in cubic feet. Operate the
identification for standard pressure and temperature conditions is 14.5 compressor at load. Close the air valve between the receiver and plant
PSIA or 60 F.

air system. Drain the receiver down to 70 PSIG. Close the drain valve
quickly. Record in seconds the required time to pump to 100 PSIG.
BRAKE HORSEPOWER (bhp): Now work the following equation:
Is the measured horsepower input at the compressor shaft. The If this is close to the rated capacity of your air compressor, then you can
horsepower output of the driver must equal or exceed the compressor be relatively sure the demand on your air system is too high and you
bhp plus any drive losses. need additional air.
C = COMPRESSOR CAPACITY IN CFM
LOAD FACTOR:
Is the ratio of the available demand for compressed air during a certain V = RECEIVER & PIPING VOLUME IN CU. FT.
period of time to the maximum rated output capacity of the compressor.
P2 = FINAL CUT OUT PRESSURE PSIA
= 100 PSIG + 14.7 = 114.7 PSIA
NOTES:
P1 = INITIAL PRESSURE PSIA
= 70 PSIG + 14.7 = 84.7 PSIA

V (P2 - P1) 60 SEC.


C = (14.7) (TIME-SEC.)
* Assume the receiver and piping volume were 80 cu. ft.
* Assume the pump-up time is 15 seconds.
Then solve:

(80) (114.7 - 84.7) (60)


C = (14.7) (15)

144,000
C = 220.5

C = 653 cubic ft./min. = actual capacity of existing air compressor

28 1
TERMINOLOGY CONTINUED COMMON LEAK PROBLEM AREAS
UNLOAD (No Load): COUPLINGS, HOSES, TUBES AND FITTINGS
Air compressor continues to run (usually at FULL RPM), but NO air is Tubes and push-to-lock fittings are common problems.
delivered because intake is either closed off or modified, NOT allow-
ing inlet air to be trapped. DISCONNECTS
O-rings required to complete the seal may be missing.
MODULATING UNLOAD: FILTERS, REGULATORS AND LUBRICATORS (FRLs)
Air compressor continues to run and air supply is matched to demand Low first-cost improperly installed FRLs often leak.
by partial unloading. This is usually accomplished by a regulator
controlled floating inlet. OPEN CONDENSATE TRAPS
Improperly operating solenoids and dirty seals are often problem
START-STOP CONTROL: areas.
Air supply is matched to demand by actual starting and stopping of the
unit. PIPE JOINTS
Missed welds are a common problem.
CUT-IN/CUT-OUT PRESSURE: CONTROL AND SHUT-OFF VALVES
The settings on a pressure switch used to either load or unload the air Worn packing through the stem can cause leaks.
compressor on constant speed application. The cut-out pressure is
also referred to as maximum pressure, the point at which there is NO POINT OF USE DEVICES
AIR DELIVERED. The cut-in pressure is also referred as Old or poorly maintained tools can have internal leaks.
minimum pressure - the pressure that the system is allowed to fall to
FLANGES
before additional air volume is called for. The compressor runs at full
Missed welds are a common problem.
load between cut-in and cut-out.
CYLINDER ROD PACKING
VARIABLE DISPLACEMENT CONTROLS: Worn packing materials can cause leaks.
Also called Rotor Length Adjustment in oil cooled Rotary Screw
controls. Particularly efficient in holding constant speed from 60% to THREAD SEALANTS
100% capacity variable speed control. Below this usually goes to blow Incorrect and/or improperly applied thread sealants cause leaks.
down and idle.
HOW DO YOU FIND LEAKS?
VARIABLE SPEED CONTROL:
Most commonly applied in oil cooled Rotary Screws. Very efficient from Since air leaks are almost impossible to see, other methods must be
about 50% to 100% capacity. Below 50% usually defaults to modula- used to locate them. The best way to detect leaks is to use an
tion of Blow Down and idle. ultrasonic acoustic detector, which can recognize the high frequency
hissing sounds associated with air leaks. These portable units consist
RATED PRESSURE: of directional microphones, amplifiers, and audio filters, and usually
The operating pressure at which the air compressors performance (CFM have either visual indicators or earphones to detect leaks. A simpler
and BHP - Horsepower required) is measured. method is to apply soapy water with a paint brush to suspect areas.
Although reliable, this method can be time consuming. Other methods
SPECIFIC POWER: include: smoke sticks, candles, foam, manometers and stethoscopes.
Used to compare air compressor efficiency unless otherwise stated. Ultrasonic detectors can find mid to large sized leaks. The advantages
Usually in form of BHP/100 ACFM or CFM/HP. of ultrasonic leak detection include: versatility, speed, ease of use, the
ability to perform tests while equipment is running and the ability to find
a wide variety of leaks.
GENERAL TERMS
HOLE DIA. AIR LEAKAGE AT 100 PSI COST PER YEAR
COMPRESSORS: IN. CFM $.06 KWH
Are machines which compress air or gases from atmospheric pressure 1
/32 1.62 $158
to a higher discharge pressure. 1
/16 6.5 $633
BOOSTER COMPRESSORS:
1
/8 26 $2,532
Are machines which compress air or gases from a pressure higher
1
/4 104 $10,130
than atmospheric to a still higher discharge pressure.
WHAT DO SYSTEM LEAKS COST?
VACUUM PUMPS:
Are machines designed for compressing air or gases from an initial Determine size of leak either through calculation or actual size of
pressure which is below atmospheric to a pressure which is at or close orifice.
to atmospheric pressure.
1
/4 inch orifice can pass 104 CFM @ 100 PSIG.
RECIPROCATING COMPRESSORS: A typical 25 horsepower oil flooded Rotary Screw Air Compressor.
Are positive displacement machines used to increase the pressure of a
definite volume of gas by volume reduction. The compressing element At 6 cents a kW and 8,000 hours of operation, this can equal
is a simple piston which reciprocates back and forth in a cylinder. $9,946.00.

26 3
USEFUL FORMULAS * ORIFICES ARE REQUIRED
ANTICIPATING YOUR
1. COMP. RPM =
motor pulley p.d. x motor RPM FUTURE AIR REQUIREMENTS
comp. pulley p.d.
The following charts will be helpful to anyone planning a future air system or
requirement. Remember, these are averages for various types of tools and you
comp. pulley p.d. x comp. RPM should always consult the manufacturer for exact air requirements and analyze
2. MOTOR PULLEY p.d. =
motor RPM your own operation to evaluate normal.

