Compressed Air System Design

The cheapest time to get a compressed air system right is before it is built. Systel designs compressed air systems for new plants and expansions, sized from measured data on comparable plants rather than from the sum of nameplate ratings.

Why new systems start oversized

New compressed air systems are usually sized by adding up the air consumption figures of every machine and adding a margin, then a second margin for future expansion. The result is a compressor room that runs part-loaded for years, a pressure set-point higher than the process needs and a distribution network that was never checked for pressure drop. Each of those costs energy for the life of the plant.

Systel has measured the actual demand of plants in textiles, tyres, ceramics and other industries for 24 years. That record is what a design should start from.

What the design covers

• Demand estimate by department and by shift, based on the machines you are installing and on measured demand in comparable plants.
• Compressor room: number and size of compressors, the mix of fixed and variable speed, and how they should be sequenced.
• Air treatment: dryer type and capacity, filtration grade for the processes that need it, and condensate handling.
• Storage: receiver sizes and positions, including local receivers for large intermittent users.
• Distribution: header layout and pipe sizes checked for pressure drop at full and future demand, and the pressure each area actually needs.
• Measuring points: where flow, pressure, power and dew point sensors should go, so the plant can be monitored from the first day of production.

For expansions

When a new unit or line is added to an existing plant, the question is often whether to extend the existing compressor station or build a second one. Systel answers it from measured data on the existing system, so the decision does not rest on estimates alone.

What you receive

A design report with the demand basis, equipment sizing, layout recommendations and the list of measuring points, ready for your consultant, contractor or equipment supplier to quote against. System design is a paid engagement. Systel does not sell compressors, so the recommendation is not tied to any brand.

After commissioning

Plants that install sensors at the design stage start with a measured baseline from day one. That is the starting point for a Systel digitization project and the Performance Programme.

By invitation. Not a free audit. A feasibility visit is where scope, sensor points and project value are frozen. It starts with a phone call.

Request a feasibility discussion · See how the programme works