Complete Air System Explorer

Explore the System

Tap a component, follow the air path, switch to condensate flow, or use system-value mode for a clearer complete-system overview.

Explore Mode

CompressorStep 1 of 8 · Explore mode

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≈1% / 2 PSI Pressure Optimization U.S. DOE rule of thumb near 100 psig at full output: every 2 psi increase in discharge pressure raises compressor energy use by about 1%. The total system effect can be higher when lower pressure also reduces unregulated demand. Verify savings against the actual system.

20–30% possible loss Leak Management U.S. DOE guidance notes that poorly maintained compressed-air systems can lose 20–30% of compressor output to leaks, while a well-maintained system should be below 10%. Actual leakage must be measured at the site.

+13.5% efficiency Optimization Case Study A U.S. DOE Better Plants case study reported a 13.5% improvement in system-level energy efficiency at Waupaca Foundry Plant 1 after a comprehensive compressed-air optimization project. This is a documented example, not a projected Sullivan-Palatek savings rate.

Potential energy opportunities are application-specific. Verify savings through a compressed-air system assessment.

Tap the numbered points to explore each system stage.

01 · Generate

Compressor

Air Path

System Advantage

Why plan the complete system?

A coordinated system approach helps align generation, storage, treatment, drainage, and condensate management with the application from the start.

Matched Equipment

Compressor, storage, treatment, and drains are selected to work together instead of being pieced together later.

Planned Air Quality

Dryer and filtration decisions are driven by the application, helping avoid downstream air-quality surprises after installation.

Condensate Management

Zero-loss drains and condensate treatment are part of the design discussion from the beginning—not forgotten until startup.

Upfront Value

Planning the complete system together can simplify procurement, reduce integration changes, and support stronger long-term value.

Complete-System Value: A coordinated purchase can provide package advantages on qualifying equipment while helping reduce the cost and disruption of adding missing components later.

Interactive Application Tool

Build Your Air System

Start with the airflow and pressure your application requires. The builder creates a preliminary Sullivan-Palatek system, sizes compatible treatment components, and lets you choose compatible alternatives at each equipment point to see how the complete system changes.

Design → Refine → Quote

1 · Design Basis01

Required Airflow (CFM)

Working Pressure (PSI)

Air Quality Goal Sets the starting treatment approach. Final dew point and air-quality requirements are confirmed for the application.

Advanced System ControlsDrive · dryer · filtration

Compressor Drive Preference

Dryer Type

Pre-Filter

Post-Filter

Preliminary sizing: the builder matches available Sullivan-Palatek equipment to the requested flow, pressure, and treatment starting point. Final dew point, receiver storage, electrical requirements, pressure drop, controls, and installation details are confirmed during application review.

Design Flow

440 CFM

Requested plant airflow

Pressure Basis

125 PSI

120-PSI treatment column

Active Path Capacity

— CFM

Compressor + active flow-rated components

System Check

Sizing…

Checking capacity + layout logic

Checking

Reviewing system path…The builder is checking the active component order and capacity.

Active Air PathBuilding path…

Active Equipment—

Concept Storage—

Condensate Points—

Distribution

Main Air Path

Condensate Management

Plant Ring Main · Simplified Distribution View

From 08 · Plant Air

Point of Use

Condensate Collection Header

3 · Refine Component

Compressor

Building selection…

Equipment Option

Workflow: enter CFM + PSI + air-quality goal, build the preliminary system, then refine equipment or use Modify Layout to rearrange/remove stages, add catalog air treatment, or add a second compressor as a parallel source. Blocking capacity/order conflicts are shown in red and must be corrected before the layout is treated as workable. Final sequencing, pressure drop, controls, engineered sizing, and commercial details are confirmed by Sullivan-Palatek.

Application Tool

Oil Carryover Calculator

Estimate downstream lubricant carryover using compressor flow, inlet temperature, operating time, and oil carryover in PPM. This tool is especially useful when discussing air treatment and filtration requirements.

