Six Steps to Optimization, Step 4 – Turn Off Your Compressed Air When Not in Use

Step 4 of the Six Steps To Optimizing Your Compressed Air System is ‘Turn off the compressed air when it isn’t in use.’  Click on the link above for a good summary of the all the steps.

6 Steps from Catalog

Two basic methods to set up a compressed air operation for turning off is the ball valve and the solenoid valve. Of the two, the simplest is the ball valve. It is a quarter turn, manually operated valve that stops the flow of the compressed air when the handle is rotated 90°. It is best for operations where the compressed air is needed for a long duration, and shut off is infrequent, such as at the end of the shift.

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Manual Ball Valves, from 1/4 NPT to 1-1/4 NPT

The solenoid valve offers more flexibility. A solenoid valve is an electro-mechanical valve that uses electric current to produce a magnetic field which moves a mechanism to control the flow of air. A solenoid can be wired to simple push button station, for turning the air flow on and off – similar to the manual valve in that relies on a person to remember to turn the air off when not needed.

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A Wide Array of Solenoid Valve Offerings for Various Flows and Voltage Requirements

Another way to use a solenoid valve is to wire it in conjunction with a PLC or machine control system. Through simple programming, the solenoid can be set to turn on/off whenever certain parameters are met. An example would be to energize the solenoid to supply an air knife when a conveyor is running to blow off parts when they pass under. When the conveyor is stopped, the solenoid would close and the air would stop blowing.

The EXAIR EFC (Electronic Flow Control) is a stand alone solenoid control system. The EFC combines a photoelectric sensor with a timer control that turns the air on and off based on the presence (or lack of presence) of an object in front of the sensor. There are 8 programmable on/off modes for different process requirements. The use of the EFC provides the highest level of compressed air usage control. The air is turned on only when an object is present and turned off when the object has passed by.

efcapp
EFC Used To Control Bin Blow Off Operation

By turning off the air when not needed, whether by a manual ball valve, a solenoid valve integrated into the PLC machine control or the EXAIR EFC, compressed air usage will be minimized and operation costs reduced.

If you have questions about the EFC, solenoid valves, ball valves or any of the 15 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer
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Candy Producer Saves $4600 in Compressed Air with EXAIR’s EFC

A few months ago, I took a phone call from a manufacturing engineer who worked at a large candy production facility here in the United States. Extra chocolate was dripping out of the candy molds onto the conveyor belt below.  Within a few hours the belt was dirty enough they would have to stop the line and clean the residual chocolate off the belt. 

The best solution I found was a 72” 316 Stainless Steel Super Air Knife. It worked great when powered at 60 psig inlet pressure. The laminar flow of the Super Air Knife was perfectly suited for this application.  The knife was mounted between the mold and the belt to help solidify and blowoff the excess drips of chocolate. There was one drawback, the Super Air Knife was not needed to blow the belt continuously and the continuous demand was not desirable during peak production.

The simple solution for this was the EXAIR Electronic Flow Control, the EFC minimizes compressed air use by turning off the air when a sensor is triggered. Since there was a 4.5-minute time gap between each mold set this was a great solution. When the photoelectric eye saw a mold, it then told the solenoid valve to open and supply the knife with compressed air for 30 seconds while the mold was open and the excess chocolate would be dripping. See the Savings calculations below;

efcapp

Without using the EFC

(* Using $ 0.25 per 1000 SCFM used)

  • 72” Super Ion Air Knife = 165.6 SCFM @ 60 PSIG
  • 165.6 SCFM x 60 minutes x $ 0.25 / 1000 SCFM = $ 2.48 per hour
  • $ 2.48 per hour x 8 hours = $ 19.84 per 8-hour day
  • $ 19.84 x 5 days = $ 99.20 per work week
  • $ 99.20 per week x 52 weeks =$5,158.40 per work year without the EFC control

 

With the EFC installed (turning the compressed air off for 4 minutes 30 seconds with a 30 second on time = 6 minutes/hour compressed air usage)

  • 165.6 SCFM x 6 minute x $ 0.25 / 1000 SCFM = $ 0.25 per hour
  • $ 0.25 per hour x 8 hours = $ 2.00 per 8-hour day
  • $ 2.00 x 5 days = $ 10.00 per work week
  • $ 10.00 per week x 52 weeks = $520.00 per work year with the EFC control 

$ 5,158.40 per year (w/o EFC) – $ 520.00 per year (w/ EFC) = $4,638.40 projected savings per year by incorporating the EFC.

