When operating any of your Intelligent Compressed Air Products, something that often gets overlooked is the importance of delivering clean, dry air to those point-of-use products. Many of our products have very tight orifices to help reduce the volume of compressed air they consume. In addition, most have no moving parts to wear out and require no maintenance. That is, unless you’re using unfiltered compressed air.
Rust and scale are commonly found within the distribution system inside your facility. Old iron pipe and receiver tanks are the common culprits. A common misconception is that the air is already filtered as it exits the compressor. While this may be true, there’s still places in the distribution system that can cause issues downstream.
To eliminate the hassle of taking things apart to periodically clean, EXAIR recommends installing a point-of-use filter for all of our Intelligent Compressed Air Products. Kits are available for purchase that come with a properly sized filter to ensure your air is sufficiently clean. To see how quickly debris can clog your products, check out my video below demonstrating the difference between dirty and clean air with a Model 110006 6″ Super Air Knife.
If you’ve already purchased and installed products without filters, it’s never to late to go back and install one. Contact an EXAIR Application Engineer today and we’ll be happy to help you determine the proper size for the volume of air you’re products need.
If you need a deeper understanding about how EXAIR’s products can be applied and help your process or product, feel free to contact us and we will do our best to give you a clear understanding of the benefits when using our engineered compressed air products. We can also explain proper implementation of accessory items such as compressed air filters and regulators.
Why should you consider a Pressure Regulator when designing your compressed air system? As many know, our products and those of other product manufacturers have a certain set of specifications regarding performance at stated input pressures. But what if your application doesn’t require that “full, rated performance”? Maybe instead of needing two pounds of force, you only need one pound? Sometimes more force does not produce the desired result for an application. By that, I mean you cause damage to the target or other surrounding items in the application. Or, perhaps blowing too hard (or vacuuming too hard in the case of a Line Vac or E-vac) might cause the vessel or the material you are picking up to collapse or deform (due to too much power).
There is also the concern about using more energy than one really needs to in order to achieve the desired effect in an application. In other words, if you can achieve your goals with only 40 PSIG, then why would you ever use 80 PSIG to accomplish the goal? By reducing your compressed air from 80 down to 40 PSIG, you can easily reduce the air consumption of the “engineered” solution by another 40% or more. Once you have installed engineered air nozzles to reduce compressed air on blow off applications, a pressure regulator can fine tune the pressure to save even more energy.
Then there is the issue of taking advantage of the pressure differential (from 80 down to 40 PSIG) that creates a little bit more air volume capacity. At 80 PSIG, your compressed air to free air volume ratio is 6.4:1. At 40 PSIG, it is only 3.7:1. The net effect is you effectively have an overall larger volume of air you can use for other applications in your facility. By reducing compressed air pressure of your demand applications, you may be able to reduce over all compressor discharge pressure. Reducing compressor discharge pressure by 2 PSIG also reduces required input power by 1 percent – so keep your pressure as low as possible!
Regulating pressure is definitely warranted given the benefits that compliment the operation of the core EXAIR products.
If you need a deeper understanding about how EXAIR’s products can help your application, feel free to contact us and we will do our best to give you a clear understanding of all the benefits that can be had by our products’ use as well as proper implementation of accessory items such as compressed air filters and regulators.
EXAIR’s Intelligent Compressed Air Products have no moving parts and require no maintenance. Most EXAIR products require no direct maintenance, and will continue to require no maintenance if the supplied air is clean. Keeping air clean, in EXAIR’s case, can be done with a simple water/dirt or oil filter separator close to the application of the product – usually within 10 feet. The reason for the filters is that many products have very tight orifices that could get clogged from contaminants such as particulate, condensate, and lubricant.
Oil is commonly present in a compressed air supply, whether that’s intentional or not. Many air compressors are lubricated by a constant supply of oil, inevitably some of this oil ends up in the air supply. As the compressor wears, more oil is permitted to pass and ends up in the distribution system. While this is kept to a minimum with proper maintenance, it is impossible to prevent unless using an oil-free compressor.
Sometimes oil is present in the air supply intentionally. Many pneumatic devices require a precise amount of oil to keep the internal moving parts lubricated. In the case of EXAIR Intelligent Compressed Air Products, we recommend particulate-free, moisture-free, and oil-free air.
EXAIR offers a line of Oil Removal Filters. These coalescing style filters are used to remove very fine water vapor as well as any residual oil. These filters are highly recommended to be installed just prior to dryers that contain a media that would be compromised by lubricant passing through it. Coalescing filters utilize an element typically made up of glass fibers that “coalesce”, or combine, the fine water vapor and oil aerosols until the droplet size becomes large enough that it drops off into the filter bowl. With a coalescing filter, the most common cause of pressure drop increase is due to particulate clogging the element. Because of this, a particulate filter should always be installed just prior to coalescing filters. Check out this video demonstrating an Auto-Drain Filter and Oil-Removal Filter in action:
Without filtration, oil in the air supply will pass through the point of use device and into your product or process. The elimination of this problem is such a simple solution. Don’t neglect your compressed air system and ensure you’re delivering clean, dry, oil-free air to all of your EXAIR Intelligent Compressed Air Products.