A For Ingenuity, F For Performance

Over the past month or so, I have had several customers taking advantage of the EXAIR Efficiency Lab.  This one that came in really stood out to me though.  This is a 48″ long Steel pipe that was custom designed and made by the customer.  The unit has slots that we believe were EDM’d into the pipe.

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The customer was using this to blow debris off sheets of steel.   Once we got the pipe hooked up and set to run we were only able to generate 3.5 psig inlet pressure to the pipe.   The measured consumption was 176.55 SCFM at 3.5 psig inlet pressure.  They were utilizing 80 psig inlet pressure, needless to say it was slightly overkill for the application.    At 80 psig the pipe would consume over 1,400 SCFM of compressed air.

We were able to replace the pipe with a 48″ Super Air Knife Kit that still produced the necessary force to remove the debris from the steel, and only consumed 139.2 SCFM at 80 psig.   The customer was able to save 1,252.8 SCFM and reduced the noise level drastically.   The amount of air saved is equivalent to a little more than a 300 HP compressor.   The amount of air saved is equivalent to 31.3 cents per minute of operation.

We get surprised (still) every now and then at the amount of compressed air customers are willing to use for applications. This example was a surprising one. But, now we have a customer who knows that EXAIR knows how to save compressed air and keep the plant running…while staying OSHA compliant…while reducing noise levels.

These guys took some time and spent some money to make this custom homemade blow off pipe. Needless to say, something that costs more and is custom, isn’t always better.  If you have a compressed air application in house and would like to see how you can optimize it, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Supervisory Control Systems

SCS Interface

Like I like to do, I’ve been doing some reading about compressed air and compressed air control.  A few weeks ago I wrote about throughput control and I’ve been going over a case study about supervisory control systems (SCS).  These are the devices which dictate primary and secondary compressor system operation to maximize not only throughput, but efficiency too.

In the same blog mentioned above I discussed the methods used to control a compressor, and the other side of that equation is the actual controller which is giving the commands.  These supervisory type of controls are happily routed through a PLC so that, for example, when the discharge flow spikes, a suction throttle valve can be cycled on to restrict the intake flow.  A feedback loop that functions in real time, with controlled set points, can take a compressed air system to the next level.

In the photo at the top of this blog a sketch of the SCS for a hybrid system is shown.  This is from a case study which walks through the blending of a centrifugal compressor and a reciprocating compressor.  On the surface this sounds like it may be complicated and in actuality it’s extremely complicated.  Apparently the biggest problem is heat accumulating as a result of load fluctuations.  In addition to the heat load, there’s the logic needed to allow each compressor to start in sequence, independently, or manually.  For this application, the solution was found using two main lines and two sub lines of ladder logic.  Simple and clever at the same time!

SCS Ladder Logic

Do you have a similar setup to share or interest in this particular case study?  Email me at LeeEvans@EXAIR.com and we can correspond directly.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Seeing is Believing

My wife and I are searching for our first home this week, which has been an eye-opening experience in many ways.  There are so many things that you have to learn about financing, home inspection, layouts, locations and insurance.  There is insurance or warranties for the home, title, and asbestos, but that is for another day.

The thing that my wife and I both noticed is that we wouldn’t look at any houses that didn’t have pictures available.  We just assumed that if they didn’t have pictures available the place wasn’t worth our time.  The one house without pictures that we did visit was disaster.  The one photo of the outside of the house was very old, but there were no pictures of the inside of the house. When we got a closer look at the outside of the house, the paint was peeling, the yard was a mess, and the screen door was locked.  We couldn’t get inside to see the rest of the house.  This leads me to be very hesitant to consider any purchase without seeing at least a photo of the unit.  If you are trying to sell a product and you don’t have photos readily available it seems safe to assume that since it wasn’t important enough to the sellers to put the photos online, it wasn’t worth my time looking at the place or product to find out what they were trying to hide.  I’m very weary of any sale of product were I can’t see what I’m buying.

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At EXAIR.com, we provide all of the specs for our products to anyone who would like the information on our products.  In our Application Database, we feature many of the applications that we have in our thirty years of experience of making compressed air products.  The CAD Library has detailed dimensional drawings for all of our products.  Finally in the Video Library all of our products are explained and shown in action.  We strive to provide you the most information about our products  available.  Furthermore, we allow you to take advantage of a 30 day trial on all cataloged products – not only can you see it first, you can use it in your application!Capture

Dave Woerner
Application Engineer
davewoerner@exair.com
@EXAIR_DW

Summer…Here For A Limited Time…

All good things must come to an end, they say, and this summer is no exception.  My sons returned to school this week, both attending the same school, on the same schedule, until my eldest enters high school next year.  This coming Monday is Labor Day, the Official© End of Summer.  And that means that our Boy Scout Troop will start wearing their “Class A” uniforms, instead of the “Class B” t-shirts that are authorized for June-August meetings.

In most of the Midwest, this is also the weekend that most pool owners will “winterize” and put their covers on.  I have a good friend who purposely has a party on the 2nd or 3rd Saturday of September, to blatantly flaunt this convention, but he’s just delaying the inevitable.  I’m going anyway.

At EXAIR, we also know summer as “Cabinet Cooler Season.”  It’s no secret, or surprise, that inquiries – and sales – for Cabinet Cooler Systems will pick up when the ambient temperatures rise…that’s the “external heat load” part of the equation in action!  Of course, some places have elevated ambient temperatures even in the months that end with an “R”…places like boiler rooms, blast furnaces, bakeries, etc.  And I’ve had the pleasure to talk to callers who want to protect electrical panels in two out of three of those places, just today.