EFC287x250

This example illustrates, clearly, why choosing the EFC is a good idea. It has the ability to keep compressed air costs to a minimum and saves compressed air for use within other processes around the plant. With this type of compressed air savings, the unit would pay for itself in less than 3 months.

If you would like to see how we might be able to improve your process or provide a solution for valuable savings, please contact one of our Application Engineers.

Jordan Shouse
Application Engineer
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General Good Ideas For The Compressor Room

When considering your compressor room all too often the phrase applies “out of sight and out of mind”.  Of course, we all know that is not a good approach to the compressor room or really anything in life.  Unfortunately, many of us take for granted that very system that delivers the power to keep our machines, equipment and tools operating.

Air Compressor
Compressor Room Located Outdoors

So, what can we do keep the ‘lungs” of our plants performing reliably and efficiently?  Since this Blog is about “General Good Ideas For The Compressor Room”, I have some points below for your consideration.

  • Ideally the compressor room should be centrally located to minimize the length of the pipes and allows for easier noise control. With long piping runs leaks become more likely and frictional losses are increased.
  • The compressor room should be sized to allow for easy maintenance and future expansion.
  • For efficient operation air compressors need clean intake air. Intake air that is dusty, dirty or contains gaseous contamination will reduce the efficiency and possibly the longevity of your equipment.
  • The compressor room needs adequate ventilation since air compressors generate significant heat. If excessive heat is allowed to build up it reduces the efficiency of the air compressor raising utility costs, causes compressor lubricant to break down prematurely that could possibly result in increased maintenance and compressor failure.
  • What is the velocity of the air through the main headers? If the speed is above 1200 FPM many dryers have reduced efficiency and speeds greater than this can also carry moisture past the drainage drop legs.
  • Excess friction caused by too small of a diameter piping creates pressure loss, which reduces efficiency and if the compressor is ran above its pressure rating to overcome the frictional losses increases energy consumption, maintenance costs and down time.

Now that your compressor room is shipshape in Bristol fashion, you might think that all is well.  While that may be true, chances are there are other significant additional savings to be had.  EXAIR specializes in point of use compressed air products that are highly efficient and quiet!  If you have any blow-offs that are open tube or howl as loud as the ghost of Christmas yet to come, check out EXAIR’s Super Air Nozzles.  They are highly efficient and quiet, in fact they meet OSHA Standard 29 CFR – 1941.95 for maximum allowable noise and OSHA Standard 29 CFR 1910.242 (b) for higher than 30 PSIG blow-off pressure.  All of EXAIR’s compressed air products are engineered to minimize compressed air consumption and take advantage of the Coanda effect.  Simply stated EXAIR’s highly engineered, intelligent designs entrain (combine) ambient air with the compressed air supply which saves you money!

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EXAIR Super Air Nozzle entrainment

EXAIR also offers the Ultra Sonic Leak Detector.  Simply point the device at a suspected leak which are typically found at unions, pipes, valves and fittings from up to 20’ away.   Plants that are not maintaining their plumbing can waste up to 30% of their compressors output through undetected leaks.

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EXAIR Ultra Sonic Leak Detector

EXAIR has a complete optimization product line that the Ultra Sonic Leak Detector is in that includes the Electronic Flow Control, Digital Flowmeter’s and a Digital Sound Level Meter.  All designed to either increase the safety or efficiency of your compressed air usage.

EXAIR has 15 other product lines all designed to increase your process efficiency and save you money by using you compressed air supply efficiently.  Why not visit the EXAIR website or call and request a free catalog?