motor pulley p.d. x motor RPM


INDUSTRIAL TOOLS & EQUIPMENT
3. COMP. PULLEY p.d. = AIR AVG. FREE NORMAL
comp. RPM
PRESSURE EQUIPMENT AIR CONS. LOAD
RANGE CFM FACTOR**
comp. pulley p.d. x comp. RPM
4. MOTOR RPM =
motor pulley p.d. 90-100 *Dusting Gun (Blow Gun) 3.0 10%
90-100 *Drill, 1/6 to 1/8 4.0 25%
5. FREE AIR = piston displacement x volumetric eff. (%) 90-100 *Drill, /8 to /8
3 5
7.0 25%
90-100 *Screwdriver, #2 to #6 Screw 1.0 15%
90-100 *Screwdriver, #6 to 5/16 Screw 3.0 15%
6. REQUIRED PISTON free air 90-100 *Tapper, to /4
3
3.0 15%
=
DISPLACEMENT vol. eff. 90-100 *Nutsetters, to 3/8 3.0 15%
90-100 *Nutsetters, to 3/4 5.0 15%
7. PISTON DISPLACE- Cyl. bore x Cyl. bore x stroke in In. x RPM 90-100 *Impact Wrench, 3/8 sq.dr. 2.0 20%
= 90-100 *Impact Wrench, 1/2 sq.dr. 3.5 20%
MENT IN CU.FT. MIN* 2200
90-100 *Impact Wrench, 5/8 sq.dr. 5.0 20%
90-100 *Impact Wrench, 3/4 sq.dr 7.5 20%
8. CU. FT. COM- cu. ft. free air x atmospheric pressure 90-100 *Impact Wrench, 1 sq.dr. 10.0 20%
=
PRESSED AIR (PSIG + 14.7)
90-100 *Die Grinder, Small 4.0 30%
90-100 *Die Grinder, Medium 5.0 30%
9. CU. FT. cu. ft. compressed air x (PSIG + 14.7) 90-100 *Horizontal Grinder, 2 10.0 30%
= 90-100 *Horizontal Grinder, 4 14.0 30%
FREE AIR atmospheric pressure
90-100 *Horizontal Grinder, 6 16.0 30%
10. CU. FT. FREE AIR 90-100 *Horizontal Grinder, 8 20.0 30%
90-100 *Vertical Grinders & Sanders,
REQD TO RAISE vol. of rec. in cu. ft. x PSIG 5 Pad 10.0 30%
=
REC. FROM 0 GAUGE atmospheric pressure 90-100 *Vertical Grinders & Sanders,
TO FINAL PRESSURE 7 Pad 14.0 30%
90-100 *Vertical Grinders & Sanders,
11. CU. FT. FREE AIR 9 Pad 20.0 30%
REQD TO RAISE REC. 90-100 *Filing & Sowing Mach., small 3.0 15%
FROM SOME PRESS. vol. of rec. (final PSIG initial PSIG) 90-100 *Filing & Sowing Mach., large 5.0 15%
= x 90-100 *Burring Tool, small 4.0 30%
GREATER THAN 0 in cu. ft. (atmospheric pressure)
GAUGE TO A FINAL 90-100 *Burring Tool, large 5.0 30%
HIGHER PRESSURE 90-100 *Bench Rammer 5.0 40%
90-100 *Floor Rammer 7.0 40%
90-100 *Backfill Tamp 15.0 40%
12. PISTON SPEED IN 2 x stroke (in inches) x RPM
FT. PER MIN.
=
12 90-100 *Compression Riveter 1.0 10%
90-100 *Automatic Drills 6.0 25%
cu. ft. 90-100 *Air Motor, 1 HP 10.0 25%
13. GALLONS = .134 90-100 *Air Motor, 2 HP 15.0 25%
90-100 *Air Motor, 3 HP 20.0 25%
90-100 *Air Motor Hoist, 1000# 5.0 10%
14. CU. FT. = gallons x .134 90-100 *Air Motor Hoist, 2000# 5.0 10%
90-100 *Cylinder Type Hoist 1.5 10%
15. TOTAL FORCE IN HAMMERS
LBS. OF AIR = Area of Cylinder x PSIG of air
Dia. in sq. inches press. used 90-100 *Scaling Hammer 4.0 35%
CYLINDER 90-100 *Chipping Hammer 7.0 35%
90-100 *Riveting Hammer 15.0 35%
16. CFM OF FREE SPRAY GUNS
AIR REQUIRED
TO OPERATE
Vol. of Cyl. Cycles
= in cu. ft. x per min. x
(Gauge Press. + 14.7) 90-100 *Point Spray Gun (Production) 8.5 50%
(14.7) 90-100 *Point Spray Gun (Touch-up) 3.5 25%
AIR CYLINDER
Always check with tool manufacturers for actual consumption of tools being used.
(SINGLE ACTING) The above are based on averages and should not be considered accurate for
any particular make of tools. The free air consumptions listed herein are based
For Double Acting Cylinders Multiply by 2. on the use of the normal load factors shown in the adjacent column. Load factor
is a percentage that expresses the normal actual usage of air as compared to
the maximum usage that will occur if the tools throttle valve is turned fully open
* Piston displacement for multi-stage compressors - only the low and the tool is operated continuously at maximum capacity (Load factors should
pressure cylinder is considered. be adjusted based on your own individual operating conditions).

24 5
FRICTION OF AIR IN HOSE

SYSTEM

SYSTEM
1/0 3/0 4/0 300 500 2-4/0 2-300 2-500 MOTOR

2/0 3/0 250 350 2-3/0 2-4/0 2-350 MOTOR


(208V)

(240V)
100 110 125 175 200 250 300 400 600 600 800 200V

110 150 200 225 250 350 450 600 800 230V
S

S
GAUGE CU. FT. OF AIR PER MINUTE AT 80 PSIG
HOSE

100 100 150 200 200 300 350 400 500 600
104 130 154 192 248 312 360 480
414 552
200
PRESSURE 20 30 40 50 60 70 80 90 100 110 120 130

--
SIZE
OF LINE LOSS OF PRESSURE (PSI) IN 50 FT. LENGTHS OF HOSE

100 125 175 200 250 300 400 500 600


150

50 1.8 5.0 10.1 18.1


60 1.3 4.0 8.4 14.8 23.4
125

221 285 359

70 1.0 3.4 7.0 12.4 20.0 28.4


/2 80 0.9 2.8 6.0 10.8 17.4 25.2 34.6
100

90 0.8 2.4 5.4 9.5 14.8 22.0 30.5 41.0


100 0.7 2.3 4.8 8.4 13.3 19.3 27.2 36.6
75

110 0.6 2.0 4.3 7.6 12.0 17.6 24.6 33.3 44.5
177
60

50 0.4 0.8 1.5 2.4 3.5 4.4 6.5 8.5 11.4 14.2
60 0.3 0.6 1.2 1.9 2.8 3.8 5.2 6.8 8.6 11.2
120 150
50

70 0.2 0.5 0.9 1.5 2.3 3.2 4.2 5.5 7.0 8.8 11.0
3
/4 80 0.2 0.5 0.8 1.3 1.9 2.8 3.6 4.7 5.8 7.2 8.8 10.6
40

90 0.2 0.4 0.7 1.1 1.6 2.2 3.1 4.0 5.0 6.2 7.5 9.0
100 0.2 0.4 0.6 1.0 1.4 2.0 2.7 3.5 4.4 5.4 6.6 7.9
30

80
92

110 0.1 0.3 0.5 0.9 1.3 1.8 2.4 3.1 0.9 4.9 5.9 7.1
THREE PHASE MOTOR DATA - For 60 Hz 1800 RPM Standard Motor

50 0.1 0.2 0.3 0.5 0.8 1.1 1.5 2.0 2.6 3.5 4.8 7.0
11.0 17.5 25.3 32.2 48.3 62.1 78.2

100
25

68
3

60 1.1 0.2 0.3 0.4 0.6 0.8 1.2 1.5 2.0 2.6 3.3 4.2
70 -- 0.1 0.2 0.4 0.5 0.7 1.0 1.3 1.6 2.0 2.5 3.1
20

90
54

80
90
4

1 80 -- 0.1 0.2 0.3 0.5 0.7 0.8 1.1 1.4 1.7 2.0 2.4
90 -- 1.1 0.2 0.3 0.4 0.6 0.7 0.9 1.2 1.4 1.7 2.0
15

90

80

60
42
60
6

100 -- 1.1 0.2 0.2 0.4 0.5 0.6 0.8 1.0 1.2 1.5 1.8
10

60

60

40
28
50

10

110 -- 0.1 0.2 0.2 0.3 0.4 0.6 0.7 0.9 1.1 1.3 1.5
8

These devices are to be considered as continuously operating devices


71/2

50

45
10

30
40

when operating normally. All other devices listed are to be considered


10
9.6 15.2 22

as intermittently operated when operating normally. When the devices


consist of a large number of the continuously operated type, and if only a
35

30
12

25
25

14
5

few are to be used at one time, the compressor should have a capacity
at least equal to the total consumption of all those tools used
17.5

simultaneously, in addition to the consumption of all the intermittently


20

20
14

14

15
3

operated tools, if any.


