No one likes paying their bills at the end of the month. But, if you can save yourself some money, it helps to make it a little easier. For this customer, he received a monthly bill for his compressed air.
An industrial facility consisting of four separate manufacturing plants and a power company that supplied all of them with utilities, i.e. hot water, natural gas, electricity, and compressed air. The parent company decided to reorganize and sell the entities. At the end of it, the power company was controlled by a different organization than the manufacturing plants. The power plant was contracted to still supply the utilities to the individual plants, but now they would be charged individually on a monthly basis.
Being that compressed air is one of the most expensive utilities, the general manager of a solid-state electronic plant really noticed the charge on his bill. He did an estimate on the amount of air that his equipment was using, and he compared it to the charges. There was roughly a 20% difference in the figures. Because of the excessive amount of money, he contacted EXAIR to see what we could offer.
In discussing their system, the compressed air was supplied through one 6” schedule 40 black pipe. The pipe came into the facility in the ceiling and it branched off to supply the entire shop with compressed air. He was looking for something to measure the compressed air flow with the ability to measure a cumulative amount. He could use this amount to compare to his monthly usage. He was also concerned about cutting into his compressed air line as this could cause him much downtime and additional costs. He needed something easy to install, accurate, and versatile.
I suggested our 6” Digital Flowmeter with the Model 9150 Summing Remote Display. EXAIR Digital Flowmeters are designed to measure flow continuously and accurately. You do not need to weld, cut, or disassemble pipe lines to install. With a drill guide, the Digital Flowmeter can be easily mounted onto the 6” black pipe by drilling two small holes. After that, they just had to insert the Digital Flowmeter into the holes, and tighten the clamp around the pipe. The total procedure took less than 30 minutes, so downtime was minimal. The EXAIR Digital Flowmeter measures flow by comparative analysis with thermal dispersion; so, the accuracy is very high and recalibration is not required.
With the option of the Summing Remote Display, they could attach it to the Digital Flowmeter and display the flow remotely up to 50 feet away. They mounted it on the wall next to his office for the operational functions. With a simple press of a button, it can show the current flow rates, daily flow rates, and cumulative flow rates. So, during the billing cycle, he was able to get the cumulative measurement to compare the results, and reset the counter to zero for the next month.
Believe it or not, the power company was correct in their measurements. But, not to waste an entire blog, I did have him turn the compressed air supply off after business hours to watch the flow rate. He did find his 20% difference in compressed air leakage. The Digital Flowmeter was able to measure low flows to target other problem areas in your compressed air system. Now he had another chore in leak detecting and pipe fixing.
EXAIR Optimization line has different products that can help you to get the most out of your compressed air system. With the customer above, he was able to measure his compressed air flow with the Digital Flowmeter, as well as detecting other issues. I will now have to talk to him about our Ultrasonic Leak Detector.