Control Air Pressure at the Point of Use with EXAIR’s Pressure Regulators

In any application necessitating the use of compressed air, pressure should be controlled to minimize the air consumption at the point of use. Pressure regulators are available to control the air pressure within the system and throttle the appropriate supply of air to any pneumatic device. As the last of the six steps to optimizing your compressed air system, controlling air at the point of use can often be overlooked. To help you achieve this, EXAIR offers a line of point of use pressure regulators to make sure you’re operating at the optimal pressure for your application.

Pressure regulators utilize a control knob that is turned to either increase/decrease tension on a spring. The spring puts a load on the diaphragm which separates internal air pressure from the ambient pressure. Typically made of a flexible rubber material, these diaphragms react very quickly to changes in the air supply. By either increasing or decreasing the flow of air based on the load on the diaphragm, downstream pressure remains fairly constant.

Regulator Internal

While one advantage of a pressure regulator is certainly maintaining consistent pressure to your compressed air devices, using them to minimize your pressure can result in dramatic savings to your costs of compressed air.

As pressure and flow are directly related, lowering the pressure supplied results in less compressed air usage. EXAIR recommends operating your Intelligent Compressed Air Products at the minimum pressure necessary to achieve a successful application. If you notice a desirable result at a pressure of 60 PSIG, or even less, there’s no need to run full line pressure. In-line point of use pressure regulators are the simplest and most reliable way to allow you to dial down the pressure to any compressed air operated product. For example, a Model 110012 Super Air Knife will consume 42 SCFM when operated at 100 PSIG. When the pressure is reduced to 60 PSIG, this drops to just 27.6 SCFM. That’s a 34% reduction in compressed air usage, just by dialing down the pressure at the point of use!

When selecting a pressure regulator for your application, it’s critical that it is appropriately sized to supply adequate volume to the point of use devices downstream. Doing so, minimizes the risk of experiencing “droop”. Droop is a decrease in outlet pressure from the specified setting due to an increase in flow rate.  Droop occurs when the demand at the point of use exceeds the volume of air that the regulator can supply. By ensuring the pressure regulator is rated to deliver sufficient volume of air, you’ll reduce the chances of experiencing droop. EXAIR offers pressure regulators in kits along with many of our products, we’ve done the hard part for you and made sure they’re properly sized!

If you’re looking for ways to help lessen the demand on your compressor, EXAIR’s team of Application Engineers will be happy to help. Reach out to us via phone, chat, or e-mail and see for yourself just how easy it can be to start saving compressed air!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

EXAIR Products: The Importance of Oil Removal Filters

Oil Removal Filter
Oil Removal Filters

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.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD