Choosing the right air lines for a shop environment is critical to ensure proper functionality of pneumatic tools and equipment. The air lines carry compressed air from the compressor to the point of use, so they need to be durable, flexible, and sized properly for the application. There are a few key factors to consider when selecting air lines for a shop:
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Type of Line
The most common types of air line used in shops are:
- Polyurethane – This flexible, lightweight hose is abrasion and oil resistant. Polyurethane works well for portable air tools.
- PVC – Rigid PVC tubing is suitable for permanent overhead or underground air line runs. It is not very flexible.
- Rubber – Rubber hoses are durable and weather/abrasion resistant. They are a good general purpose air line.
- Nylon – Nylon air hoses are extremely durable even when dragged across concrete floors. They are kink resistant.
- Stainless Steel – Stainless steel braided hose offers maximum durability and can withstand very high temperatures.
Consider factors like flexibility, durability, and oil resistance when selecting the right type of line for the application.
Line Size
Air line size is specified by inside diameter (ID). Common sizes are 1/4, 3/8, 1/2, and 3/4 inch ID. The right size depends on:
- Air flow requirements – Bigger tools need more airflow which requires larger lines.
- Length of run – Longer runs may need larger lines to overcome pressure drops.
- Number of connections – More connections/tools requires a larger main line.
In general, a 1/4″ line can run a single small nail gun. A 3/8″ line can run one larger tool like an impact wrench. And a 1/2″ or larger line is appropriate for multiple tool connections.
Fittings
The fittings connect air lines together and allow connections to tools. Common types are:
- Barb – Simple push-on fitting for low pressure air.
- Compression – Provides an air tight seal when tightened. Reusable.
- Push-to-Connect – Easy push in fitting for fast connections.
- Pipe Thread – Screw on fitting provides very secure high pressure connection.
Choose fittings in the same size as the air line for maximum airflow. Make sure any thread fittings match (NPT or BSP).
Air Line Components
Beyond the lines and fittings, there are a few other important components that make up an air distribution system:
Main Distribution Header
The main distribution line that runs compressed air from the compressor/tank to sublines around the shop. This main header line needs to be sized appropriately to feed all shop tools without pressure drops. Typical sizes range from 3/4″ to 1 1/2″.
Ball Valves
Ball valves allow sections of the air system to be shut off for maintenance. Full port ball valves have a flow path equal to the line size for minimal restriction.
Drain Valves
Low point drain valves allow water that accumulates in the lines to be drained periodically. This helps prevent water damage to tools.
Filters
Filters remove particulates and condensed water droplets from the air. They protect tools from impurities that can cause damage. Install filters at the compressor and point of use.
Pressure Regulators
Regulators control line pressure for optimal tool performance. They allow higher shop pressure to be reduced for individual tool connections.
Lubricators
Lubricators inject oil into the air line to provide lubrication for air tools. The oil helps prevent wear and tear. Mostly used for air motors or rotary tools.
Utility Hoses
Flexible utility hoses provide the final connection between distribution lines and tools. Use spring guards to protect the hose from damage.
Installation Considerations
Proper installation of air lines is crucial for safety and performance:
- Use appropriate hangers to suspend overhead lines – don’t use wire or string that can cut into the hose.
- Avoid tight bends or kinks that will restrict airflow.
- Cut lines square and deburr all cuts to allow proper sealing with fittings.
- Use thread sealant to ensure leak free threaded connections.
- Route lines away from traffic areas to prevent damage.
Also make sure to size lines generously, use minimal 90 degree bends, and slope lines 1-2% to allow condensate drainage. Leave access to ball valves, drains, and filters for maintenance. Finally, label lines and organize manifold connections neatly.
Example Shop Air Line Layout
Here is an example air line layout for a small to medium size shop running multiple air tools:
| Component | Type |
|---|---|
| Main Distribution Header | 1″ Black Iron Pipe or 1 1/4″ Rubber Hose |
| Ball Valves | 1″ Full Port Ball Valves |
| Main Filter | 1 Micron Filter with Auto Drain |
| Pressure Regulator | 0-150 PSI Regulator |
| Branch Lines | 3/4″ Rubber Hose or PVC |
| Point of Use Filters | 5 Micron Filters |
| Utility Hoses | 3/8″ Polyurethane with Spring Guard |
This layout provides clean, regulated air to multiple connection points around the shop for efficient operation of pneumatic tools. Proper sizing, filtration, and organization are key.
Maintenance Tips
Routine maintenance of shop air lines will maximize performance and tool life:
- Drain moisture from the system weekly using low point drains.
- Check filters regularly and drain/clean as needed based on pressure drop.
- Inspect lines and listen for leaks. Fix any leaks immediately.
- Replace frayed or damaged utility hoses.
- Lubricate fittings and valves that may bind up.
- Check all connections are tight. Tighten if loose.
Also rebuild shop regulators and lubricators as recommended by the manufacturer. Having a strict maintenance schedule will keep the air system running optimally.
Safety Precautions
Compressed air can be dangerous if proper safety precautions are not followed:
- Wear eye protection – air can propel debris that could damage eyes.
- Never point nozzles at yourself or others.
- Never use compressed air to clean clothes, hair, skin, etc.
- Relieve pressure in lines before servicing.
- Use restraints on hose connections to prevent whipping if disconnected.
- Keep oily surfaces clean to prevent slipping.
Additionally, follow allCOMPRESSOR safety procedures like venting tanks before servicing. Post warning signs of the maximum pressure rating on distribution lines.
Conclusion
Setting up an efficient and safe compressed air distribution system in a shop environment requires selecting the right size and type of lines, components, and fittings based on the tools being used. Polyurethane, rubber or PVC lines paired with quick connect fittings provide flexibility. Proper installation, labeling, and maintenance are also very important. Following safety precautions like personal protective equipment and restraining hoses is critical. Investing in quality air line components and regular maintenance procedures will ensure optimal tool performance and safety.