Tag: Compressed Air Challenge

Any Machine Is A Smoke Machine If You Operate It Wrong Enough

Published on by Russ BowmanLeave a comment

While most folks think this old adage applies only to personnel not being familiar with the OPERATION of machinery, it’s also a reminder that ‘operating it right’ necessarily includes keeping up with regularly scheduled preventive maintenance. This includes pretty much anything with moving parts and components in a system that fluids might flow through. But today, I’m going to focus on certain parts of a typical industrial compressed air system. Failing to change oil in an industrial air compressor, for example, will “let the smoke out” just as fast (and sometimes faster) than anything a day-to-day operator can do to it.

The folks at Compressed Air Challenge are dedicated to (and this is right from their website) “helping you enjoy the benefits of improved performance of your compressed air system.” Their “Best Practices For Compressed Air Systems” stresses the importance of:

  • Proper maintenance as a means to ensure operational efficiencies and systems reliability.
  • Continuous checks for preventive maintenance items.
  • Implementing a detailed system maintenance program, including schedules of required maintenance, and records of its performance.

And that’s just from the introduction. It goes on to list the major components that should be included in this program: the compressor, heat exchanger surfaces, lubricant, lubricant filter, air inlet filter, motors, belts, and air/oil separators. The steps for properly maintaining these components range from standard housekeeping practices, to mechanical operations that are typically performed by trained operators, to services that might be best handled by qualified manufacturer’s representatives:

  • Cleaning: The air compressor itself, and any heat transfer surfaces, have to be kept clean & free of contaminants. Moving parts generate heat, and dirt, scale, corrosion, etc. are essentially insulation that’ll prevent that heat from being dissipated.
  • Lubrication: It’s critical to service the lubricant & any lubricant filtration per the manufacturer’s specifications. Again – not doing this is one of the best ways to “let the smoke out” of any machine.
  • Power transmission components: Regular inspection, including alignment checks, of belts & couplings is probably the 2nd best way (next to lubrication maintenance) of keeping the moving parts of the air compressor, and its drive, in good working order.
  • Intake filter: An air compressor will try to compress anything that’s drawn in with its air intake. If it pulls in particulate, that can damage internal surfaces, especially moving parts with tight tolerances to each other, like pistons & cylinders, scrolls & casings, rotary screws & chambers, impellers & volutes, etc., depending on the type of compressor. Plus, anything that makes its way into your compressed air header will also have a chance to foul up your pneumatic tools & devices, and get on anything that you use compressed air to blow off.
  • Motors & drives: Simply put, if you can’t turn the shaft of the compressor, it won’t compress any air. Periodic checks of electric motor windings, bearings, ‘soft start’ capacitors, phase converters, etc., are among the basic maintenance items that operators can inspect.

In addition to the compressor itself, the air distribution system should be properly maintained as well:

  • Filtration: The intake filter is there primarily to protect the compressor. Many times, the aforementioned tight tolerances between the moving parts in the air end will result in (hopefully) small amounts of particulate being carried over into the compressor discharge. There’s usually a main particulate filter, along with a dryer (for entrained moisture – the intake filter won’t do anything about that either), and possibly even a coalescing filter for oil & oil vapor. Good engineering practice calls for servicing those filters when the differential pressure across them reaches a certain value (5psid is a common one), but those elements, being relatively inexpensive, can also be replaced during regularly scheduled downtime as well.
  • Leak detection & repair: Leaks make the compressor run harder, so any reduction in the amount of compressed air leakage will, by definition, reduce the wear & tear on the compressor. EXAIR makes it easy to find them with the Ultrasonic Leak Detector.
  • Filtration Part 2: Don’t forget about contaminants that can enter the system downstream of the compressor, too. Iron pipe headers are subject to internal corrosion, which can result in rust particulate. Environmental pollution can enter if flanges or fittings are broken & made up during maintenance. Point of use filtration, like EXAIR Automatic Drain Filter Separators, can keep this debris (and any moisture that’s not removed by the compressor’s dryer) out of your pneumatic tools & products.
EXAIR has a number of Accessories and Optimization Products to help you get the most out of your compressed air system.

Compressed air is expensive enough without throwing in a bunch of easily preventable repair costs. Schedule time for maintenance, or it’ll schedule the time for you…and it may even send you a ‘smoke signal’ when it’s ready. If you’ve got questions about getting the most out of your compressed air system, we’ve got answers.

Russ Bowman, CCASS

Application Engineer
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Creating an Efficient Compressed Air System

Published on by Tyler DanielLeave a comment

The electrical costs associated with generating compressed air make it the most expensive utility in any industrial facility. In order to help offset these costs, it’s imperative that the system is operating as efficiently as possible. I’d like to take a moment to walk you through some of the ways that you can work towards making your compressed air system more efficient.

The first step you should take is to identify and fix any leaks within the distribution piping. According to the Compressed Air Challenge, up to 30% of all compressed air generated is lost through leaks. This ends up accounting for nearly 10% of your overall energy costs!! To put leaks in perspective, take a look at the graphic below from the Best Practices for Compressed Air Systems handbook.

