An Ultrasonic Leak Detector can also help to improve your monthly electric bill

Leaks cost you money

In my blog last week, “A Digital Flowmeter can help to improve your monthly electric bill”, I wrote about a company that was being charged for compressed air that was being used in the facility.  To give you the short version, a Digital Flowmeter determined that the power supply company was not miscalculating the amount of compressed air usage, but the facility had compressed air leaks.

Now that he found the issue, he focused on the next step; to find and fix the leaks in his compressed air system.  Being that EXAIR already helped him in measuring the air flow, he wondered if we could also help him to find the leaks.  And we can.  I recommended the model 9061 Ultrasonic Leak Detector.

Ultrasonic Leak Detector

Whenever a leak occurs, it will generate an ultrasonic noise.  These noises have a range of frequencies from audible to inaudible.  The frequencies in the range of 20 Khz to 100 Khz are above human hearing.  The Ultrasonic Leak Detector can pick up these high frequencies, and make the inaudible leaks, audible.  The model 9061 has three sensitivity ranges and LED display; so, you can find very small leaks at a great distance away.  This unit comes with two attachments.  The parabola attachment can locate leaks up to 20 feet (6.1 meters) away.  This was great for locating leaks in pipes that ran in the ceiling.  Once you find an area with a leak, the tube attachment could define the exact location.  When he started using it, he was amazed with the performance.  The Ultrasonic Leak Detector found 44 leaks in his facility.  He tagged all the locations for the maintenance crew to fix.

As an example for how much compressed air costs, a 1/16” diameter leak in a compressed air line will lose roughly 4 SCFM of air at 100 psig.  An air compressor needs 1 horsepower of energy to make roughly 4 SCFM of compressed air.   As you can see, it take a lot of energy to supply a small leak.  If we go one step further to equate a cost to this leak, it costs roughly $0.25/1000 SCF (SCF is Standard Cubic Foot).  Being that this company was operating 5 days per week at 24 hours, this one small hole in a compressed air line would cost him $43.20/month.  With 44 leaks throughout his plant, you can see how this could add up to be a large amount of money at the end of each month.

The EXAIR Optimization line uses different devices to help you to get the most out of your compressed air system.  With this customer, he was “throwing” money away each month.  With the Ultrasonic Leak Detector, he could now put that excess money back into the company’s “pocket” for future use.

 

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Super Air Knives Make Beer Bottle Labels Stick; EFC Optimizes Efficiency

The Super Air Knife has been featured as the cover photo of every EXAIR Compressed Air Products catalog since I got here in 2011…except for Catalog #26 in 2013, which featured the Super Ion Air Knife. BIG difference, right there.

The highlighted application photos may change from catalog to catalog, but one that always remains is the iconic (I think, anyway) image of the Super Air Knives blowing off the orange soda bottles:

This is a darn-near ‘textbook’ application for the Super Air Knives…the even, laminar flow wraps around the bottles, stripping moisture away. Among other reason why this is important, it improves the next step in the process – the labels stick better.

One of the many simple and effective ways an EXAIR Super Air Knife is commonly used.

In my younger, intemperate days, I’d join my friends at a popular watering hole to celebrate special occasions like…well, Tuesday, for example. Sometimes, there’d be a ballgame on the TV, or lively conversation, to entertain us. Other times, we’d make a game out of trying to separate the labels from the beer bottles, in one piece.

Some years later, I tried to teach my young sons this game…except with root beer bottles. It didn’t work near as well, because these labels adhered much tighter to the root beer bottles in my dining room than the ones on the beer bottles at the bar.

Some years after that (those boys are teenagers now,) I became an Application Engineer at EXAIR, and found out that this drying-the-bottles-to-make-the-labels-stick-better thing was for real, because I got to talk to folks in the bottling business who told me that the Super Air Knives had made all the difference in the world for their operation.

Just the other day, I had the pleasure of helping a caller who operates a micro-brewery, and had just installed a set of 110009 9″ Aluminum Super Air Knives for the express purpose of (you guessed it, I hope…) making their labels stick better. The only thing that could make it better, according to them, was if they could use less compressed air, and they were interested in what the EFC Electronic Flow Control could do for them.

Click here to calculate how much you can save with an EXAIR EFC Electronic Flow Control.