**Normal load factor is the percentage of time the throttle valve is open
6.8
7.8

15

15
14

14

10
10
2

during normal use.


11/2

COMPRESSED AIR RECEIVER


6.0
6.9

15

15
14

14

10
10

CAPACITY
(NEC) - AMPS MINIMUM 2.2 3.2 4.2
(NEC) - AMPS MINIMUM 2.5 3.7 4.8

Thermal-Magnetic Breaker 15 15 15

Thermal-Magnetic Breaker 15 15 15
14

14
1

8
4 6.25 8

CAPACITY CAPACITY IN CU.FT. OF FREE AIR


TANK AT GAUGE PRESSURE SHOWN
IN
5.6
/4

14

14

DIMENSION
3

GALLONS 0 50 100 125 150 175 200


/2

14

14

14 x 33 20 2.7 12.0 20.8 25.3 30.0 34.4 38.9


4
1

16 x 38 30 4.0 18.0 31.2 38.0 45.0 51.6 58.4


With Dual Element Time

With Dual Element Time


FULL LOAD CURRENT

FULL LOAD CURRENT


COPPER WIRE SIZE -

COPPER WIRE SIZE -


THWN, XHHW - SIZE

THWN, XHHW - SIZE


(75 C) THW, THHN-

(75 C) THW, THHN-

20 x 48 60 8.0 36.0 62.4 76.0 90.0 103.2 116.8


Delay Fuse - AMPS

Delay Fuse - AMPS


MOTOR X

Trip Rating - AMPS

Trip Rating - AMPS


CIRCUIT BREAKER

CIRCUIT BREAKER
FUSIBLE SWITCH

FUSIBLE SWITCH

20 x 63 80 10.7 48.0 83.2 101.3 120.0 137.6 155.7

24 x 67 120 16.0 72.0 124.8 152.0 180.0 206.4 233.6


30 x 84 240 32.0 144.0 249.6 304.0 360.0 412.8 467.2

22 7
DISCHARGE OF AIR

5.86
2.88

4.75
.94

8.45
.53
.24

3.76
1.47
.14

2.11
THROUGH AN ORIFICE

350

11.5
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE

In cubic feet of free air per minute at standard atmospheric pressure of


14.7 lb. per sq. in. absolute and 70 F

4.35
3.34

5.50
6.80
.28

2.45

9.78
1.70
1.09
.61
.16

13.4
300
GAUGE
PRESSURE
DIAMETER OF ORIFICE
BEFORE 1
ORIFICE /64 /32 /16 /8 1/4 3/8 1/2 5/8 3/4 7/8 1
1 1 1

2.02
.73
.33

3.96

6.55
1.30

8.07
2.91
.19

5.16
IN LBS.

15.9
11.6
250

PER
SQ.IN. Discharge in cubic feet of free air per minute
1 .028 .112 .450 1.80 7.18 16.2 28.7 45.0 64.7 88.1 115
2 .040 .158 .633 2.53 10.1 22.8 40.5 63.3 91.2 124 162
2.50
.23

.90

3.58

6.36
4.89

9.95
8.06
1.60
.41
.11

19.5
14.3
200

3 .048 .194 .775 3.10 12.4 27.8 49.5 77.5 111 152 198
4 .056 .223 .892 3.56 14.3 32.1 57.0 89.2 128 175 228
5 .062 .248 .993 3.97 15.9 35.7 63.5 99.3 143 195 254
2.08
3.26
4.68
.30
.53

6.37
8.31
.14

1.17

13.0
150

10.5
6 .068 .272 1.09 4.34 17.4 39.1 69.5 109 156 213 278
7 .073 .293 1.17 4.68 18.7 42.2 75.0 117 168 230 300
9 .083 .331 1.32 5.30 21.2 47.7 84.7 132 191 260 339
12 .095 .379 1.52 6.07 24.3 54.6 97.0 152 218 297 388
.36

3.83

9.80
.62
1.38
2.47

5.51
7.50
.17
125

12.4
15.3
15 .105 .420 1.68 6.72 26.9 60.5 108 168 242 329 430
LINE PRESSURE - PSIG

20 .123 .491 1.96 7.86 31.4 70.7 126 196 283 385 503
25 .140 .562 2.25 8.98 35.9 80.9 144 225 323 440 575
.44

2.99
4.67
.20

1.68
.76

6.71
9.15
11.9
100

30 .158 .633 2.53 10.1 40.5 91.1 162 253 365 496 648
35 .176 .703 2.81 11.3 45.0 101 180 281 405 551 720
40 .194 .774 3.10 12.4 49.6 112 198 310 446 607 793
.56

8.58
.26

5.96
3.81
.97
2.15
.10

45 .211 .845 3.38 13.5 54.1 122 216 338 487 662 865
75

50 .229 .916 3.66 14.7 58.6 132 235 366 528 718 938
60 .264 1.06 4.23 16.9 67.6 152 271 423 609 828 1082
70 .300 1.20 4.79 19.2 76.7 173 307 479 690 939 1227
2.98
5.29
.78
.36

1.34
.13
50

80 .335 1.34 5.36 21.4 85.7 193 343 536 771 1050 1371
90 .370 1.48 5.92 23.7 94.8 213 379 592 853 1161 1516
100 .406 1.62 6.49 26.0 104 234 415 649 934 1272 1661
.92

3.52
.43

1.59
.16

110 .441 1.76 7.05 28.2 113 254 452 705 1016 1383 1806
40

120 .476 1.91 7.62 30.5 122 274 488 762 1097 1494 1951
125 .494 1.98 7.90 31.6 126 284 506 790 1138 1549 2023
.52

4.30
.20

1.94
1.12

150 .582 2.37 9.45 37.5 150 338 600 910 1315 1789 2338
30

200 .761 3.10 12.35 49.0 196 441 784 1225 1764 2401 3136
250 .935 3.80 15.18 60.3 241 542 964 1508 2169 2952 3856
300 .995 4.88 18.08 71.8 287 646 1148 1795 2583 3515 4592
.67

2.50
.26

1.44
20

400 1.220 5.98 23.81 94.5 378 851 1512 2360 3402 4630 6048
500 1.519 7.41 29.55 117.3 469 1055 1876 2930 4221 5745 7504
750 2.240 10.98 43.85 174.0 696 1566 2784 4350 6264 8525 11136
.78
.30

1.69

1000 2.985 14.60 58.21 231.0 924 2079 3696 5790 8316 11318 14784
15

Table is based on 100% coefficient of flow. For well rounded entrance, multiply values
by 0.97. For sharp edged orifices a multiplier of 0.61 may be used for approximate
results. Values for pressures from 1 to 15 lbs. gauge calculated by standard adiabatic
.36
.94

formula. Values for pressures above 15 lbs. gauge calculated by approximate formula
10

proposed by S.A.
Moss. Where:
0.5303 ACp1 W = discharge in lbs. per sec.
W =
FREE AIR

T1 A = area of orifice in sq. in.