Compressed air leaks don’t just waste energy, but they can also contribute to other operating losses. If enough air is lost through leaks, this can also cause a drop in system pressure. This can affect the functionality of other compressed air operated equipment and processes. This pressure drop can affect the efficiency of the equipment causing it to cycle on/off more frequently or to not work properly. This can lead to anything from rejected products to increased running time. With an increase in running time, there’s also the need for more frequent maintenance and unscheduled downtime.

You can perform a compressed air audit in your facility using an EXAIR Model 9061 Ultrasonic Leak Detector. If you’d prefer someone come in and do this for you, there are several companies that offer energy audit services where this will be a focal point of the process.

Speaking of maintenance, proper compressor maintenance is also critical to the overall efficiency of the system. Like all industrial equipment, a proper maintenance schedule is required in order to ensure things are operating at peak efficiency. Inadequate compressor maintenance can have a significant impact on energy consumption via lower compressor efficiency. A regular preventative maintenance schedule is required in order to keep things in good shape. The compressor, heat exchanger surfaces, lubricant, lubricant filter, air inlet filter, and dryer all need to be maintained. This can be done yourself or through a reputable compressor dealer. The costs associated with these services are outweighed in the improved reliability and performance of the compressor. A well-maintained system will not cause unexpected shutdowns and will also cost less to operate.

The manner in which you use your compressed air at the point of use should also be evaluated. Inefficient, homemade solutions are thought to be a cheap and quick solution. Unfortunately, the costs to supply these inefficient solutions with compressed air can quickly outweigh the costs of an engineered solution. An engineered compressed air nozzle such as EXAIR’s line of Super Air Nozzles are designed to utilize the coanda effect. Free, ambient air from the environment is entrained into the airflow along with the supplied compressed air. This maximizes the force and flow of the nozzle while keeping compressed air usage to a minimum.

Another method of making your compressed air system more efficient is actually quite simple: regulating the supply pressure. By installing pressure regulators at the point of use for each of your various point of use devices, you can reduce the consumption simply by reducing the pressure. This can’t be done for everything, but I’d be willing to bet that several tasks could be accomplished with the same level of efficiency at a reduced pressure. Most shop air runs at around 80-90 psig, but for general blowoff applications you can often get by operating at a lower pressure. Another simple, but often overlooked, method is to simply shut off the compressed air supply when not in use. If you haven’t yet performed an audit to identify compressed air leaks this is even more of a no-brainer. When operators go to lunch or during breaks, what’s stopping you from just simply turning a valve to shut off the supply of air? It seems simple and minute, but each step goes a long way towards reducing your overall air consumption and ultimately your energy costs.

Tyler Daniel, CCASS


Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

Image taken from the Best Practices for Compressed Air Systems Handbook, 2nd Edition

What’s So Great About Compressed Air?

Published on by Russ BowmanLeave a comment

Compressed air is commonly known as “the fourth utility” – along with electricity, water, and gas – due to its ubiquitous use in modern industry. But…why? If you compare the power required to make it, versus the work you can get out of it, it’s abysmally inefficient. And, while it won’t electrocute you, drown you, or blow you up (like the “first three” utilities, respectively), purposely depressurizing a compressed air line comes with its own particular set of risk factors.

Of course, benefits outweigh inefficiencies and risks in many things most of us do every day. Over half of the energy released in your car’s engine goes to heat & friction, instead of turning the wheels. Insurance companies say the typical American driver has a 77% chance of getting into an automobile accident EVERY YEAR, and that most of us will be in up to THREE traffic accidents in our lifetimes. Looking at the number of fellow commuters I saw on my way to work this morning, it’s clear, though, that most of us are ready to accept that inefficiency and risk. And that’s not so surprising, considering they’re mitigated greatly by ever improving technology in fuel efficiency, and safety.

It’s, of course, the same with compressed air use, and the “first three” utilities as well: regulation, training, and engineering lower the aforementioned risks to broadly accepted levels. These disciplines also provide for the most efficient use, in spite of the inherent inefficiencies (no engine is 100% efficient) – getting the most out of what you have is “the name of the game”. So, how does all of this apply to industrial use of compressed air?

SAFETY

  • Regulation: In the United States, the Occupational Health & Safety Administration (OSHA) limits the nozzle pressure or or opening of a gun, pipe, cleaning lance, etc., when used for cleaning to 30psi, to protect against dead-ending such a device against your skin, which can cause a deadly condition known as an air embolism. This same directive mandates “effective chip guarding” to keep the blown off debris from hitting the operator. EXAIR Corporation has been in the business of making engineered compressed air products that comply with this directive for almost forty years now.
  • Training: There are companies whose sole purpose is to train & certify personnel in both the management, and operation, of industrial equipment in a safe manner. At EXAIR Corporation, our Safety Manager maintains certification from such an agency, which qualifies him to conduct regular training to ensure safe operation of tools, equipment, and chemicals used in the manufacture of our engineered compressed air products.
  • Engineering: In the “Hierarchy of Controls” established by the National Institute of Occupational Safety & Health (NIOSH), “Engineering Controls” is considered to be less effective than “Elimination” or “Substitution” of the hazard, but more effective than “Administrative Controls” or “Personal Protective Equipment”. THAT’S why EXAIR Corporation has been doing what we do – and why we’re so successful at it – for all this time.
For more on this, I can’t recommend my colleague Jordan Shouse’s recent blog on the subject highly enough. Go read it now…this blog will wait.

