Emergent Energy Solutions
    Compressed Air System Sizing

    System Sizing Tool

    Enter your compressor horsepower ratings to automatically calculate peak flow, recommended pipe header sizes, and air dryer capacity for systems up to 150 PSI.

    Disclaimer: All calculations provided by this tool are estimates based on industry-standard formulas and general engineering guidelines. Results do not account for site-specific field conditions such as pipe fittings (elbows, tees, valves), flow turbulence, elevation changes, pipe surface roughness, or system leaks. Contact Emergent Energy Solutions for a comprehensive engineering assessment tailored to your facility.

    How to Use This Tool

    1

    Enter Compressors

    Add HP & type for each running unit

    2

    Set Pressure Target

    Define your generation pressure (PSI)

    3

    Review Pipe Sizing

    Get header & ring-main recommendations

    4

    Calculate Pressure Drop

    Add pipe length, fittings & dryer specs

    5

    Export Report

    Download your sizing summary as PDF

    System Configuration

    Define your compressor fleet and calculate pressure drop

    Compressor Inputs

    Enter HP for up to 6 compressors (systems up to 150 PSI). Flow is estimated at ~4.5 CFM per HP.

    Note: Only include compressors expected to run simultaneously. Exclude standby or backup units to avoid oversizing piping and dryer capacity.

    System-wide discharge pressure setpoint for all compressors.

    Pipe Pressure Drop Calculator

    Estimate pressure drop at the point of use using the empirical compressed air formula:ΔP = C × L × Q1.85 / (d5 × P)Where ΔP = pressure drop (PSI), C = 0.000596, L = pipe length (ft), Q = flow (SCFM), d = pipe inside diameter (in), P = gauge pressure (PSI).

    A single header feeds air in one direction. The full flow travels the entire pipe length, resulting in higher pressure drop over long runs.

    Each fitting adds equivalent straight pipe length based on L/D ratios from Crane TP-410. These are added to the pipe length before calculating pressure drop.

    Branch Take-Off Pressure Drop

    Calculate additional pressure drop from the main header to the point of use through a branch line.

    Enter Compressor Data

    Add at least one compressor HP value to see system sizing recommendations for piping, flow, and dryer capacity.