CFM

300
500
750
1000
1500
2000
2500
3000
3500
4000
4500
5000
6000
7000

C = Coefficient of flow
P1 = Upstream total pressure in lbs. per sq. in absolute
T1 = Upstream temperature in F abs.
CONTINUED

Values used in calculating above table were:


SCHEDULE
PIPE SIZE
NOMINAL

C = 1.0, p1 = gauge pressure + 14.7 lbs./sq. in.


40
3

T1 = 530 F abs.

Weights (W) were converted to volumes using density factor of 0.07494 lbs./cu. ft. This is
correct for dry air 14.7 lbs. per sq. in. absolute pressure and 70 F. Formula cannot be used

where p1 is less than two times the downstream pressure.

20 9
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
CONTINUED
NOMINAL CFM LINE PRESSURE - PSIG
PIPE SIZE FREE AIR 10 15 20 30 40 50 75 100 125 150 200 250 300 350
75 .19 .16 .13 .10
100 .28 .24 .20 .16 .13 .11
150 .69 .57 .49 .38 .31 .26 .19 .15 .12 .10
200 1.20 1.00 .85 .66 .54 .46 .33 .26 .21 .18 .14 .11
250 1.53 1.31 1.02 .83 .70 .51 .40 .33 .28 .21 .17 .15 .13
300 1.89 1.47 1.20 1.01 .73 .57 .47 .40 .31 .26 .21 .18
400 2.50 2.04 1.73 1.25 .98 .80 .68 .52 .42 .36 .31

18
2 500 3.87 3.16 2.67 1.93 1.51 1.24 1.05 .81 .65 .55 .48
SCHEDULE 600 4.50 3.81 2.75 2.15 1.77 1.50 1.05 .93 .79 .68
40 800 4.87 3.82 3.13 2.66 2.04 1.65 1.39 1.20
1000 7.55 5.90 4.85 4.12 3.16 2.56 2.16 1.86
1250 9.12 7.49 6.35 4.87 3.96 3.32 2.87
1500 10.8 9.17 7.02 5.70 4.80 4.14
1750 12.5 9.54 7.74 6.50 5.62
2000 16.3 12.5 10.1 8.50 7.35
2250 15.8 12.8 10.8 9.30
2500 19.4 15.8 13.3 11.4

FRICTION OF AIR IN HOSE - Pulsating Flow*


SIZE OF HOSE, GAUGE CU.FT. FREE AIR PER MIN. PASSING THROUGH 50 FT. LENGTHS OF HOSE
COUPLED PRESSURE 20 30 40 50 60 70 80 90 100 110 120 130 140 150
EACH END, IN. AT LINE, LB. LOSS OF PRESSURE (PSI) IN 50 FT. LENGTHS OF HOSE
50 1.8 5.0 10.1 18.1
60 1.3 4.0 8.4 14.8 23.4
70 1.0 3.4 7.0 12.4 20.0 28.4
1
/ 2 80 0.9 2.8 6.0 10.8 17.4 25.2 34.6
90 0.8 2.4 5.4 9.5 14.8 22.0 30.5 41.0
100 0.7 2.3 4.8 8.4 13.3 19.3 27.2 36.6
110 0.6 2.0 4.3 7.6 12.0 17.6 24.6 33.3 44.5

11
50 0.4 0.8 1.5 2.4 3.5 4.4 6.5 8.5 11.4 14.2
60 0.3 0.6 1.2 1.9 2.8 3.8 5.2 6.8 8.6 11.2
70 0.2 0.5 0.9 1.5 2.3 3.2 4.2 5.5 7.0 8.8 11.0
3 80 0.2 0.5 0.8 1.3 1.9 2.8 3.6 4.7 5.8 7.2 8.8 10.6
/ 4
90 0.2 0.4 0.7 1.1 1.6 2.3 3.1 4.0 5.0 6.2 7.5 9.0
100 0.2 0.4 0.6 1.0 1.4 2.0 2.7 3.5 4.4 5.4 6.6 7.9 9.4 11.1
110 0.1 0.3 0.5 0.9 1.3 1.8 2.4 3.1 3.9 4.9 5.9 7.1 8.4 9.9
50 0.1 0.2 0.3 0.5 0.8 1.1 1.5 2.0 2.6 3.5 4.8 7.0
60 1.1 0.2 0.3 0.4 0.6 0.8 1.2 1.5 2.0 2.6 3.3 4.2 5.5 7.2
70 -- 0.1 0.2 0.4 0.5 0.7 1.0 1.3 1.6 2.0 2.5 3.1 3.8 4.7
1 80 -- 0.1 0.2 0.3 0.5 0.7 0.8 1.1 1.4 1.7 2.0 2.4 2.7 3.5
90 -- 1.1 0.2 0.3 0.4 0.6 0.7 0.9 1.2 1.4 1.7 2.0 2.4 2.8
100 -- 1.1 0.2 0.2 0.4 0.5 0.6 0.8 1.0 1.2 1.5 1.8 2.1 2.4
110 -- 0.1 0.2 0.2 0.3 0.4 0.6 0.7 0.9 1.1 1.3 1.5 1.8 2.1
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
CONTINUED
NOMINAL CFM LINE PRESSURE - PSIG
PIPE SIZE FREE AIR 10 15 20 30 40 50 75 100 125 150 200 250 300 350
20 .45 .38 .32 .25 .20 .17 .13 .10
35 1.29 1.07 .92 .71 .58 .49 .35 .28 .23 .19 .15 .12 .10
50 1.81 1.40 1.15 .97 .70 .55 .45 .38 .29 .24 .20 .17
75 3.10 2.53 2.14 1.54 1.21 .99 .84 .65 .52 .44 .38
1 100 4.39 3.70 2.68 2.09 1.72 1.46 1.12 .91 .76 .66
SCHEDULE 125 5.70 4.10 3.22 2.64 2.24 1.72 1.39 1.17 1.01
40 150 5.88 4.60 3.78 3.20 2.46 1.99 1.68 1.45

16
200 8.05 6.61 5.61 4.30 3.49 2.94 2.53
250 10.3 8.87 6.72 5.45 4.59 3.96
300 12.6 9.66 7.85 6.60 5.70
400 17.2 14.0 11.7 10.1
500 21.8 18.3 15.8

Table 1. Refrigerated Air Dryer Performance (11 data per 100 CFM @ 100 PSIG)

50 F Dew-Point Unit
Inlet temperature 125 120 115 110 105 100 95 90
Inlet water vapor - lbs./hr. 4.7168 4.1008 3.5552 3.0756 2.6532 2.2836 1.9580 1.6764
Lbs. water removed/hr. 4.2900 3.6740 3.1284 2.6588 2.2264 1.8565 1.5312 1.2496
Water removed, percent 90.95 89.59 87.99 86.12 83.91 81.31 78.20 74.54
Percent of design point 280.2 239.9 204.3 172.9 145.4 121.1 100.0 81.6
Sensible load - btu./hr. 3181 2969 2757 2545 2333 2121 1908 1697
Latent load - btu./hr. 4595 3935 3351 2837 2425 1989 1640 1338
Total load - btu./hr. 7676 6894 6108 5382 4758 4110 3548 3035
Percent of design 216.3 194.3 172.2 181.7 134.1 115.8 100 85.5
Operation kw./hr. .67 .60 .53 .47 .41 .36 .31 .27