EFFICIENCY

  • Regulation: Since the energy crisis of the 1970’s, the United States Department of Energy has implemented numerous initiatives directed at improving energy efficiency. If you’ve ever shopped for a home appliance, you’re likely familiar with EnergyStar ratings. They have a similar program for commercial and industrial air compressors. While they’re not a government body with powers to mandate regulations, the Compressed Air Challenge membership consists of manufacturers & distributors, users, research & development agencies, energy efficiency organizations, and utilities, with key focus on providing direction for the most efficient operation of compressed air systems…from generation to point of use.
  • Training: Speaking of the Compressed Air Challenge, they, and other organizations like the Compressed Air & Gas Institute (CAGI) conduct formal training sessions, in addition to the documented direction I mentioned above. CAGI also has a personnel certification program for those interested in developing credibility and confidence by demonstrating knowledge, understanding, and expertise in the design & operation of compressed air equipment. You can even get a cool logo to put on your business cards and in your signature line.
  • Engineering: While there are multiple avenues to engineer SAFE compressed air products, not all of them are necessarily efficient as well. At EXAIR Corporation, we set ourselves above the fray by maintaining focus on safety AND efficiency. In their discussion of controls that I mentioned above, NIOSH has this to add on the subject of Engineering Controls: “The initial cost of engineering controls can be higher than the cost of administrative controls or PPE, but over the longer term, operating costs are frequently lower, and in some instances, can provide a cost savings in other areas of the process.” (emphasis mine)

To answer the question I posed in this blog’s title, there are many considerations that make compressed air great to use…among them are:

  • Pneumatic tools are lighter, cheaper, more mobile, and lower maintenance than their electrical counterparts. The risk of electrocution is also avoided.
  • Compressed air distribution systems are easier and less costly to install than electrical grids or natural gas lines.
  • Compressed air doesn’t lose energy over distance like steam.
  • Compressed air leaks, while potentially costly, don’t present an inherent safety risk to plant personnel like gas leaks or electrical “leaks” (aka electrocution hazards).

Add in safety and efficiency, and THAT’S what’s so great about compressed air. If you’d like to find out how EXAIR Corporation can help YOU get the most out of our compressed air use, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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Intelligent Compressed Air: Refrigerant Dryers

Published on by Tyler DanielLeave a comment

When we talk with customers about their EXAIR Products, we also discuss the quality of their compressed air. Many of our products have no moving parts and are considered maintenance-free when supplied with clean, moisture free compressed air. One of the most critical aspects of a compressed air distribution system is the dryer.

No matter where you are in the world, the atmospheric air will contain water vapor. Even in the driest place in the world, McMurdo Dry Valley in Antarctica, there is some moisture in the air. As this air cools to the saturation point, also known as dew point, the vapor will condense into liquid water. The amount of this moisture will vary depending on both the ambient temperature and the relative humidity. According to the Compressed Air Challenge, a general rule of thumb is that the amount of moisture air can hold at a saturated condition will double for every increase of 20°F. In regions or periods of warmer temperatures, this poses an even greater problem. Some problems that can be associated with moisture-laden compressed air include:

  • Increased wear of moving parts due to removal of lubrication
  • Formation of rust in piping and equipment
  • Can affect the color, adherence, and finish of paint that is applied using compressed air
  • Jeopardizes processes that are dependent upon pneumatic controls. A malfunction due to rust, scale, or clogged orifices can damage product or cause costly shutdowns
  • In colder temperatures, the moisture can freeze in the control lines

In order to remove moisture from the air after compression, a dryer must be installed at the outlet of the compressor. It is recommended to dry the compressed air to a dew point at least 18°F below the lowest ambient temperature to which the distribution system or end use is exposed. A dew point of 35-38°F is often sufficient and can be achieved by a refrigerated dryer (Best Practices for Compressed Air Systems). This makes the refrigerant dryer the most commonly used type in the industry.

A refrigerant dryer works by cooling the warm air that comes out of the compressor to 35-40°F. As the temperature decreases, moisture condenses and is removed from the compressed air supply. It’s then reheated to around ambient air temperatures (this helps to prevent condensation on the outside of distribution piping) and sent out to the distribution system.

With your air clean and dry at the point of use, you’re making sure you get the most out of EXAIR’s Intelligent Compressed Air Products without adhering to pesky maintenance procedures.

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

Compressor image courtesy of Tampere Hacklab via Flickr Creative Commons License