As a micro-brewery, their production lines don’t run near as fast…nor do they want them to…as some of the Big Names in the business. As such, there’s some space between the bottles on the filling lines, and they thought that turning the air off, if even for a fraction of a second, so they weren’t blowing air into those empty spaces, would make a difference. And they’re right…it’s a simple matter of math:

Two 9″ Super Air Knives, supplied at 80psig, will consume 26.1 SCFM each (52.2 SCFM total). This microbrew was running two 8 hour shifts, 5 days per week. That equates to:

52.2 SCFM X 60 minutes/hour X 16 hours/day X 5 days/week X 52 weeks/yr = 13,029,120 standard cubic feet of compressed air, annually.  Using a Department of Energy thumbrule which estimates compressed air cost at $0.25 per 1,000 SCF, that’s an annual cost of $3257.00*

Let’s say, though, that the micro-brewery finds that it takes one second to blow off the bottle, and there’s 1/2 second between the bottles.  The EFC is actually adjustable to 1/10th of a second, so it can be quite precisely set.  But, using these relatively round numbers of 1 second on/0.5 seconds off, that’s going to save 1/3 of the air usage…and the cost…which brings the annual cost down to $2171.00*

*As a friendly reminder that the deadline to file our USA income tax returns is closing fast, I’ve rounded down to the nearest dollar.  You’re welcome.

That means that the Model 9055 EFC Electronic Flow Control (1/4 NPT Solenoid Valve; 40 SCFM) with a current 2017 List Price of $1,078.00 (that’s exact, so you know) will have paid for itself just short of one year. After that, it’s all savings in their pocket.

If you’d like to find out how much you can save with EXAIR Intelligent Compressed Air Products, give me a call.

Russ Bowman
Application Engineer
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Super Air Knife Cleans Rotary Mesh Screen

Last week I worked with an OEM who was looking for a more effective method of cleaning the wire mesh on the rotary screeners they manufacturer. Rotary screens, also know as trammel screens (think of a washing machine drum), separate solid materials by passing the parts through a rotating perforated cylinder, typically elevated on the feed side, to help keep the material moving through to the exit side. With the spiraling motion of the cylinder, the smaller parts begin to pass through the mesh screen, where they are commonly recovered in some type of hopper or fed onto a conveyor system.

Example of a screener/trammel used to separate gravel and sand.

In this particular application, their proprietary machine design features a non-vibratory system used in separating pet foods. The screener is working as far as separation but the problem they were having was as the pet food passes through the rotating mesh cylinder, it leaves an oily residue on the screen. Due to this being a food application, they are unable to use any type of cleaning brush over concerns that some of the fibers may break loose, contaminating the finished product, so they were looking at using air as an alternative solution.

I recommended they incorporate our 48″ Stainless Steel Super Air Knife in the application. The Super Air Knife is our most efficient unit, as far as compressed air usage, using only 2.9 SCFM per inch of knife when operated at 80 PSIG supply. The end to end, high velocity airflow produced by the unit would span the 48″ width of the screen. The top of their machine is removable, so I suggested they also incorporate our Model # 9060 Universal Mounting System. The Model # 9060 provides for an easy installation as well as a simple way to change the distance and direction of the knife to provide the most effective blowoff. With the cover off, they could easily move the knife into position to perform the cleaning.

Super Air Knife mounted to Universal Mounting System. (note: longer knives require multiple systems)

If you are considering an Air Knife to use in your process and would like to discuss the application, please give us a call at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Trommel and sluicebox image courtesy of Roy Luck via Creative Common License

A Digital Flowmeter can Help Improve Your Monthly Electric Bill

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.

Monthly Bill

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.

EXAIR Digital Flowmeter

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.

EXAIR Summing Remote

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.

 

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Picture: Calculator Calculation Insurance by stevepb.  Creative Commons CC0 Public Domain

Digital Flow Meters Prevent Rework by Measuring Air Flow to a Paint Gun

EXAIR Digital Flowmeter

EXAIR Digital Flow Meters are used to measure compressed air use throughout a facility, and they can also provide preventive measurements for critical processes.

A customer of ours had a paint booth that was used to touch-up large metal panels.  Inside that paint booth, they had two, High Volume Low Pressure (HVLP) paint spray guns.  These paint guns work well as they limit the air pressure to the air cap to reduce overspray and bounce back.  With the lower air pressure, the paint can have a tendency to dry and block a portion of the nozzle.  This can affect the atomization and the lay down of the paint.  To overcome this, operators have a tendency to increase the air pressure which can create other issues in spraying, as well as using excessive paint.  They decided to install some compressed air flow meters in their compressed air lines to monitor their paint system, and with the idea to prevent quality of spray problems before they occur.  They contacted EXAIR to get a better understanding on what we can offer.

In discussing their system, I learned they had an enclosed semi-downdraft spray booth.  They had two runs of ½” NPT Schedule 40 compressed air lines that came from the mainline above.  Both compressed air lines were positioned outside the booth in the left and right back corner.  (Each HVLP spray gun had its own compressed air supply).  The compressed air pipes ran down along the wall with standoffs in the back area.  From there, it elbowed into a filtration system then into the spray booth.  The customer mentioned that he did not have much room between the wall and the spray booth.  The booth had windows located in the door about 20 feet away.  As for their HVLP spray guns, they were set up to operate at 15 SCFM and 30 PSIG.  Depending on how often the spray guns were used during the operation, the paint had a tendency to dry and start to cause blockage.  Before the operator knew it, the paint gun started to become inconsistent, causing blemishes.  They would then have to rework the panel which was costly, affecting profitability.

