Pressure drop in a compressed air system refers to the loss of air pressure between the compressor discharge and the point of use. It’s caused by resistance as air moves through components like piping, filters, dryers, valves, and fittings.
💨 Why It Matters
- Excessive pressure drop reduces system efficiency.
- To compensate, operators often increase system pressure, which wastes energy and increases wear.
- Every 2 PSI increase in system pressure can raise energy costs by about 1%.
🔧 Where Pressure Drop Happens
| Component | Typical Cause |
| Piping | Too small, long runs, rough interior |
| Filters | Dirty or undersized filters |
| Dryers | Restricted flow or undersized units |
| Fittings & Valves | Tight bends, leaks, or restrictions |
| Quick-connect Couplings | Small internal diameter or wear |
📉 How It's Measured
- Pressure drop is usually measured in PSI or bar.
- Ideally, the total pressure drop from the compressor to the point of use should be less than 10% of the system’s operating pressure.
- Example: In a 100 PSI system, no more than 10 PSI drop.
🛠️ Reducing Pressure Drop
- Use larger diameter piping.
- Minimize bends, elbows, and long runs.
- Regularly maintain filters and dryers.
- Choose components with low pressure drop ratings.
- Design the system with a loop layout instead of a long straight run for better flow distribution.
💡 Real-World Analogy:
Think of pressure drop like water flowing through a garden hose:
- A kink, a small nozzle, or a long hose reduces the pressure at the spray end.
- Same with air—any restriction reduces the pressure available to your tools or processes.
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