Pressure drops in an industrial air system can disrupt productivity, increase energy costs, and lead to equipment strain. We often see facilities struggle with this issue without realizing how many small factors contribute to it. Therefore, knowing how to troubleshoot these pressure drops effectively can prevent long-term inefficiencies and unnecessary maintenance.
In this guide, we’ll break down the most common causes, how to isolate the problem, and what steps we recommend to get everything back to optimal operation. At Air Compressors Canada, we deal with these challenges often, and our approach focuses on both diagnosing the root cause and improving the overall system health.
Understand the Basics of Pressure Loss
Firstly, let’s define what we’re dealing with. A pressure drop refers to the loss of air pressure between the compressor and the end-use equipment. In other words, the compressed air system is producing pressure that isn’t fully reaching its destination.
That loss usually comes from friction inside the piping, restrictions, leaks, or issues within the compressor or filtration stages. As a result, you’ll see machines underperform, cycles running longer, or downstream tools failing to function as intended.
Recognizing the warning signs early gives us a clear advantage. Pressure gauges placed at different stages in the system provide valuable information if we know how to read them correctly.
Check for Leaks First
We always recommend starting with the simplest and most common cause. Leaks are often responsible for a surprising amount of pressure loss. For instance, a small leak in a connector or fitting might not seem serious, but over time, it can bleed off a lot of air.
Use an ultrasonic leak detector if you have one. Alternatively, soapy water sprayed on joints and fittings will reveal bubbling where air escapes. That is to say, visual tools still work when advanced equipment isn’t available.
Once located, repair leaks immediately. Even minor sealing with proper thread tape or replacing worn gaskets can make a big difference. In addition, recheck the area after repairs to make sure the leak has been fully addressed.
Evaluate the Piping System
After that, move to the piping. The layout and condition of your pipes can cause pressure drops even without any leaks. Long piping runs, sharp bends, and internal corrosion increase resistance, which causes the pressure to fall before reaching the endpoint.
We advise walking the entire system length and visually inspecting the pipe condition. Are there unnecessary elbows or narrow sections? Has rust started forming internally? These are all important questions to consider.
In some cases, the answer may be upgrading your piping layout. For example, switching to larger diameter pipes in high-demand areas or shortening certain pathways could reduce resistance and help maintain consistent pressure throughout the system.
Examine the Compressor and Receiver Tank
If the piping checks out, we move to the compressor itself. Make sure the compressor is sized properly for the application. Likewise, if the demand has increased due to added equipment, the existing system might now be underpowered.
Check the output pressure at the compressor before any filters or dryers. This gives a clear picture of what the machine is producing. Compare that to readings further downstream. A major gap may point to issues like clogged filters or worn internal components.
Also, inspect the receiver tank. If it’s too small, it won’t buffer demand fluctuations effectively, leading to pressure dips during peak usage. Adding a larger or secondary receiver tank might smooth things out and provide consistent flow.
We’ve outlined these and other tips in our overview of industrial air compressor supplier services, especially when evaluating systems that require more than basic fixes.
Inspect Filters and Dryers for Blockage
Next, look closely at your filtration system. Filters and dryers can cause significant pressure drops if they’re clogged or not maintained regularly. We see many operations neglect filter replacements until they become a serious bottleneck.
Start by checking pressure gauges before and after the filters. A large difference between them usually means the filter is restricting flow. Consequently, you’ll want to replace or clean these components depending on their type.
If you’re using desiccant or refrigerated dryers, confirm they are working efficiently. A saturated desiccant bed or a dryer with a malfunctioning cooling system adds unnecessary resistance to the airflow.
To avoid this, we suggest including regular dryer inspections in your maintenance plan. As we’ve seen over time, consistent upkeep saves more money than reactive repairs.
Measure Demand vs Supply Accurately
Another step is comparing actual air demand to supply capacity. Sometimes, the system works perfectly but is simply overloaded. For instance, adding new tools or operating more machines at once increases demand that the system was never designed to meet.
Use a flow meter or conduct an audit to determine total air consumption. Once you understand the demand curve throughout the day, you can decide whether changes are needed.
This might involve staggering equipment usage, adding storage capacity, or upgrading the compressor. Similarly, understanding peak demand helps you pinpoint pressure drop episodes that might not happen during light load periods.
We recently included this step in a broader discussion on compressor performance optimization found on our page about compressed air systems and components.
Look for Underrated Hose or Tool Attachments
Pressure drops aren’t always a system-wide issue. In some cases, they are caused by attachments at the very end of the line. Hoses that are too small in diameter or worn internal fittings can choke airflow at the last moment.
It’s easy to overlook these details, but they play a big role in overall efficiency. Check the diameter of hoses, especially if they feed high-volume tools. Likewise, quick-connect couplings that aren’t rated for the right pressure or flow can restrict air even if the rest of the system is sound.
Switching to larger hoses or upgrading couplers can improve tool performance without making any large infrastructure changes.
Use Pressure Drop as a Diagnostic Tool
One of the most valuable insights we can offer is to treat pressure drop as a signal rather than just a symptom. In other words, pressure differences between sections of the system can guide you directly to the source of trouble.
Install temporary pressure gauges at various points along the system. Record the pressure at each stage from the compressor to the final equipment. A sharp drop between two points means you’ve isolated the restriction.
This data-driven method eliminates guesswork. Moreover, it allows for targeted repairs instead of overhauling large portions of the system unnecessarily.
Develop a Routine Maintenance Plan
Lastly, the best way to prevent pressure drops is to monitor the system consistently. Routine checks, filter replacements, leak detection, and system audits should all be part of the monthly plan.
We find that keeping a log of pressure readings over time also helps spot trends before they become bigger issues. Sudden shifts in those numbers often indicate wear, scaling, or performance loss.
As a reliable industrial air compressor supplier, our team always recommends scheduling annual performance evaluations for larger facilities. These checks provide an outside perspective and ensure the system runs at maximum efficiency without avoidable downtime.
If you’re experiencing ongoing pressure loss or just want to improve system reliability, reach out using our Contact Us form. We can help troubleshoot issues, assess system performance, and provide practical recommendations that suit your facility’s needs.
FAQs
What is an acceptable pressure drop in a compressed air system?
A general rule is no more than 10 percent of the compressor’s discharge pressure. Anything above that usually indicates problems in the distribution system.
How often should filters be changed in an industrial air system?
That depends on the operating environment and hours of use. However, most filters should be checked monthly and replaced every 3 to 6 months for optimal performance.
Can piping material affect pressure drops?
Yes. Materials like steel and iron tend to corrode over time, increasing resistance. Aluminum or specially treated piping often performs better in the long term.
What tools are best for detecting leaks?
Ultrasonic leak detectors are the most accurate, but a basic spray bottle with soapy water can work well for small-scale inspections.
Should I upgrade the compressor if I have pressure drops?
Not always. First check for leaks, filter blockages, and undersized piping. Only after ruling out these causes should a system upgrade be considered.