Tag: compressed air flow control

How Much Air are you using? Step 1: Measure your Compressed Air use

Published on by Jordan T ShouseLeave a comment

At EXAIR ,our Application Engineering team strive to give our customers, the best advise possible. Very often we are going to have a product that is going to help in your application, but sometimes it’s. “Hey we don’t have what you’re looking for, but here is a resource I think will help!” We want to be a subject-matter expert to you, the person using the products on your compressed air system. And that is why most of our team here are Certified Compressed Air System Specialists (CCASS) through CAGI.

Since air compressors use a lot of electricity to make compressed air, it is important to use the compressed air as efficiently as possible. EXAIR has six simple steps to optimize your compressed air system. Following these steps will help you to cut electrical costs, reduce overhead, and improve your bottom line. In this blog, I will cover the first step – Measure the air consumption to find sources that use a lot of compressed air.

****But if you are interested in the other steps here are some blogs written by some of my colleagues! Step 2 , Step 3, Step 4, Step 5, Step 6. (Teaser, the Fall 2023 Webinar may be about Step 4!)

Processes lead to continuous improvement.

Real time Data is important to diagnose wasteful and problematic areas within your compressed air system. To measure air consumption, flow meters are used to find the volume or mass of compressed air per unit of time. Flow rates are very useful data points to find problems like leaks, over-use in blow-offs, waste calculations, and comparison analysis.There are many different types of flow meters. Many of them entail a breakdown of your current compressed air lines by cutting, welding, or dismantling for installation. This will add cost in downtime and maintenance staff. But, not with the EXAIR Digital Flowmeters. In this blog, I will share the features and benefits of the Digital Flowmeters including options for you to start measuring and optimizing your compressed air system in Step 1.

Overall, it only takes a few minutes to install and start measuring. The installation kit comes with a drill bit and a drill guide to properly locate the two holes on the pipe. The Digital Flowmeter uses a clamp to mount to the pipe and to seal the area around the probes. Once it is powered, the unit is ready to measure the air flow inside the pipe with a large LED display. The display can be customized to show flow readings in three different units; SCFM, M3/hr or M3/min; and, it can display the Daily Usage and Cumulative Usage.

To get started, the EXAIR Digital Flowmeter is a thermal dispersion device that can accurately measure compressed air flows. They use two sensing probes for comparative analysis. One probe is a temperature sensing probe, and the other is a flow-sensing probe. By comparing these, the Digital Flowmeter can measure precisely the mass air flow without needing to be recalibrated. They are a cost-effective, accurate, and simple way to measure compressed air flow. EXAIR stocks Digital Flowmeters to ship same day for U.S. and Canadian customers.

Digital Flow Meter with Data Logger

We also offer a 30-day unconditional guarantee to try them out. We stock meters for pipe diameters from ½” NPT to 4″ NPT Schedule 40 black pipe. EXAIR can also offer flow meters up to 8″ NPT black pipe; copper pipes with diameters from 3/4″ to 4″, and aluminum pipes with diameters ranging from 40mm to 101mm. If you have another type of piping for your compressed air system, you can give us the material, O.D. or I.D., and wall thickness. We may still be able to offer a Digital Flowmeter calibrated for you.

When you need to analyze your pneumatic components, flow is an important point in diagnosing the overall “health” of your compressed air system. EXAIR Digital Flowmeter can give you that important data point. With optimization, you can cut your energy consumption, find additional capacity, improve pneumatic efficiencies, and save yourself money. This blog is an overview of Step 1 of six steps. You may have more questions; and, that is great! You can find them in other EXAIR blogs, (linked above) or you can contact me or any of our Application Engineers here at EXAIR.

Jordan Shouse
Application Engineer

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Leaks Got You Down

Published on by Brian FarnoLeave a comment

Recently I blogged about a refrigerant leak in my homes HVAC system. For that, I had to use a special leak detector which sniffed out gases within the air. Compressed air systems are not as complicated and a simple Ultrasonic Leak Detector can be utilized to find leaks that may be getting you down. Those compressed air leaks can cause inaudible pressure loss within a production line. This leads to equipment faulting out, maybe even compressors over working and an increase in energy demand. So how do you fight a foe that you cannot see, feel, or hear?

Equipping yourselves with the right tools is the ideal way, converting ultrasonic emissions into an audible level by the human ear and a visual representation as well can be done easily with the new EXAIR Ultrasonic Leak Detector. This detector was demoed by Tyler Daniel in a recent video and can be shipped same day on orders received by 2 PM ET that are shipping within the US. So why exactly do you need to worry about this?

Well, leaks can actually account for up to 30% of an industrial facilities compressed air capacity. If you have a 2,000 SCFM compressed air system, That could result in 2,000 * .30 = 600 SCFM of compressed air being wasted. 600 SCFM costs the average user $72.00 USD per 8 hour shift of operation. If you operate for 3 shifts per day and average 6,000 hours of operation per year, then that equates to $54,000 USD per year in savings if you just find and fix the 30 % of airflow that is leaking out.

If you want to discuss how to use the ULD or what a good approach is to how to break down and optimize a compressed air system, that is what our entire team of Application Engineers is for. Contact an Application Engineer today!