13

35 F Dew-Point Unit
Inlet temperature 125 120 115 110 105 100 95 90
Inlet water vapor - lbs./hr. 4.7168 4.1008 3.5552 3.0756 2.6532 2.2836 1.9580 1.6764
Lbs. water removed/hr. 4.4792 3.8632 3.3176 2.8380 2.4156 2.0460 1.7204 1.4388
Water removed, percent 94.96 94.20 93.31 92.27 91.10 89.60 87.00 84.80
Percent of design point 260.4 224.15 192.8 164.9 140.4 118.9 100.0 83.6
Sensible load - btu./hr. 3818 3605 3393 3181 2969 2757 2544 2332
Latent load - btu./hr. 4797 4134 3545 3042 2581 2191 1842 1540
Total load - btu./hr. 8615 7739 6938 6223 5540 4948 4386 3872
Percent of design 196.4 176.4 159.2 141.9 126.3 112.8 100.0 88.3
Operation kw./hr. 1.10 .99 .89 .78 .71 .63 .56 .49
DETERMINING ADDITIONAL GENERAL TERMS CONTINUED
COMPRESSED AIR REQUIRED TO
SINGLE-ACTING COMPRESSORS:
BRING YOUR AIR SYSTEM Are machines which compress on only one side of the piston.
BACK TO 100 PSIG Compression takes place on only one stroke per revolution of the
compressing element.

Once the actual existing compressed air capacity is known, it is DOUBLE-ACTING COMPRESSORS:
relatively easy to mathematically determine the air required to bring the Are machines which compress on both sides of the piston. The
air system up to 100 PSIG: running gear consists of a crank and crosshead mechanism with the
piston rod attached to the crosshead, and extending into the
CFM (REQUIRED) = CFM P2 compressor cylinder through a packing box. Compression takes place
P1 on both strokes in each revolution.

653 (114.7) = 884 CFM AIR RECEIVERS:


CFM (REQUIRED) =
84.7 Are large tanks placed in compressed air systems. A receiver acts
primarily as a pulsation damper and warehouse for air. It also serves to
Therefore, the total air capacity required to hold 100 PSIG is 884 CFM collect condensate. Consequently, it is advisable to equip receivers
and the additional then is 884 - 653 or 231 cubic feet per minute. with automatic moisture traps.
Additional compressed air is required to meet the current demand.
SINGLE STAGE COMPRESSORS:
Depending on the type of system and type of air supply, a leakage or Are machines which use only one step or stage to compress from the
unload factor should be added to any requirement. This is generally initial pressure to the final discharge pressure.
from 20% to 30% depending on the condition.
MULTI-STAGE COMPRESSORS:
Are machines which use more than one step or stage to compress from
Using a 20% extra capacity factor, the total air requirement would then the initial pressure to the final discharge pressure. For example, a two
be 884 x 1.20 = 1060 CFM and an additional (1060 - 653) 408 CFM stage compressor compresses in two steps; a three stage compressor
would be recommended. compresses in three steps, etc.

ANALYZING THE COST OF INTERCOOLERS:


Are heat exchangers used to remove the heat of compression between
SYSTEM LEAKS stages of compression on multi-stage compressors.

A shortage in capacity is often due to or certainly partially due to system AFTERCOOLERS:


leakage. Air system leaks are a continuing source of lost power and Are heat exchangers designed to remove the heat of compression after
should always be minimized. A number of small leaks to that of a 1/4 the final stage of compression in addition to removing moisture from
orifice would at 100 PSIG pass CFM of compressed air. This is a the compressed air.
25HP air compressor to you. A .04 per KWH operating 8,000 hours
per year, (3 shifts) this would cost you $6,600 in power cost to do no MOISTURE SEPARATORS:
work. Are used generally in conjunction with aftercoolers and intercoolers to
collect and remove the moisture which has condensed in compressed
air lines.
Defective tools, shut-off valves, packings, fit-ups, drain cocks, etc.,
should be continually checked. Most plants can always afford the
AUTOMATIC MOISTURE TRAPS:
maintenance labor and parts to correct leaks. Total system leakage
Are devices designed to automatically eject from the system the
can be identified by measuring time in seconds for the system (receiver) moisture collected in the separator.
pressure to drop from 100 to 90 PSIG with no air supply or usage:
ABSOLUTE PRESSURE:
For example, assume the total receiver and piping of the system is 120 Is the existing gauge pressure (as read on a gauge) plus atmospheric
cubic feet. If the plant has a 90 second bleed down rate is 90 PSIG pressure. Atmospheric pressure at sea level is 14.7 PSIA; therefore,
when no production air is being used, this is leakage. for 100 pounds gauge, the absolute pressure (PSIA) is 100 plus 14.7,
or 114.7 PSIA.
The calculated leakage capacity is:
RATIO OF COMPRESSION:
(120) (114.7 - 104.7) (60) = 54 CFM Is the absolute discharge pressure divided by the absolute suction
CFM (LEAKAGE) =
(90) 14.7 pressure. For a compressor taking in atmospheric air at sea level and
compressing it to 100 pounds gauge, the ratio of compression is
TOTAL COMPRESSED AIR LEAKAGE = 54 CFM X 1.15 = 62 CFM 114.7/114.7 = 7.8.

* Add 15% to adjust for the higher leakage rate at the 120 PSIG to 90 (Note that in compressors, ratio of compression is a ratio of pressures.
PSIG (30 PSIG x .5) It should not be confused with the similar term used by internal
combustion engine manufacturers. In engines, ratio of compression is
* Any leakage rate beyond 5% of the total system should be corrected. a ratio of volumes)

2 27
WHAT IS ELECTRIC ENERGY COST? TERMINOLOGY
HP x .746 x HRS. x RATE CFM DISPLACEMENT:
ELECTRIC ENERGY COST (DOLLARS) =
MOTOR EFFICIENCY CUBIC FEET PER MINUTE measures the volume displaced by the
air compressor at full RPM - but not Delivered Air or Usable Air.
This is the formula for electric energy cost in dollars, and you can see it
is a function of: CFM DELIVERED CUBIC FEET PER MINUTE:
Volume of air delivered to the system by the air compressor at rated
The number of hours of operation pressure.
The power used to drive the Compressor (HP)
The power rate (cents per kW) ICFM:
The motor efficiency INLET CFM is rated volume of Inlet air (at Inlet conditions i.e.:
temperature and pressure 14.7 PSIG at sea level) taken in to the
This formula is acceptable as accurate for estimating and comparison compressor.
purposes. (Your actual power bill can be further affected positively or
negatively by such things as Power Factor - Demand Charges, etc.). ACFM:
Is the actual cubic feet per minute of inlet compressed air delivered to
the system at a specified point at the final discharge pressure. i.e.: the
THE MAGNITUDE OF compressor delivers 625 ACFM of compressed air at 100 PSIG at the
ENERGY COST (ELECTRIC)! discharge end of the aftercooler.