Sullivan-Palatek Calculator

Oil Carryover Calculator

Estimate the amount of compressor lubricant passed downstream from airflow, inlet temperature, operating time, and oil carryover in PPM.

Operating Conditions

Enter the compressor conditions and select the Sullivan-Palatek lubricant in use.

Compressor Flowair volume

CFM

Inlet Air Temperatureexact entry

°F

Enter the exact inlet temperature, including decimals if needed (example: 72.5).

Air Densitycalculated from inlet temperature

lb/ft³

Operating Hourstime period

hours

Oil Carryoverparts per million by weight

PPM

Sullivan-Palatek Lubricantdensity preset

Lubricant density used Automatically set by lubricant selection

kg/L

Select Custom / other lubricant to enter a different lubricant density.

Calculated Results

Estimated lubricant passed downstream during the entered operating period.

Oil Carryover Results

Gallons passed downstream

0.628gal

Estimated total lubricant volume carried downstream over the selected operating hours.

Mass Flow

18.79 lb/min

Total CF (000)

30,000.00 thousand ft³

Total Lbs Air (000)

2,255.20 thousand lb

Lbs Lubricant

4.510 lb

Fl. Oz. Passed Downstream

80.44 fl oz

Lubricant Density

0.860 kg/L

Air density: 0.0752 lb/ft³ · Lubricant: Palasyn 45 · Lubricant density: 0.860 kg/L

Calculation basis: air mass is calculated from CFM, inlet-air density, and operating time. Lubricant mass is calculated from the entered PPM by weight, then converted to fluid ounces and gallons using the selected lubricant density.

Application Tool

Air Receiver Tank Size Calculator

Estimate receiver storage from airflow, usable pressure range, and required drawdown time, then compare the result with the Sullivan-Palatek receiver options in this system catalog.

Sullivan-Palatek Calculator

Air Receiver Tank Size Calculator

Calculate conservative drawdown storage using the CAGI receiver formula and match the result to the Sullivan-Palatek vertical receiver sizes available in this builder.

Storage Conditions

Enter the free-air demand and the pressure band the receiver is allowed to use.

Air Demandfree air flow

CFM

Use the demand the receiver must support during the event. The current builder flow can be loaded with the button below.

Starting Pressurereceiver / header high

PSIG

Minimum Pressurelowest acceptable pressure

PSIG

Storage Timedrawdown duration

sec

Calculated Results

Minimum gross receiver volume for the entered drawdown event, assuming no compressor air is added during the storage interval.

Receiver Storage Result

Minimum calculated receiver volume

—gal

Calculated from the usable pressure band and the amount of free air required during the drawdown period.

Receiver Volume

— ft³

Usable Pressure Band

— PSI

Free Air Required

— SCF

Sizing Basis

14.7 PSIA atmosphere

V = T × C × P_a ÷ (P₁ − P₂)

How to use it: this is a drawdown-storage calculation, not a pressure-vessel rating check. Sullivan-Palatek product matching is based on catalog gallon capacity only; final receiver quantity, placement, pressure rating, controls, and application suitability should be confirmed during system review.

Build the right system for your application.

Work with Sullivan-Palatek or your authorized distributor to review airflow, pressure, storage, air-quality, and condensate-management requirements for your application.

Application note: Compressed-air system layouts are application-specific. Equipment selection, sequence, sizing, pressure, air-quality requirements, and condensate treatment should be confirmed with Sullivan-Palatek or your authorized distributor.

Complete Air.One System.

Explore the System

Compressor

Why plan the complete system?

Matched Equipment

Planned Air Quality

Condensate Management

Upfront Value

Build Your Air System

Compressor

Oil Carryover Calculator

Operating Conditions

Air Receiver Tank Size Calculator

Storage Conditions

Build the right system for your application.

Complete Air.
One System.