Services
Air Compressor Pipework Installation Services
The efficiency of your compressed air system is determined by the quality of your pipework. Poor pipework design increases pressure drop which raises energy bills and destabilises tools and machinery.
You might generate the power, but only good pipework delivers it.
Search Air provides professional Air Compressor Installation Services and pipework design across Yorkshire and the East Midlands. Unlike general mechanical contractors, we use friction-loss calculations. We control velocity which ensures your distribution network delivers full power without waste. We comply strictly with PSSR 2000 regulations and BCAS best practices.
How Does Pipework Impact Energy Efficiency?
Pressure drop (loss of pressure caused by friction as air moves through a pipe) destroys system efficiency. It is the primary cause of energy waste in industrial air systems.
- The Energy Cost: For every 1 bar of pressure drop, your compressor consumes approximately 7% more energy.
- The Financial Impact: A typical 37 kW compressor running 24/7 can waste between £8,000 and £12,000 per year due to bad pipework.
- Velocity Control: Undersized pipework increases resistance dramatically. This forces the compressor to work harder. It raises your energy bills immediately.
We calculate the correct pipe diameter based on your kW rating and total distance. We maintain air velocity between 6 and 10 meters per second. This protects dryers from overload, prevents moisture re-entrainment and ensures your tools receive stable pressure.
Which Pipework Material Is Best for Compressed Air?
Material choice defines system longevity. It also dictates safety and cleanliness. We recommend aluminium or stainless steel over traditional materials which ensure stable pressure and clean air for our clients in Leeds, Sheffield, and beyond.
| Feature | Aluminium (AIRnet) | Galvanised Steel | Stainless Steel |
|---|---|---|---|
| Flow Efficiency | High (Smooth Bore) | Low (Rough / Turbulent) | High |
| Corrosion Risk | None | High (Internal Rust) | None |
| Leak Risk | Low (O-ring seals) | High (Threaded joints) | Low |
| Installation Speed | Fast (Push-fit / Clamp) | Slow (Thread / Weld) | Fast (Press-fit) |
| Best Use Case | General Industry | Not Recommended | Food / Pharma |
Aluminium (Atlas Copco AIRnet)
Aluminium is the modern standard for general industrial applications. It features a mirror-smooth bore. This minimises friction and the material does not corrode. This prevents rust contamination in your air tools and valves. AIRnet systems use modular push-fit or torque-clamp connections which allows for installation speeds up to 85% faster than steel.
Stainless Steel
Stainless steel is mandatory for hygiene-critical environments. This includes pharmaceutical and food production facilities requiring Food-Grade Pipework for Guaranteed Purity. Modern press-fit stainless steel systems eliminate welding. They reduce installation time and ensure hygienic, particle-free airflow to meet ISO 8573-1 Class 0 standards.
Galvanised Steel (The Traditional Liability)
We generally advise against galvanised steel for new installations. The zinc layer breaks down from acidic condensate, which exposes raw steel. Corrosion accelerates with age. Every year the internal roughness increases. This raises pressure drop and contaminates downstream equipment.
PVC and Plastic
Rigid plastic pipes like PVC or ABS are dangerous. They are often prohibited by insurance policies. They become brittle under pressure and exposure to synthetic compressor oils. If they fail, they shatter into sharp shrapnel. The UK Health and Safety Executive (HSE) strictly advises against their use.
What Are the Benefits of Atlas Copco AIRnet?
AIRnet is a complete compressed air distribution solution designed for operational excellence.
- 10-Year Leak-Free Guarantee: The system comes with a comprehensive warranty on pipes and fittings.
- Smart Integration: We can integrate pipework with Atlas Copco AIRScan flow diagnostics and SMARTLINK monitoring. This verifies real energy savings.
- Modular Design: Fittings are reusable. You can modify the system easily without production downtime.
- Connection Technology: Diameters of 20–50 mm use PF series push-fit connections. Diameters of 63–158 mm use Black Series torque clamps.
How Should You Design the System Layout?
The geometric layout of your pipework affects pressure stability. We provide full CAD layout drawings for facilities across the East Midlands and Yorkshire.
Ring Main (Loop) Architecture
A ring main is the preferred layout for most industrial facilities. The main pipe loops around the facility and returns to the source. This allows air to flow to a usage point from two directions. This reduces pressure differential at peak load by up to 30%. It prevents tool stalling and allows you to isolate sections for maintenance without shutting down the plant.
Condensate Management and Goosenecks
Water is a natural byproduct of air compressors. Pipework must prevent this water from reaching your tools. We install “gooseneck” drops. These exit from the top or side of the main header. Gravity keeps liquid water in the main header. We install the header with a slight gradient (1:100) which guides water to drain traps.
What Are the UK Regulations for Pipework?
Compliance with UK safety legislation is mandatory. Search Air ensures your installation meets all legal requirements.
Pressure Systems Safety Regulations 2000 (PSSR 2000)
Pipework is a pressure system. PSSR 2000 applies to systems operating above 0.5 bar.
- Written Scheme of Examination (WSE): Systems where the pressure-volume product of the receiver exceeds 250 bar-litres require a WSE.
- Installer Responsibilities: We ensure pipework withstands maximum working pressure and that it is protected from vibration, impact, and external loads.
- BCAS Best Practice: We follow British Compressed Air Society (BCAS) BPG 101-6 for installation standards.
Pipe Marking (BS 1710)
Safety standards require proper identification. Compressed air pipes must be marked with Light Blue (20 E 51). We apply labels indicating the contents and direction of flow. This ensures safety for maintenance personnel.
Professional Servicing Available
Our Atlas Copco trained technicians provide comprehensive maintenance and repairs for all major compressor brands. With depots in Leeds, Nottingham, and Sheffield, we’re never far away.
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Professional Servicing Available
What Is the Installation Process?
Our installation methodology ensures safety. It ensures system integrity with minimal disruption.
- Site Survey & Design: We assess your flow requirements and design the system using Modern, Modular AIRnet Piping to minimise pressure loss.
- Preparation: Pipes are square-cut and deburred. This prevents damage to O-ring seals. We mark insertion depth to guarantee secure connections.
- Support Installation: We install supports at specific intervals (typically 2–4 meters). Sliding clips allow for thermal expansion. This prevents sagging and leaks.
- Assembly: We assemble the system using non-destructive techniques. No hot work permits are required which improves safety and speed.
- Pressure Testing: We conduct a pneumatic pressure test at 1.1 to 1.25 times the working pressure. This verifies the system is leak-free.
- Commissioning: We provide a commissioning certificate. We supply technical documentation for your compliance records.
Why Choose Search Air?
William G. Search Ltd has served the UK industry since 1946. We became an Employee Ownership Trust in 2024. Our team is personally invested in your success.
- Premier Distributor: We have been a Premier Distributor for Atlas Copco since 2001.
- In-House Engineers: We use our own fully trained engineers. We do not use subcontractors.
- Local Support: We operate depots in Leeds, Sheffield, and Nottingham. We provide rapid response across Bradford, Doncaster, and Chesterfield.
- Comprehensive Service: Beyond installation, we offer leak detection, energy audits, and air quality testing.
- Compliance: We assist with Written Schemes of Examination. This keeps you legal and safe.
Secure Your Efficiency and Compliance Today
Do not let poor pipework compromise your production. Stop wasting energy. Protect your equipment. Improve your airflow. Upgrade to a modern system that pays for itself in energy savings.
Contact Search Air today for a free pipework survey and quote. We will assess your current system and design a solution that improves flow, reduces costs, and ensures safety.