To see the magnitude of your potential expenditure in power cost, FOR EXAMPLE
calculate the power cost of a 100 HP Air Compressor:

6,000 hours a year Inlet = 700 ICFM Compressed to 625 ACFM


Rate of $.07/kW at 14.7 PSIA, 0 PSIG at 114.7 PSIA, 100 PSIG
Motor efficiency .90

(100) (.746) (6,000) (.07)


ELECTRIC ENERGY COST = .90

ELECTRIC ENERGY COST = $34,800 PER YEAR

A 100 HP Air Compressor would have a $34,800 per year power cost.

The initial purchase price of a 100 HP Air Compressor, lubricated, for


plant air will probably range from $35,000 to $50,000 depending on the SCFM:
type. Standard Cubic Feet Per Minute is ACFM or ICFM CONVERTED to
standard intake conditions - (60 F, 0% RH & 14.7 PSIG usually) for

In short, the ELECTRIC ENERGY COST OF OPERATION in a Heavy rating using equipment. To size for other than standard conditions, i.e.:
Duty Cycle-Full Load 6,000 Hours (2 Shifts Plus)) CAN EQUAL OR altitude or hot weather corrections must be made.
EXCEED THE INITIAL COST OF THE UNIT EVERY YEAR. Perhaps
PSI:
we should pay attention to this often overlooked continuing cost. A
Pounds Per Square Inch - A rating of air pressure in the system.
POSITIVE VARIANCE OF 15% - 25% in energy cost can be a
significant savings in any operation, and this is obtainable. PSIA ABSOLUTE:
Pressure. i.e.: Sea level - 14.7 PSIA or 0 PSIG (gauge pressure).
CONVERSION FACTORS
PSIG:
TO CONVERT FROM TO MULTIPLY BY Gauge pressure shows amount of air pressure above ambient; i.e.:
Sea level = 0 PSIG = 14.7 PSIA.
Kilowatt Hours (kW h) Horsepower Hours (hp h) 1.341 0
CONSTANT SPEED CONTROL:
Unit runs continuously but matches air supply to demand by loading
Watts (W) Horsepower (hp) 0.001341 0 or unloading the compressor.

TO CONVERT FROM TO DIVIDED BY FULL LOAD:


Air compressor is running at FULL RPM with Fully Open Inlet and
Bars Pounds Force per Sq. In. (lbf/in2) (PSI) 14.504 Discharge delivering maximum volume (ACFM) at Rated Pressure
(PSM).

4 25
AUTOMOTIVE SERVICE

SYSTEM

SYSTEM
2/0 3/0 4/0 350 MOTOR

2/0 3/0 250 MOTOR


(480V)

(600V)
110 125 200 225 250 350 460V

110 150 200 200 250 575V


S

S
EQUIPMENT

175 200 250 350

175 200 300


124 156 180 240

125 144 192


200
AIR AVG. FREE
PRESSURE EQUIPMENT AIR CONS.

150
RANGE CFM
70- 100 *Air Filter Cleaner 3.0

125
70- 100 *Body Polisher 2.0
70- 100 *Body Sander (Orbital) 5.0

100 150
100

99

1
70- 100 *Brake Tester 3.5
70- 100 *Carbon Remover 3.0

100 100 150


75

96

77
70- 100 *Carwasher 8.5

3
90- 100 Dusting Gun (Blow Gun) 2.5

100
120-150 *Grease Gun 3.0

60

77

62

90
3

4
THREE PHASE MOTOR DATA - For 60 Hz 1800 RPM Standard Motor CONTINUED
70- 100 *Panel Cutter 4.0

100
70- 90 Drill, 1/16 to 3/8 4.0

50

90
65

52

80
4

6
125-150 *Impact Wrench, 3/8 sq.dr. 2.0

40

90

80
52

80

60
41
6

6
125-150 *Impact Wrench, 1/2 sq.dr. 3.5
125-150 *Impact Wrench, 5/8 sq.dr. 5.0

30

80
40

60
32
60

50
125-150 *Impact Wrench, 3/4 sq.dr. 7.5

8
125-150 *Impact Wrench, 1 sq.dr. 10.0

25

10
34

70

60
27
50

40
8
70- 90 *Die Grinder 5.0
90- 100 *Vertical Disc Sanders 10.0

20

60

22

45
10

10
27

40

30
90- 100 *Filing & Sawing Machine, small 3.0
90- 100 *Filing & Sawing Machine, large 5.0

12
15

10

40

35
21

30

25
17
90- 100 *Burring Tool 5.0
145- 175 Hydraulic Lift 6.0
10

25
14

14

20
14

20

20
11
125-150 Hydraulic Floor Jack 6.0
120-150 Pneumatic Garage Door 3.0
71/2

9.0
14

14

15
11

15
20

20
90- 100 Radiator Tester 1.0
90- 100 Spark Plug Cleaner 5.0

6.1
7.6

15

15
14

14
15

10
5

90- 100 Spark Plug Tester 0.5

6.25
4.8

3.9
14

14
15

15
HAMMERS
3

8
5.6 6.25
90- 100 *Air Hammer 4.0
3.4

2.7
15

15
14

14
2

5
90- 100 *Tire Hammer 12.0
125-150 *Bead Breaker 12.0
11/2

3.0

2.4
14

14
15

15

4
SPRAY GUNS
1.7
2.1

3.2
15

15
14

14
1

90- 100 *Engine Cleaner 5.0


1.6

1.3
3.2

2.5
/4

14

14
15

15
90- 100 *Paint Spray Gun (Production) 8.5
3

90- 100 *Paint Spray Gun (Touch-up) 3.5


(NEC) - AMPS MINIMUM 1.1

(NEC) - AMPS MINIMUM 0.9

1.8
/2

90- 100 *Paint Spray Gun (Undercoating) 19.0


Thermal-Magnetic Breaker 15

Thermal-Magnetic Breaker 15
14

14
2
1

90- 100 Spring Oiler 4.0


With Dual Element Time

With Dual Element Time


TIRE TOOLS
FULL LOAD CURRENT

FULL LOAD CURRENT


COPPER WIRE SIZE -

COPPER WIRE SIZE -


THWN, XHHW - SIZE

THWN, XHHW - SIZE


(75 C) THW, THHN-

(75 C) THW, THHN-


Delay Fuse - AMPS

Delay Fuse - AMPS


MOTOR X

Trip Rating - AMPS

Trip Rating - AMPS


CIRCUIT BREAKER
CIRCUIT BREAKER

FUSIBLE SWITCH

FUSIBLE SWITCH
125-150 Rim Stripper 6.0
125-150 Tire Changer 1.0
125-150 Tire Inflation Line 1.5
125-150 Tire Spreader 1.0

125-150 *Vacuum Cleaner 6.5

6 23
BLASTING DATA

SYSTEM

SYSTEM
MOTOR

MOTOR
(120V)

(240V)
230V
115V
S

S
APPROXIMATE AIR CONSUMPTION
(CFM) PER BLAST NOZZLE

10

50

90

60
--

--
--

--

6
NOZZLE PRESSURE
NOZZLE
SIZE 80 PSI 90 PSI 100 PSI 120 PSI

71/2

100
110

60
80

40

80
3

8
1
/8 18 20 22 26
3
/16 (*3) 41 45 49 58

40
90

80
56

28

60
10
5

4
1
/4 (*4) 72 80 90 105
5
/16 (*5) 113 125 140 160

12

25
50
34

70

35
17
3

8
3
/8 (*6) 163 182 200 235
7
/16 (*7) 215 240 270 315

20
12
30
50
10

14
24

25
2
1
/2 (*8) 290 320 350 410
5
/8 (*10) 454 500 550 640

11/2

15
12

30
20

40

14
10

20
3
/4 (*12) 652 720 790 925

APPROXIMATE ABRASIVE

12
25
30
14

14
16

15
1

8
CONSUMPTION (LBS./HR.)
PER BLAST NOZZLE

13.8

6.9
/4

20
25

15
14

14

10
NOZZLE PRESSURE 3
NOZZLE
SIZE 80 PSI 90 PSI 100 PSI 120 PSI

4.9
9.8
/2

15

15
20
14

14

7
1

1
/8 115 130 140 165

10
15

3.6

5.6
7.2

/16 (*3) 260 290 320 375


/3

15
14

14
1
SINGLE PHASE MOTOR DATA (60 Hz)

1
/4 (*4) 460 500 560 660

2.9

4.5
5.8

/16 (*5) 725 825 900 1050


/4

15
15
14

14
9
1

3
/8 (*6) 1050 1155 1260 1475
6.25

2.2

3.2
4.4

/16 (*7) 1450 1600 1750 2050


/6

15
14

14
15
1

1
/2 (*8) 1850 2000 2250 2650 SIZE - (75 C) THW, THHN- THWN,
SIZE - (75 C) THW, THHN- THWN,

AMPS MINIMUM COPPER WIRE


AMPS MINIMUM COPPER WIRE

5
/8 (*10) 2900 3125 3520 4100
Thermal-Magnetic Breaker Trip
Thermal-Magnetic Breaker Trip

FULL LOAD CURRENT (NEC) -


FULL LOAD CURRENT (NEC) -

With Dual Element Time Delay


With Dual Element Time Delay

3
/4 (*12) 4180 4500 5060 5950
MOTOR X

Air volume and pressure are very important. The blasting production
CIRCUIT BREAKER
CIRCUIT BREAKER

FUSIBLE SWITCH
FUSIBLE SWITCH

rate will increase with higher blasting pressures and decrease with lower
Rating - AMPS
Rating - AMPS

blasting pressures. The National Association of Corrosion Engineers


XHHW - SIZE
XHHW - SIZE

Fuse - AMPS
Fuse - AMPS

data suggests that 1.5% of production is lost for each 1 PSI reduction in
blast nozzle pressure. Pressure drop through the blast unit itself is
normally less than 1 PSI. Air pressure loss can be avoided by using the
shortest possible hose of adequate size.

8 21
LOSS OF AIR PRESSURE

2.96

9.02
4.62
6.62
.20
.28

1.20
1.68
.49
.76
.13
DUE TO FRICTION - IN PSI 100 FT.

350

11.8
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
OF PIPE OR HOSE 100 PSI GAUGE
INITIAL PRESSURE

.23
.33

3.42
.88

5.36
1.39
1.95
.57
.15

7.70
10.5
13.7
300
CU. FT. EQUIVALENT TYPICAL
FREE CU. FT. Nominal Diameter, In. (I.D.)

2.32
.39
.68

1.66

6.39
1.05
AIR COMPRESSED 1

4.07
.27
.18

9.13
.10

12.5
16.3
PER MIN. AIR/MIN. /2 /4 1 1 /4 1 /2 2 2 /2 3 3 /2 4
3 1 1 1 1

250
10 1.28 2.6 .1 .03

2.04
.48
.22
.33

5.02
.83
20 2.56 6.9 .4 .11 .03 .01

1.30

2.87
.13

7.86

15.4
20.0
11.3
200
30 3.84 .59 .9 .25 .06 .07
40 5.12 1.6 .45 .10 .05

2.66
50 6.41 2.5 .69 .16 .07 .02

3.73
.44

6.55
.62
.28

1.69
1.09
.12
.16

10.3
14.7
150
60 7.68 3.6 1.00 .23 .10 .03
70 8.96 4.9 1.40 .32 .14 .04
80 10.24 6.5 1.80 .41 .18 .05 .02

.73
.33

4.40
1.99
1.28
.51

3.14

7.82
.19
.14

12.1
125
90 11.52 8.3 2.30 .52 .23 .06 .02

LINE PRESSURE - PSIG


100 12.81 2.80 .65 .29 .08 .03
125 15.82 4.90 1.0 .45 .12 .05

.89

2.43
3.83
.63

5.36
9.40
.23

1.56
.41
.11
.17
100
150 19.23 6.30 1.5 .64 .17 .07 .02
175 22.40 1.9 .87 .24 .09 .03
200 25.62 2.6 1.14 .31 .12 .04 .02

.52

2.00

4.89
.80
.30

6.85
.21

3.10
.14

1.14
75
250 31.64 4.0 1.79 .49 .19 .06 .03
300 38.44 5.8 2.58 .69 .27 .08 .04 .02
350 44.80 3.51 .94 .36 .11 .05 .03

.72

4.30
6.78
.29

1.58
2.76
.19

.41
.11

1.11
50
400 51.24 4.58 1.21 .48 .15 .07 .04
450 57.65 5.80 1.54 .59 .19 .09 .05
500 63.28 7.16 1.92 .74 .23 .11 .06

.85
.23
.35
.49

1.87
3.27
1.31
.13

5.17
40
600 76.88 2.76 1.07 .34 .16 .08
700 89.60 3.77 1.45 .46 .21 .11
800 102.50 4.90 1.90 .59 .28 .14

2.28
4.00
.28
.43
.60
1.04
1.60
.16
30
900 115.30 6.23 2.41 .76 .35 .18
1000 128.10 7.69 2.98 .93 .44 .22
1500 192.30 6.70 2.10 .98 .49

2.95
.36
.55
.22

1.34
.77

2.07
20

2000 256.20 3.74 1.73 .88


2500 316.40 5.84 2.72 1.38
3000 384.60 8.41 3.91 2.00
.64
.42

.90
.24

1.57
15

3500 447.80 5.82 2.72


4000 512.40 6.94 3.55
For longer or shorter lengths of pipe or hose, the friction loss is
.50
.80
.29

1.08
10

proportional to the length; i.e.: for 50 ft., one-half of the above; for 400 ft.,
four times the above, etc.
NOTES:
FREE AIR

1. These figures are for estimating - different types of pipe and hose
CFM

1250
200
250
300
400
500
600
800
1000

1500
150

2000
2500
3000
3500
4000
may have rougher linings and cause higher pressure drops.

2. Couplings and fittings increase the pressure drop some.


CONTINUED

3. Lower initial pressures cause increased pressure drop.


SCHEDULE
PIPE SIZE
NOMINAL

4. Higher initial pressure causes lower pressure drop.


2 /2

40
1

Piping for a sample system of 3,000 CFM at 100 PSIG of central air, with
five 600 CFM uses figured according to the chart for loss of air pressure
due to friction.