When you are looking for expert advice on safe, quiet and efficient point of use compressed air products give us a call.   We would enjoy hearing from you!

Steve Harrison
Application Engineer
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Image taken from the Best Practices for Compressed Air Systems Handbook, 2nd Edition

Ultrasonic Leak Detector: Because Leaks Won’t Find (Or Fix) Themselves

I once worked in an equipment repair shop with a small and simple compressed air system…just a 5HP single acting piston compressor that sat atop a 50 gallon tank, in the corner by “The Big Truck”. The majority of our work was field service, and management was big on maintaining our service trucks, so we checked tire pressures every Monday morning as we rolled out, and kept a tire chuck handy to ensure proper inflation. It was also used to supply a couple of air guns that were used at our drill press and soldering/assembly station. One morning, I noticed the air compressor was running when I arrived…I thought it was odd, because I knew for a fact it hadn’t been used in at least 16 hours, but that compressed air went someplace, right? We had a leak. Well, at least one.

This was mid-December, and the week between Christmas and New Year’s Day was characteristically slow, and typically devoted to a thorough shop cleaning. We also took the opportunity to get some bottles of soapy water and check for leaks at the handful of pipe fittings that comprised the system…for the uninitiated, if you have a leaky fitting, the escaping air blows bubbles in the soapy water (a cheap, messy way in other words). We found some bubbling, undid those fittings, cleaned them, and applied fresh pipe thread sealant (I don’t want to start any arguments, but I was taught that tape is more of a thread protectant than an effective sealing agent) and, in addition to replacing a couple of well-worn hoses, we were up and running.  And we never heard the compressor running first thing in the morning again.

Not all compressed air systems are as simple as that, though.  Many go from a room with several large & sophisticated air compressors, to corners of every building on the grounds.  Through valves & manifolds, to cylinders, machinery and blow offs, with more connections than you could soap-and-water check in a month.

In those cases, the EXAIR Model 9061 Ultrasonic Leak Detector makes short(er) work of finding the leaks.  With both visual (LED’s on the face) and audible (headphones) indications, even very small leaks are easy to detect with the parabola installed.  The precise location can then be found with the tubular extension.

EXAIR Ultrasonic Leak Detector “hones in” on the exact location of a leak in a compressed air line.

You’ll still have to fix the leaks yourself, but finding them is oftentimes more than half the battle.  And, once fixed, it can be worth a million (cubic feet of compressed air, that is.)

EXAIR’s Ultrasonic Leak Detectors are not only useful for finding compressed air leaks; they’re popular in a variety of other areas:

Additionally, they can be used to identify faulty bearings, brake systems, tire & tube leaks, engine seals, radiators, electrical relay arcing…anything that generates an ultrasonic sound wave.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Cleaning Glass After a Cutting Machine, Super Air Knives to the Rescue

Glass cutting machine

A glass cutting facility was having issues with small shards of glass leaving the cutting machine.  After scribing and breaking individual panes, small pieces of glass would come apart from the edges of the glass.  These glass fragments would go downstream causing cuts on transport wheels as well as creating blemishes in the surface of the glass.  They needed a non-contact way to clean the glass as the panes left the cutting machine.

Their operation started with a 156” (3.96m) wide sheet of glass placed at the front of the cutting machine.  The glass was moved into the machine where it would scribe different dimensions and sizes to minimize any scrap.  As the machine was scribing, a protective separator would close off the cutting machine to protect the operators.  Once finished, the protective separator would open, allowing the glass sheet to exit on the other side of the machine.  As the glass was coming out, a break device would “crack” the glass panes on the scribed lines.  They wanted to clean the surface as the glass sheet was coming out to keep the fragments in the machine.