One other thing that’s coming to an end this week is our seasonal Cabinet Cooler Systems Promotion.  That’s right; you’ve got just a few more days to get a free AC Sensor with a qualifying Cabinet Cooler purchase.  So, if you’re considering a Cabinet Cooler System, now’s the time.  We can quickly and easily calculate your enclosure’s total heat load with just a few key pieces of data.  Use our online Cabinet Cooler Sizing Guide to get it to us, or email it in.  For immediate service, call us with the data…we’ll do it while you wait. These products are in STOCK and we can ship same day on orders we receive before 3:00 pm Eastern.

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Web: www.exair.com
Blog: https://blog.exair.com/
Twitter: twitter.com/exair_rb
Facebook: http://www.facebook.com/exair

Super Ion Air Knife Eliminates Static in Geotextile Manufacturing Process

Geotextiles are any permeable textile material which is used to increase soil stability, provide erosion control or aid in drainage. And there are a large variety of types of geotextile fabric available.

Our Australian distributor (Compressed Air Australia) was contacted by one such company who manufactures these materials and were having significant problems with static electricity on their production line. Operators and machine sensors were being discharged to. This basically caused an un-safe working condition which also affected reliability of the process.

The customer found EXAIR Static Eliminators and worked with our distributor to select (2) of our 30” Super Ion Air Knives to blow onto the fabric as it is being processed through a series of rollers.

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The Super Ion Air Knife blows onto the fabric from 1.5 meters away with only 2 BARG input pressure. The customer could not be happier that the Super Ion Air Knives were able to solve his static problem immediately.

The Static Eliminators were located just above an access gate and are mounted with custom brackets made by the end user to facilitate setting the proper blowing angle for maximum effect.

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Customers will often ask, “Where in my process is it best to locate the static eliminator?” The answer is that you want to locate the static eliminator at the last possible point in your process, just up-stream of where the problem is occurring. Many times, static electricity is generated at multiple points along the processing line, especially for a web-based product like fabric. Thus the strategy of locating the static eliminator in this manner reduces the number of units required to keep a process running problem free.

Neal Raker, Application Engineer
nealraker@exair.com

Cincinnati, A Great Place for Customer Service

Living in the greater Cincinnati area I often wondered where the name came from.  During the settlement of our nation, settlers named their cities after those back in their homeland. The name Cincinnati did not seem to fit that scenario though.

A little research I found that the original surveyor, John Filson  named it “Losantiville” from four terms, each of different language. It means “The town opposite the mouth of the Licking River,” “ville” is French for “city,” “anti” is Greek for “opposite,” “os” is Latin for “mouth,” and “L” was all that was included of “Licking River”.

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In 1790, Arthur St. Clair, the governor of the Northwest Territory, changed the name of the settlement to “Cincinnati” in honor of the Society of the Cincinnati, of which he was a member. The Society of the Cincinnati is an historical, hereditary lineage organization founded in 1783 to preserve the ideals and fellowship of the American Revolutionary War officers, many of whom were granted land in this area for their services.

There are other cities in the U.S. by the name of Cincinnati but none of them have developed into any significance.   Cincinnati, Arkansas –  originally buzzard roost, Cincinnati, California – was a mining town, Cincinnati, Indiana – on they county survey but no town. Cincinnati, Iowa  total population  357 and declining.

We are in a world of change. Things last only as long as they serve a purpose. Towns and municipalities come into fruition to serve  an industry. When they can no longer provided the amenities and resources for a growing industry, the industry leaves and the community dries up.

Businesses share the same fate when they lose their purpose…that is to serve the customers needs. The market and customer demand is ever-changing. When Business fails to recognize a changing market as in the case of Kodak, they  go by the way of the dinosaurs.

EXAIR is on the cutting edge of customer service. Our employees are all ingrained with the notion that we are all here to serve. As I said in a previous blog, that notion is ingrained in all EXAIR employees which is why we have been able to maintain better than 99% on-time deliveries. We listen to what the customer needs and deliver. It also is what drives our product development.

We truly appreciate the opportunity to serve you. Call us at 1-800-903-9247 and ask to speak with one of our application engineers.

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363
Web: http://www.exair.com
Twitter: http://www.twitter.com/exair_jp
Facebook: http://www.facebook.com/exair

Today We Say Goodbye

Today is a sadhappy, well let’s just say it’s a day here at EXAIR.   It is back to school time throughout most of the country and sadly enough, it is the last day of our Co-Op’s final quarter semester as a Co-Op.

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You may notice him from his star role in films such as, Escape To The Planet Of Professor Penurious, Will It Launch, Penurious 2012, What I Do, and The Professor “Raps”? I’m Speechless.   Yes, he is the first and only Co-Op here to get a face tattoo, for work purposes.   Needless to say the Co-Op program here at EXAIR is not the normal engineering Co-Op experience.

We like to think that we have given our Co-Op the experience of a lifetime.   The truth is, he has learned a good amount about compressed air and how to save it, mostly thanks to The Professor.  Below is Prof. Penurious in his casual Friday dress with the Co-Op and his trophy of things that didn’t make it through his time of use here at EXAIR.

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We all wish him a great final year at the wonderful University of Cincinnati, along with a great future even after he graduates.  Hopefully for him it will be far away from the Professor.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

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