EXAIR not only has products that will reduce your air consumption, cost and noise levels but also has the tools to help you calculate the annual savings and Return on Investment (ROI). Sometimes you have the materials in house to make your own pneumatic tools so you get that piece of pipe in the maintenance crib, drill several holes and connect your compressed air. It works, your team is proud of the solution and everyone moves on to the next fire, right?
Several projects later you notice that your compressed air usage seems very high so a team is assembled and challenged with a cost savings program geared towards compressed air savings. EXAIR is the company that can help. We have Intelligent Compressed Air Products, Free Expert Technical Help and savings calculators that can be used to show the savings in your reports and presentations. EXAIR’s cost savings calculator will simplify the savings for each process you study and help your efforts in purchase justifications.
We have several examples of helping our customers save money such as this blog by one of our talented Application Engineers. You will realize more than cost savings as you should also see significant sound reductions and safety improvements as all of our products meet or exceed OSHA standard 29 CFR 1910.95 (a) which outlines allowable noise exposure for personnel and OSHA standard 29 CFR1910.242 (b) Dead End Pressure requirements.
When you begin compressed air cost savings program and have questions as to where to start, how to calculate and how to prepare your justifications please give EXAIR a call and talk with one of our many talented Application Engineers. EXAIR’s Intelligent Compressed Air products and Application Engineers will support all your efforts to decrease compressed air usage, reduce sound levels and increase the safety of your environment.
The best way to save compressed air is to simply turn it off when it’s not being used. This might seem pretty simple, but there may be processes in your facility where this couldn’t be achieved by just turning a valve. In applications where product is traveling along a conveyor, and must be dried, cooled, or blown off, there is likely some spacing in between the parts. It isn’t necessary to keep the blowoff running constantly if there’s periods of intermittent spacing. To help reduce the overall load on the air compressor, implementing a solution to shut the air off in between each part can have a dramatic impact. EXAIR’s Electronic Flow Control, or EFC, is designed to improve efficiency by reducing overall compressed air usage. It utilizes a photoelectric sensor that detects when the part is present. When it’s not, it triggers a solenoid valve to close and shut off the compressed air supply.
One way to use the Electronic Flow Control would be for Turning a Atomizing Spray nozzle on to coat your product. For example see the photo below where you could use the EFC to sense the pants coming down the line. Then turn the air supply on to spray a bleach solution to get the weathered look you are after. Once the pants pass the EFC will turn the nozzle off, replacing a manual operation awhile saving compressed air and your liquid solution!
Another use would be to tell when a hopper that is being filled by a Line Vac is empty or over filled. You can adjust the sensor and the control module to sense that the hopper is empty and it will turn the compressed air on to the Line Vac to then feed the hopper. Then set the timer module so it will run for the length of time it takes to fill the hopper. The other way would be to place the sensor at the top of the hopper and have it sense when the pile of media has reached the full level.
The EFC models available from stock can accommodate flows up to 350 SCFM. For applications requiring more compressed air, EFCs with dual solenoids are also available. If you have an application in one or more of your processes where intermittent compressed air use could help save you money, give us a call. We’d be happy to take a look at the application and help determine just how quickly the EFC could start paying YOU
When discussing ROI, return on investment, for an industrial compressed air system it is necessary to understand what it costs to produce compressed air. Generally we calculate that it costs .25 cents to produce 1,000 SCF (Standard Cubic Feet) of compressed air here in the Midwest of the United States. For our example let’s consider a typical 250 HP industrial compressor running 24 hours per day/5 days per week for 52 weeks. This compressor can generate 374,400,000 SCF per year, using the industry standard utility cost for the Midwest of .25 cents per 1,000 SCF it will cost $93,600 to produce that volume of compressed air.
To avoid wasting money on compressed air generation it is extremely important to eliminate unintended or wasteful compressed air use in your plant. The two main offenders are leaks and open tube blow-offs. While soapy water is a good method for discovering leaks, EXAIR offers the Ultrasonic Leak Detector. This handy device allows leaks to be detected at distances of up to 20′ away! Also consider how safe and convenient it is to find leaks in overhead pipes while standing on the ground instead of on a ladder. Using a tool like this to do an entire system leak audit can easily result in many small leaks being identified and when fixed result in a large savings.