EXAIR Super Air Knife model 1100108

EXAIR has always been the leader in manufacturing the longest air knives in the industry.  The EXAIR Super Air Knives can be manufactured up to 108” (2.74m) long in one continuous length.  But, for this application, we had to tackle it in a different manner to reach across the entire width of 156” (3.96m).  EXAIR had a solution, the model 110900 Coupling Bracket Kit.  This can combine aluminum Super Air Knives for additional length.  It has all the hardware to securely attach the Super Air Knives end-to-end to get a continuous air flow along the entire length.  With the Coupling Bracket Kit, I recommended a model 110072, 72” (1.83m) long aluminum Super Air Knife with a model 110084, 84” (2.13m) aluminum Super Air Knife.  The customer was now able to clean the entire section of glass just in front of the exit of the cutting machine.  With the air knives directed to blow at a slight angle in the counter-flow direction, this non-contact form of cleaning was able to keep the shards inside the machine without scratching the surfaces.

Air Knife Coupling Bracket Kit

The Super Air Knives are designed to be the most efficient air knives in the market place.  It has a 40:1 amplification ratio which entrains 40 parts of ambient air to every 1 part of compressed air.  So, it will save you compressed air which in turn, will save you money.  Here at EXAIR, we like to go one step further for our customers.  EXAIR offers an Optimization product line to save the customer even more money, to reduce even more waste, and to become even more energy efficient.  For this customer above, I recommended an Electronic Flow Control, EFC.  This uses a photoelectric sensor to turn on a system only when compressed air is needed.  It is a small PLC unit with a timer control.  I recommended the model 9064-2 which has two solenoid valves to operate each Super Air Knife.  The photoelectric sensor can be adjusted for light and dark object, but for glass, we had to look for an alternative way.  I was able to have the customer place it on the protective separator.  Now, the Super Air Knives will remain turned off until after the scribing was completed. When the separator moved up, it would trigger the timing operation of the EFC.  By adding the EFC to their system, they were able to reduce the amount of compressed air by one-half.

click on picture for mor information

If you have a wide area that needs to be blown off, cooled, or dried; EXAIR may have a solution for you.  For the customer above, EXAIR was able to combine Super Air Knives with optimization for an efficient and effective way to clean a wide surface.  If you would like to discuss a solution for your “wide” application, you can contact an Application Engineer at EXAIR to discuss.

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

The Value Of A Pressure Regulator At Every Point Of Use

regulator
EXAIR Pressure Regulator

To understand the value of a having a Pressure Regulator at every point of use we should start with identifying the two types of Pressure Regulators, Direct Acting & Pilot Operated.  Direct Acting are the least expensive and most common (as shown above), however they may provide less control over the outlet pressure, especially if they are not sized properly.  However when sized properly they do an outstanding job.  Pilot Operated Regulators incorporate a smaller auxiliary regulator to supply the required system pressure to a large diaphragm located on the main valve that in turn regulates the pressure.  The Pilot Operated Regulators are more accurate and more expensive making them less attractive to purchase.  The focus of this Blog will be on the Direct Acting Pressure Regulator.

The Direct Acting Pressure Regulator is designed to maintain a constant and steady air pressure downstream to ensure whatever device is attached to it is operated at the minimum pressure required to achieve efficient operation.  If the end use is operated without a regulator or at a higher pressure than required, it result’s in increased air demand and energy use. To clarify this point, if you operate your compressed air system at 102 PSI it will cost you 1% more in electric costs than if the system was set to run at 100 PSI! Also noteworthy is that unregulated air demands consume about 1% more flow for every PSI of additional pressure.  Higher pressure levels can also increase equipment wear which results in higher maintenance costs and shorter equipment life.

Sizing of the Air Regulator is crucial, if it is too small to deliver the air volume required by the point of use it can cause a pressure drop in that line which is called “droop”.  Droop is defined as “the drop in pressure at the outlet of a pressure regulator, when a demand for compressed air occurs”.  One commonly used practice is to slightly oversize the pressure regulator to minimize droop.  Fortunately we at EXAIR specify the correct sized Air Regulator required to operate our devices so you will not experience the dreaded “droop”!