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

June’s PRESS RELEASE: New Ultrasonic Leak Detector For Energy Conservation

Published on by Tyler DanielLeave a comment

The generation of compressed air accounts for approximately 1/3 of all energy costs in an industrial facility. According to the Compressed Air Challenge, about 30% of that compressed air is lost through leaks. This means nearly 10% of your facility’s energy costs are simply wasted through poor connections, faulty air valves, improper installation, etc. In addition to simply wasting money, compressed air leaks can also contribute to a variety of other operating losses. A leak can cause a drop in system pressure. When this occurs, end users may not operate as efficiently and have an adverse effect on production. This same drop in system pressure will also cause the equipment to cycle on/off more often, shortening the life of your compressor and other equipment. If the leaks cause an issue in supply volume, it may lead to the belief that more compressor capacity is necessary, further increasing your operating costs.

To put leaks in perspective (assuming energy costs of .10/ kWh):

  • A $200/year leak cannot be felt or heard
  • A $800/year leak can be felt, but not heard
  • A $1,400/year leak can be felt and heard.

(Compressed Air Challenge)

If you walk through your facility, how many leaks can you hear? These are only the REALLY bad ones!!  So if we know that a large amount of compressed air is leaking, what do we do about it? A proper leak prevention plan is the key to success. Since these leaks are impossible to see and some cannot even be heard, you need a tool to help assist you. EXAIR’s NEW Model 9207 Ultrasonic Leak Detector is the right tool for the job. When compressed air leaks through a pipe, it creates an ultrasonic signature due to turbulence. While this sound is not always detectable by the human ear, this meter will allow you to locate leaks up to 20’ away.

High pressure gases create a high frequency turbulence when moving into an area with lower pressure. This results in an ultrasonic noise that is outside the range of human hearing. The ULD detects these signatures, creating an audible sound through the supplied headphones and indicating the intensity via the front-facing LED display as the meter is brought closer to the origin.

The ULD comes with attachments allowing you to filter out background noise in a typical industrial plant and includes “+” or “-“ buttons for fine-tuning the meter’s sensitivity settings. This new model offers heightened ability to detect leaks in hard-to-reach areas while also complying with IEC 613326-1 standard that designates its ability to operate in typical electromagnetic environments found within an industrial plant.

In almost any industrial plant, huge amounts of savings can be realized rather easily by implementing a leak protection program. EXAIR has the Model 9207 Ultrasonic Leak Detector ready to ship same-day from stock. Get yours on order today and start saving money!

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

Twitter: @EXAIR_TD

The Power of Optimization

Published on by John BallLeave a comment

When you take your car into the service shop for an oil change, you notice that they will check the fluids, the air filter, the belt, the tire pressure, etc.  The reason that they do this is to make sure that your car will not have any potential safety issues and to get the maximum performance from your vehicle.    

EXAIR has been the leader in “tuning up” compressed air systems.  We have been selling efficient, safe, and effective products since 1983.  At that time, we wanted to become more than a manufacturer.  We wanted to also provide a way to improve your compressed air system.  We developed this into our Optimization product line.   By design, these products are twofold.  First, it shows the importance of saving compressed air, improving safety, and refining processes.  Second, it helps to improve the performance of your compressed air system to get the most out of it.   I am going to discuss a few points about each product below:  

Electronic Flow Control:  The EFC is designed to save compressed air.  If there are any time gaps in a blowing or cooling application, then we should turn off the compressed air.  The EFC is a miniature timing PLC that uses a photoelectric sensor to turn off the compressed air.  By using less compressed air, you will be able to save a bunch of money.  This is why the light bulb in your refrigerator goes off when the door is closed (or does it?).      

Digital Sound Level Meter:  This device is used for measuring sound levels.  For safety reasons, OSHA sets decibel ratings for work environments.  The Digital Sound Level Meter is calibrated to a NIST standard to accurately measure noise level.  If you have poor nozzles on your air guns or open pipes for blow-offs, you could be violating the OSHA standard 29CFR 1910.95(a), which will result in fines.  EXAIR products are designed to meet this standard. 

Ultrasonic Leak Detector:   Many compressed air systems have leaks.  If they go unnoticed, this will affect the overall capacity of the compressed air system as well as cost a lot of money.  Leaks can account for one-third of your compressed air output.  The ULD can find these leaks to optimize your system and improve the “health” of your compressor. 

EXAIR’s Digital Flowmeter w/ USB Data Logger

Digital Flowmeter:  If you can measure flow, then you can find many ways to optimize.  The Digital Flowmeter is able to display and record the amount of flow that you are using in your compressed air system.  You can also use the Digital Flowmeters to find leaks, diagnose pneumatic problems, and use the recorded information for preventative maintenance.  In comparing EXAIR products to open pipes or competitive products, you can easily see the air savings and easily determine the payback period (which is generally in weeks).  EXAIR does offer options that are wireless, serial, or USB Datalogger types for recording, so, you can continuously monitor your compressed air system 24/7. 

With the Optimization products, you can “service” your compressed air system, so you can get the most from it.  The optimization will save you money, make your system safe, and keep things pneumatically maintained.  If you would like to discuss one or more of these products, you can contact an EXAIR Application Engineer for more details.  We can “pop the hood” and see if we can get more from your system. 

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