Now let’s look at what an open pipe or tube may consume. A single 1/4″ OD copper tube can use 33 SCFM @ 80 PSIG inlet pressure. Using the manifold pictured above as our example with 13 open tubes, each tube can consume 33 SCFM @ 80 PSI inlet pressure. With 13 open tubes running 24 hours a day, 5 days a week, 52 weeks per year equates to a total consumption of 160,617,600 SCF annually. If we installed the EXAIR model 1100 Super Air Nozzle using a simple compression fitting we would reduce the air consumption dramatically. The EXAIR 1100 Super Air Nozzle consumes 14 SCFM @ 80 PSIG inlet pressure, running 24 hours a day, 5 days a week, 52 weeks per year equates to a total consumption of 68,140,800 SCF annually. That change will save you 92,476,800 SCF annually which is equal to $23,119.20 and 24.7% of air compressor capacity! These calculations are all based on continuous running applications, if intermittent operation is possible consider the EXAIR Electronic Flow Control for even greater savings. The EXAIR Electronic Flow Control combines a photoelectric sensor with timing control that limits compressed air use by turning it off when no part is present
Open pipe blow offs also violate OSHA standard 29 CFR 1910.242(b) requirement for using compressed air for cleaning when pressurized above 30 PSIG. Not to mention they generally are louder than 90 dBA, which is the maximum allowable noise exposure without hearing protection under OSHA standard 29 CFR – 1910.95 (a). The EXAIR engineered Super Air Nozzle is a great way to avoid a OSHA fine.
A great product that will help you keep your fingers on the pulse of compressed air consumption and demand is by incorporating the EXAIR Digital Flow Meter. This handy item mounts directly to the pipe. The digital display shows the amount of compressed air being used in any leg of your distribution system. The Digital Flow Meter is offered in sizes for 1/2″ – 4″ Schedule 40 Iron Pipe and 3/4″ – 4″ Copper Pipe. It also is available with the Summing Remote Display that is prewired with a 50′ cable, it is powered by the Digital Flow Meter and with a push of the button will display either the current compressed air consumption, consumption for the previous 24 hours or the total cumulative usage.
The Digital Flowmeters are also available with wireless capability using the ZigBee mesh network protocol, data can be passed from meter to meter to extend the distance over which the wireless system can operate. Each meter has a range of up to 100′ (30 meters). Or you can opt for the USB Data Logger option. The USB Data Logger can store approximately 9 hours of readings if set to sample once every second or up to 2 years if sampled every 12 hours.
If you would like to talk about any of the quiet EXAIR Intelligent Compressed Air® products or our line of Optimization Products, feel free to contact me or any EXAIR Application Engineer.
Russ Bowman, CCASS
Application Engineer EXAIR Corporation Visit us on the Web Follow me on Twitter Like us on Facebook
Wireless capability is an option for EXAIR’s Digital Flowmeter’s. It is the efficient way to monitor your compressed air consumption wirelessly utilizing the ZigBee® mesh network. This is accomplished by a module located within the meter that transmits data to an ethernet connected gateway. Each meter has a range up to 100 feet (30 meters), however the ZigBee mesh network protocol is very versatile as it allows data to also be transmitted from meter to meter, effectively extending the distance over which the system can operate. So large facilities with great distances to cover are not a problem.
The Digital Flowmeter with Wireless Capability is offered in a kit with a wireless output flow meter, wireless to ethernet gateway, drill guide, power supplies for each component, and ethernet cable for gateway connectivity. These kits are best suited for new installations. They are also available without a gateway if you are simply adding an additional meter to a pre-existing Gateway in your plant. EXAIR simplifies this process by configuring each gateway to communicate with the flowmeter to provide the necessary communication for monitoring your system. Models from 1/2″ to 4″ iron pipe are in stock. 5″, 6″ iron pipe, copper pipe ranging from 3/4″ to 4″ diameter and aluminum pipe from 25mm to 101mm diameter are available with short lead time as a special product offering. Each digital flowmeter is calibrated for the pipe size to which it is mounted and the large digital display shows air use in either SCFM or Cubic Meters per Hour.
Setting up the EXAIR Digital Flow Meter with Wireless Capability is super easy. After the meter is installed download the graphing software from our website and install on your computer. There is also a video tutorial posted in the previous blog from Tyler Daniel, Video Blog: EXAIR’s New Wireless Digital Flowmeter Installation.
The Digital Flowmeter with Wireless Capability is designed for permanent or temporary mounting to the pipe. It requires the user to drill two small holes through the pipe using the optional drill guide which includes the drill bit and locating fixture. The two flow sensing probes of the flowmeter are inserted into these holes. The unit seals to the pipe once the clamps are tightened. No cutting, welding, adjustments or calibration are needed, ever! If the unit needs to be removed, blocking rings are available for the 1/2″ to 4″ iron pipe sizes from stock with other sizes available on short lead time as special orders.