Standard Air Knife Kit
EXAIR Standard Air Knife Kit Which Incudes Shims, Properly Sized Pressure Regulator & Filter Separator

Another advantage to having a Pressure Regulator at every point of use is the flexibilty of making pressure adjustments to quickly change to varying production requirements.  Not every application will require a strong blast sometimes a gentle breeze will accomplish the task.  As an example one user of the EXAIR Super Air Knife employs it as an air curtain to prevent product contamination (strong blast) and another to dry different size parts (gentle breeze) coming down their conveyor.

EXAIR products are highly engineered and are so efficient that they can be operated at lower pressures and still provide exceptional performance!  This save’s you money considering compressed air on the average cost’s .25 cents per 1000 SCFM.

Super Air Knife Performance
EXAIR Super Air Knife Performance Specifications At 5 Different Pressures.

If you would like to discuss Air Regulators or quiet and efficient compressed air devices, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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Business Benefits Of Compressed Air Efficiency

The primary business benefits of an efficient air compressor system are reduced operational costs, reduced maintenance and increased up-time.  With that being said, is your compressed air system costing you more than you think it should?  Are you having failures, pressure drops, inadequate volume and/or pressure?  You might think from these issues that your system has seen better days and is ready to be replaced.  However, it is possible that your existing tried and true compressor system has more life left in it than you think and with a few simple steps you could have it performing like a champ again!

It is estimated that typically plants can waste up to 30 percent of their generated compressed air and that cost is substantial.  Considering the average cost to generate compressed air is .25 cents per 1000 SCFM, that translates into .075 cents for every .25 cents spent!  Considering that energy costs have doubled in the last five years, it couldn’t be more timely to make your air compressor system more efficient.

So just where is all this waste occurring?  The largest source of compressed air energy waste is from unused or leaked compressed air and that is followed by line pressure drops, over pressurization and inadequate maintenance of the compressor.

So how can you identify this issues in your system?

1). Finding leaks can be accomplished by several methods such as soapy water applied to a suspected joint or connection or the EXAIR Ultrasonic Leak Detector.   It is a high quality instrument that can locate costly leaks in your compressed air system.  When a leak is present and audible tone can be heard in the supplied headphones and the LED display will light.  This testing can be done up to 20′ away so need to get on a ladder!

Leak Detector

2). Pressure drop is caused by is caused by the friction of the compressed air flowing against the inside of the pipe and through valves, tees, elbows and other components that make up a complete compressed air piping system.  If the piping system is to small, the flow (volume) will not be sufficient and the devices will not operate properly.  The volumetric demand would need to be added up to determine if the piping is of sufficient diameter to flow the required volume.  EXAIR’s Digital Flow Meter is an easy way to monitor compressed air consumption and waste.  The digital display shows the exact amount of compressed air being used, making it easy to identify piping that may be undersized.  Installing one on every major leg of your air distribution system to constantly monitor and benchmark compressed air usage is a fast and efficient way to see what your volume through that distribution leg is.

Flow Meter

3). Over pressurization is also an issue, as the pressure is raised to account for high demand periods, system leaks and pressure drops. Unfortunately operating at higher pressures can require as much as 25 percent more compressor capacity than needed, generating wasted air which is called artificial demand.

You can reduce the leakage rate by running the compressor at lower pressures. If you’re short on air, don’t turn up the pressure. Run your compressor at no higher pressure than what you process requires. To relieve peak demands on your system consider the EXAIR Receiver Tank.  It store’s compressed air during low usage times and releases it when the demand is increased without working your air compressor system harder.

receiver_tank

4). Finally, a preventative maintenance (PM) program will need to be implemented to keep the air compressor system running properly.  Two items that are often neglected are the drive belts and filters.  Loose belts can reduce compressor efficiency and dirty filters allow dirt to get through the system and cause pressure drops.  EXAIR has replacement elements for our line of filter separators to keep you air clean and line pressure down.

By increasing your awareness of the health of your air compressor system and implementing a PM program you can significantly reduce your costs from wasted energy and avoid costly down time from an out of service air compressor.

If you would like to discuss improving your compressed air efficiency or any of EXAIR’s engineered solutions, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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