The 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 pipe.  They did not need to unscrew filters, piping, etc. to install these in the back corners of the spray booth.  They just had to drill two small holes, insert the two probes into the holes, and tighten the clamp.  I recommended the model 9090 1/2″ Digital Flow meter.  It has a flow range from 0 to 90 SCFM which was perfect to monitor the HVLP spray guns.  The Digital Flowmeter measures flow by comparative analysis with thermal dispersion; so, the accuracy is very high and recalibration is not required.

Summing Remote Display

Since the Digital Flowmeter was located in the back corner, we needed to get a display over to the viewing window for the operators.  As an option, EXAIR offers a Summing Remote Display, model 9150.  This display has large LED numbers that can remotely displaying the flow from the Digital Flowmeter up to 50 feet away.  They installed the Summing Remote Display and mounted it outside the viewing windows of the spray booth.  The operator could now monitor the flow of the compressed air in real time with just a glance.  Now, when they were spraying paint, they could tell when the flow was starting to decrease.  They could stop and make the necessary changes to the nozzles, reducing the need to rework product.

Being able to measure the unknowns in your compressed air system as a prevention tool, it becomes much easier to evaluate, correct, and discover issues that may occur before they get out of hand.   The EXAIR Digital Flowmeters can give you the real-time flow measurements of your compressed air system to help identify problems.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Super Air Knife Shim Design Reduces Operation Costs

A customer of ours had an application where they needed to cool and dry parts on two conveyors that ran side by side.  A single 36″ Super Air Knife was chosen to provide coverage over the full width and to simplify the air plumbing and installation.  As we learned more about the application, it was discovered that there was 10″ section in the center where the the two conveyors butted up, where no parts would pass through, and hence no air was needed.

Fortunately, the EXAIR Super Air Knives can be supplied with custom shim designs to match the air flow requirements of the application.  These shims can be of various thicknesses to increase/decrease the air flow, of alternate materials such as a stainless steel shim in an aluminum air knife to increase the temperature range, or as in this case, designed to provide specific air flow patterns.

By utilizing the special shim design, it is estimated to save $865 per shift per year in compressed air costs versus the standard configuration.  That is a significant savings, and using less compressed air is high on everyone’s priority list.

Check out the video below to learn more about the EXAIR Air Knives.

akvideo

EXAIR manufactures 3 different types of air knives, in 4 different materials, up to 108″ in length.

To discuss your application and see how an EXAIR Intelligent Compressed Air Product can help your process, feel free to contact EXAIR and one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
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Twitter: @EXAIR_BB

 

 

 

How To Solve A Problem with Compressed Air

In my (almost) six years as an EXAIR Application Engineer, I’ve learned a great many things about the capabilities of our products.  The way we do business sure does make it easy:

  • We readily share application information, as a team.  If you ask me a question, you’re asking all of us.  It does neither of us any good if I tell you something MIGHT work if one of my team knows it WON’T – or if someone knows what else DOES work.  If we can offer a solution, we will.
  • We’ll test your product, free of charge.  This is a popular way of finding out which Line Vac is best for conveying a particular product, for example.
  • If you’re considering a quiet, safe, and efficient EXAIR product as an upgrade, we’ll test your current product in our award winning Efficiency Lab, so you can compare accurate performance data and analyze the expected benefits…which can be dramatic.  Try us on that.
exair-testin

Line Vac conveyance rate testing (left;) Efficiency Lab testing (right.)

 

  • We’ll let YOU test our product, risk-free.  All catalog products come with a 30 Day Unconditional Guarantee.  We invite you to put it through its paces for up to a month.  If it’s not working out, we’ll arrange return for full credit.
  • We’ll do the math.  But first, a disclaimer: strictly comparing the force or flow of an engineered product to an open-end blow off won’t always tell the tale.  Our Intelligent Compressed Air Products are creating a laminar flow which won’t generate as high of a force/thrust as open-end blowing (which is turbulent by nature,) but is MUCH more conducive to efficiency and noise reduction, as well as similar (if not improved) performance.  But back to the math: if you know the metrics you need to meet for spot cooling (like a Vortex Tube, Adjustable Spot Cooler, Cold Gun, etc.) or for liquid spraying (the liquid flow rate and/or pattern size & shape from an Atomizing Spray Nozzle, for instance,) or the heat load that a Cabinet Cooler System can handle, we’ll do the calculations and specify the appropriate product.

Regardless of the application, if it can be solved with compressed air, it’s very likely that we have a great solution.  Call me to find out how we can help.

Russ Bowman
Application Engineer
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