10 19
FRICTION OF AIR IN HOSE - Pulsating Flow* CONTINUED
SIZE OF HOSE, GAUGE CU.FT. FREE AIR PER MIN. PASSING THROUGH 50 FT. LENGTHS OF HOSE
COUPLED PRESSURE 20 30 40 50 60 70 80 90 100 110 120 130 140 150
EACH END, IN. AT LINE, LB. LOSS OF PRESSURE (PSI) IN 50 FT. LENGTHS OF HOSE
50 -- -- 0.1 0.2 0.2 0.3 0.4 0.5 0.7 1.1
60 -- -- -- 0.1 0.2 0.3 0.3 0.5 0.6 0.8 1.0 1.2 1.5
70 -- -- -- 0.1 0.2 0.2 0.3 0.4 0.4 0.5 0.7 0.8 1.0 1.3
1
1 / 4 80 -- -- -- -- 0.1 0.2 0.2 0.3 0.4 0.5 0.6 0.7 0.8 1.0
90 -- -- -- -- 0.1 0.2 0.2 0.3 0.3 0.4 0.5 0.6 0.7 0.8
100 -- -- -- -- -- 0.1 0.2 0.2 0.3 0.4 0.4 0.5 0.6 0.7
110 -- -- -- -- -- 0.1 0.2 0.2 0.3 0.3 0.4 0.5 0.5 0.6

12
50 -- -- -- -- -- 0.1 0.2 0.2 0.2 0.3 0.3 0.4 0.5 0.6
60 -- -- -- -- -- -- 0.1 0.2 0.2 0.2 0.3 0.3 0.4 0.5
70 -- -- -- -- -- -- -- 0.1 0.2 0.2 0.2 0.3 0.3 0.4
11/2 80 -- -- -- -- -- -- -- -- 0.1 0.2 0.2 0.2 0.3 0.4
90 -- -- -- -- -- -- -- -- -- 0.1 0.2 0.2 0.2 0.3
100 -- -- -- -- -- -- -- -- -- -- 0.1 0.2 0.2 0.2
110 -- -- -- -- -- -- -- -- -- -- 0.1 0.2 0.2 0.2

*For longer or shorter lengths of hose, the friction loss is proportional to the length, i.e.: for 25 ft. one-half of the above; for 150 ft., three times the above, etc.

FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
CONTINUED
NOMINAL CFM LINE PRESSURE - PSIG
PIPE SIZE FREE AIR 10 15 20 30 40 50 75 100 125 150 200 250 300 350
50 .31 .25 .22 .17 .14 .12
75 .65 .54 .46 .36 .29 .25 .18 .14 .12 .10
100 1.13 .94 .80 .62 .51 .43 .31 .24 .20 .17 .13 .11
125 1.44 1.24 .96 .78 .66 .48 .37 .31 .26 .20 .16 .14 .12
150 2.04 1.75 1.35 1.11 .94 .68 .53 .43 .37 .28 .23 .19 .17
200 3.04 2.36 1.93 1.63 1.18 .92 .76 .64 .49 .40 .34 .29
11/2 250 3.68 3.01 2.54 1.83 1.44 1.18 1.00 .77 .62 .52 .45

17
SCHEDULE 300 4.29 3.62 2.62 2.05 1.74 1.43 1.09 .89 .75 .64
40 400 6.35 4.58 3.59 2.94 2.50 1.92 1.55 1.31 1.13
500 7.12 5.59 4.59 3.89 2.98 2.42 2.03 1.76
600 8.00 6.55 5.55 4.26 3.46 2.91 2.51
700 10.8 8.89 7.55 5.78 4.70 3.95 3.40
800 11.6 9.80 7.50 6.10 5.12 4.42
1000 15.2 11.7 9.45 7.95 6.86
1200 16.4 13.3 11.2 9.61
1400 22.9 18.6 15.6 13.5
DECIMAL AND METRIC

.44

2.58
3.68

3.67
5.20
6.50
.25
.96
1.67

1.52
.61

2.37
.12

.31

1.01
350

9.14
.11
EQUIVALENTS OF COMMON

14.3
10.1
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
FRACTIONS OF AN INCH

.30

.35
2.99

4.25
6.03
1.94
4.27

.12

1.76
.51

.71

2.74
7.52

1.18
.14

1.11
300

10.6
16.6
11.7
FRACTION DECIMAL Mm
1/64 0.01562 0.397
1/32 0.03125 0.794

3.26
.35

.42

5.05
2.30
5.08

.84
3.55
8.95
1.32

1.40
.61

.15

2.10
.16

7.16
13.9

12.6
19.7
250
3/64 0.04688 1.191
1/16 0.06250 1.588
5/64 0.07812 1.984
3/32 0.09375 2.381

2.84
.43

4.02
6.22
.20

.52
6.25

8.85
2.58
1.63
.75

1.72
1.03
4.37

.18

15.6
200

11.0
7/64 0.10938 2.778

17.1
1/8 0.12500 3.175
9/64 0.14062 3.572
5/32 0.15625 3.969

2.25
.26

.68

5.25
5.70
3.70
150

.98

1.35
.57

.24
2.12

3.37

8.12
8.16
11/64 0.17188 4.366

14.4

11.5
3/16 0.18750 4.763
13/64 0.20312 5.159
7/32 0.21875 5.556

2.50

2.65
6.75

9.70
3.98
6.40
.67

.28
.80
125

1.59
9.61
4.37
.31
1.15
15/64 0.23438 5.953

12.6
1/4 0.25000 6.350

LINE PRESSURE - PSIG


17/64 0.26562 6.747
9/32 0.28125 7.144

.38

3.05

.34
.98

3.23
8.20

1.93
.81

5.31

4.74
7.53
1.41
100
19/64 0.29688 7.541

11.7
11.7
5/16 0.31250 7.938
21/64 0.32812 8.334
11/32 0.34375 8.731
23/64 0.35938 9.128

.43
.48

3.90
6.80

9.60
1.04

1.25
1.80

2.47
4.12
.12

6.19
75
3/8 0.37500 9.525
25/64 0.39062 9.922
13/32 0.40625 10.319

3.42
.60
.67
2.48
5.40

1.72
1.43

5.71
27/64 0.42188 10.716

.16
50
7/16 0.43750 11.113
29/64 0.45312 11.509
15/32 0.46875 11.906
31/64 0.48438 12.303

2.04
4.05
.79
1.70
2.94

.71
.19
40
1/2 0.50000 12.700
33/64 0.51562 13.097
17/32 0.53125 13.494
35/64 0.54688 13.891
2.08

2.50
.96
3.60

.23

4.95
.87
30

9/16 0.56250 14.288


37/64 0.57812 14.684
19/32 0.59375 15.081
39/64 0.60938 15.478
2.68

3.22
.30
1.24

1.12
20

5/8 0.62500 15.875


41/64 0.64062 16.272
21/32 0.65625 16.669
43/64 0.67188 17.066

.35
1.45

1.31
15

11/16 0.68750 17.463


45/64 0.70312 17.859
23/32 0.71875 18.256
47/64 0.73438 18.653 .42
3/4 0.75000 19.050 1.57
10

49/64 0.76562 19.447


25/32 0.78125 19.844
51/64 0.79688 20.241
13/16 0.81250 20.638
FREE AIR

53/64 0.82812 21.034


CFM

100

100

150
200
250
125
10
15

10
20
30
40
50
60
80

20
35
50
65
80
27/32 0.84375 21.431
55/64 0.85938 21.828
7/8 0.87500 22.225
57/64 0.89062 22.622
29/32 0.90625 23.019
59/64 0.92188 23.416
SCHEDULE

SCHEDULE
PIPE SIZE
NOMINAL

15/16 0.93750 23.813


/2

/4
40

40

61/64 0.95312 24.209


1

31/32 0.96875 24.606


63/64 0.98438 25.003
1/1 1.00000 25.400

14 15

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