---
title: "Compressed Air System Sizing Calculator | Pipe, Flow & Dryer Sizing"
description: "Free compressed air sizing tool for facility engineers. Calculate peak CFM, header pipe sizes, dryer capacity, and pressure drop for multi-compressor systems up to 150 PSI."
lang: en
json-ld: |
  [
    {
      "@context": "https://schema.org",
      "@type": "Organization",
      "name": "Air Compressor Sequencer",
      "url": "https://aircompressorsequencer.com",
      "parentOrganization": {
        "@type": "Organization",
        "name": "Emergent Energy Solutions",
        "url": "https://emergentenergy.us"
      }
    },
    {
      "@context": "https://schema.org",
      "@type": "HowTo",
      "name": "How to Size a Compressed Air System: Piping, Flow & Dryer Capacity",
      "description": "Calculate peak CFM, recommended pipe header sizes, air dryer capacity, and pressure drop for industrial compressed air systems up to 150 PSI.",
      "step": [
        {
          "@type": "HowToStep",
          "position": 1,
          "name": "Enter Compressor HP",
          "text": "Add the horsepower rating and type for each compressor expected to run simultaneously. Exclude standby units."
        },
        {
          "@type": "HowToStep",
          "position": 2,
          "name": "Set Generation Pressure",
          "text": "Enter your system-wide discharge pressure setpoint in PSI."
        },
        {
          "@type": "HowToStep",
          "position": 3,
          "name": "Review Pipe Sizing",
          "text": "The tool calculates peak CFM (at ~4.5 CFM/HP) and recommends header and ring-main pipe sizes."
        },
        {
          "@type": "HowToStep",
          "position": 4,
          "name": "Calculate Pressure Drop",
          "text": "Enter pipe length, size, fittings, and flow rate using the empirical Crane TP-410 method."
        },
        {
          "@type": "HowToStep",
          "position": 5,
          "name": "Export Report",
          "text": "Download your sizing summary as a PDF for engineering review or utility rebate documentation."
        }
      ]
    }
  ]
---

[![Emergent Energy Solutions](/assets/logo-BEceeyq5.png)](/)

[Home](/)[Technology](/technology)[Sizing Tool](/sizing-tool)[Savings](/savings)[Rebates](/rebates)[Resources](/resources)[Blog](/blog)[About](/about)[Contact Us](/contact)

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.

Generation Pressure Target (PSI)

System-wide discharge pressure setpoint for all compressors.

Compressor 1 — HP

TypeRotary Screw 

Add Compressor (1/6)

### 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). 

Distribution MethodSingle Primary Header (Dead-End) 

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

Pipe Size (nominal)2" Schedule 40 

Pipe Length (ft)

Flow (SCFM)

Line Pressure (PSI)

Fittings (Equivalent Length Method)

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.

90° Elbows

45° Elbows

Tees (thru branch)

Gate Valves

Ball Valves

Butterfly Valves

### Branch Take-Off Pressure Drop

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

Branch Pipe Size1" Schedule 40 

Branch Length (ft)

Branch Flow (SCFM)

### Enter Compressor Data

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