Does a 38 Day Simple ROI Sound Good? Use Engineered Compressed Air Blowoff Products!

After getting a baseline measurement of the air consumption in your facility and locating and fixing leaks in your system, it’s time to begin implementing some changes. Step 3 of the 6 Steps to Optimizing Your Compressed Air System covers upgrading your blowoff, cooling, and drying operations using engineered compressed air products.

sixsteps_3

This step can have the most impact when it comes to your bottom line. The energy costs associated with the generation of compressed air make it one of the most expensive utilities for any industrial environment. Because of this, we need to ensure that the places in your facility that are using compressed air are doing so efficiently.

EXAIR manufactures a variety of products that can help to ensure you’re using your compressed air in the best way possible. What it may seem simple, easy, and cheap to use something like an open-ended pipe or tube for blowoff, the fact of the matter is that the volume of air that these homemade solutions use quickly make them more expensive. Super Air Nozzles have been designed to entrain ambient air along with the supplied compressed air, allowing you to achieve a high force from the output of the nozzle while keeping compressed air usage to a minimum. In addition to saving air, they’ll also provide a significant reduction in overall sound level.

drilled pipe
homemade drilled pipe

Another product that can be used to increase the efficiency of your blowoff processes is the Super Air Knife. Available in lengths ranging from 3”-108” and in a variety of materials, the Super Air Knife is the ideal replacement for inefficient drilled pipes. Again, it may seem cheaper to just drill a few holes in a pipe whenever you need to cover a wide area but the volume of air consumed in addition to the incredibly high sound level will quickly drain your compressor. The Super Air Knife is also designed to entrain ambient air, at a rate of 40:1! Allowing you to take advantage of the free ambient air in addition to the supplied air.

Let’s compare the costs difference between a homemade drilled pipe and EXAIR’s Super Air Knife. The Super Air Knife has a precisely set air gap across the full length of the knife, allowing for an efficient and quiet laminar airstream. When compared to a drilled pipe, the air consumption is dramatically reduced as is the sound level. For example, let’s take an 18” section of drilled pipe, with 1/16” diameter holes spaced out every ½”. At 80 PSIG, each hole consumes 3.8 SCFM. With a total of 37 holes, this equates to a total of 140.6 SCFM.

3.8 SCFM x 37 = 140.6 SCFM

A Super Air Knife, operated at 80 PSIG with .002” stock shim installed will consume a total of 2.9 SCFM per inch of knife. An 18” SAK would then consume just 52.2 SCFM.

2.9 SCFM x 18 = 52.2 SCFM

140.6 SCFM – 52.2 SCFM = 88.4 SCFM saved 

Replacing an 18” drilled pipe with a Super Air Knife represents a total reduction in compressed air consumption of 63%! How much does this equate to in $$$? A reasonable average of cost to generate compressed air is about $0.25/ 1000 SCF. Let’s assume just a 40hr workweek:

88.4 SCFM x 60 mins x $0.25/1000 SCF = $1.33/hr

$1.33 x 40hr workweek = $53.20 USD

$53.20 x 52 weeks/year = $2,766.40 USD in yearly savings

The 2019 list price on a Model 110018 Super Air Knife is $397.00. By replacing the homemade solution with an 18” Super Air Knife, the return on investment is just over 38 working days of an 8-hr shift. If your plant runs multiple shifts, or works on weekends, it pays for itself even quicker.

Not only are these homemade solutions expensive to operate, they’re not safe either. Familiarize yourself with both OSHA 29 CFR 1910.95(a) and 29 CFR 1910.242(b) and you’ll learn just how expensive it can be if you were to be found using these devices during a random OSHA inspection. Make sure you’re utilizing the most expensive utility as efficiently and safely as possible. If you need help with determining which products are best suited for your application, give us a call. Our team of Application Engineers is ready to help!

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

Benefits of an Ultrasonic Leak Detector

Ultrasonic Leak Detector

As margins get tighter and cost of manufacturing climbs, industries are looking into different areas to be more efficient.  A big focus nowadays is in their compressed air system.  Why is this?  Manufacturers are starting to realize that it takes an abundant amount of electricity to make compressed air.  That is why EXAIR manufactures compressed air products for optimization to get the best efficiency.  But what many manufacturers don’t realize is that quiet little hissing sound from there compressed air lines is costing them much money.   That is why EXAIR has the Ultrasonic Leak Detector.

Finding leaks will save you money

Energy Star, a federal voluntary program ran by the Environmental Protection Agency, offers energy-efficient solutions.  EXAIR has partnered with Energy Star because it underscores our commitment to improve energy savings.  They even wrote an excerpt about compressed air leaks here: Energy Tips: Minimize Compressed Air Leaks.  With compressed air leaks, it can be as much as 30% of your compressed air usage.

When a leak occurs, it emits an ultrasonic noise.  The EXAIR Ultrasonic Leak Detector can pick this up.  It has a frequency range from 20 KHz to 100 KHz, above human hearing, so it can make the inaudible leaks, audible.  With three sensitivity ranges and LED display, you can find very minute leaks.  It comes with headphones and two attachments; the parabola attachment to find leaks up to 20 feet (6 meters) away, and the tube attachment for local proximity to define the exact location of the leak.

In the Energy Tips from Energy Star, they reference estimated leak rates and costs associated with these leaks.  They also recommend a leak prevention program with reference materials to help improve energy savings.  As part of that program, an Ultrasonic Leak Detector is the best way to begin.

Checking pipe fittings

To tell a common success story about the Ultrasonic Leak Detector, an EXAIR customer had a 50-horsepower air compressor.  It started to overwork, overheat, and occasionally shut down.  He thought that he would need to buy a larger air compressor to keep his plant running.  In discussing his problems and requirements, he decided to purchase an Ultrasonic Leak Detector from EXAIR to check for leaks as a possible cause.  He checked every fitting and connection in his facility.  When he finished checking the compressed air system, he found 91 leaks.  (You will be surprised with your system if it is not well maintained).

If we look at a very small 1/16” (1.6mm) diameter hole at 80 PSIG (5.5 bar), it will cost you $360 a year per leak (based on 6000 working hours per year).  Thus, 91 leaks at $360/year will equal $32,760 per year.  After the fittings were reworked with piping compound, the compressor was back operating in a normal range.  There was no need to buy a larger air compressor with capital funds, and he was able to save $32,760 a year by finding and fixing the leaks.

As a little secret with the Ultrasonic Leak Detector, it can do more than find compressed air leaks.  Any issue that creates an ultrasonic noise, the Ultrasonic Leak Detector can find it.  This will include air damper seals, circuit breakers, cracked rubber belts, gas burner leaks, refrigerant leaks, worn bearings, and air brake systems on trucks.  It is a handy tool to find potential issues or problems in other areas other than compressed air systems.

For optimization of your compressed air system, it is very important to find and correct leaks in your piping system.  The Ultrasonic Leak Detector can help you do that.  It is an inexpensive way to solve an expensive problem, compressed air leaks.  If you would like to discuss the features and benefits in more detail, you can contact an Application Engineer at EXAIR.  We will be glad to help you.

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