Tag: compressed air flow control

Eliminate Costly Leaks with the Ultrasonic Leak Detector

Published on by jasonkirbyLeave a comment

The generation of compressed air accounts for approximately one-third of energy costs in industrial environments. According to the Compressed Air Challenge, around 30% of this compressed air is lost due to leaks. As a result, nearly 10% of a facility’s energy expenses are wasted because of poor connections, faulty air valves, and improper installations. Beyond the financial implications, these leaks can cause significant operational inefficiencies. A drop in system pressure can adversely affect end-user performance, reducing production efficiency. Furthermore, this pressure decline may lead to increased cycling of equipment, potentially shortening the lifespan of compressors and other machinery. If leaks diminish the supply volume, it may create a misleading perception that additional compressor capacity is necessary, further driving up operating costs.

When a leak occurs, it produces ultrasonic noise due to turbulence, typically at frequencies exceeding 20 kHz, which are inaudible to humans. The EXAIR Ultrasonic Leak Detector, model 9207, is specifically engineered to identify these frequencies and transform them into audible sounds using a method called “heterodyning.” This device is equipped with a signal strength indicator and a bar graph display, allowing users to detect even the smallest leaks. It comes with two attachments: a parabolic microphone that can detect leaks from distances of up to 20 feet, and a tube attachment for accurately locating leaks among multiple connections within a pipe. Once a leak is detected, it can be marked for subsequent repair.

The ULD features specialized attachments that effectively reduce background noise typically found in industrial environments. It includes “+” and “-” buttons, allowing for precise sensitivity adjustments of the meter. This advanced model significantly improves leak detection in hard-to-reach areas and complies with the IEC 61326-1 standard, ensuring reliable performance in the electromagnetic conditions commonly encountered in industrial facilities.

Implementing a leak protection program in industrial facilities can lead to significant cost savings with relative ease. Should you have any inquiries regarding the integration of the Ultrasonic Leak Detector into your existing leak protection strategy, please feel free to contact us for assistance.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

Comparing and Combining Sound Levels

Published on by Al WooffittLeave a comment

Sound levels are an important safety consideration in most industrial facilities. OSHA has guidelines on allowable noise levels and exposure, covered in OSHA Standard 29CFR – 1910.95 (a). Sound levels are measured in decibels, or dB. It makes sense that a higher decibel value means a louder sound (as illustrated in the graphic below). What is not intuitive is how multiple sound levels interact and combine, or how they compare to one another.

The first thing to understand about sound levels is that they aren’t measured on a linear scale. Instead, they’re measured on a logarithmic scale. This can really throw off our intuition. For instance, a sound at 20dB is actually 10 times stronger than one at 10dB, and a sound at 30dB is 100 times stronger than 10dB. If it were a linear scale, 20dB and 30dB would only be 2 and 3 times stronger than 10dB, similar to how mass works—like 20kg being double the mass of 10kg.

You can see why this is the case with the formula for calculating sound levels, which is as follows:

It’s important to note that the sound pressure levels calculated using this formula are unweighted. To really grasp how loud something will seem to us, we have to consider how our ears pick up various frequencies. This means that low and extremely high frequencies are given less weight than on the standard decibel scale. This adjusted measurement is referred to as dBA. You can check out some typical sounds and their dBA levels in the chart below:

Because of this logarithmic scale, combining two sounds can be pretty counter-intuitive too. Our Model 1100 Super Air Nozzle generates a sound level of 74 dBA, but when you place two of them side by side, the sound level jumps to 78 dBA (and not 148dBA). This is determined using the formula below:

The specifics of this calculation are explained in this blog here, but OHSA provides a quick and easy way to calculate, as shown in the table below:

To see if you need to tackle the noise levels in your facility, you should start by taking a baseline measurement of the different processes and devices that are making the noise. EXAIR’s Sound Level Meter, Model 9104, is here to help. It’s super user-friendly and gives you a digital readout of the sound level (no need to deal with logarithms!).

If you would like to discuss sound levels in your facility, or any of your other compressed air needs, give us a call!

Al Wooffitt
Application Engineer

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Twitter: @EXAIR_AW

How To Prevent Pressure Drops

Published on by jasonkirbyLeave a comment
Issue 1

Compressed air serves as the essential utility for operation, and its performance limitations are determined by the supply available. To effectively utilize EXAIR products and pneumatic equipment, it is crucial to establish a method for transferring compressed air from the source to the point of use. This can be accomplished through three primary means: pipes, hoses, and tubes.

As compressed air travels through the distribution system, it experiences friction against the inner surfaces of pipes, tubes, and hoses. Factors such as the diameter of the pipe, its length, the number of bends, and the smoothness of the inner wall contribute to this friction. Consequently, a reduction in air pressure occurs due to this resistance. Additionally, pressure drops can also happen at the point of use, particularly if the line is inadequately sized, which can significantly affect the performance of the equipment being powered.

When designing and maintaining a compressed air system, it is essential to take pressure measurements at various locations to detect and resolve potential issues before they escalate. The Compressed Air Challenge recommends specific points for regular pressure assessments to accurately gauge the operating pressure of your system.

  • Inlet to compressor (to monitor inlet air filter) vs. atmospheric pressure
  • Differential across air/lubricant separator
  • Inter-stage on multistage compressors
  • After-cooler
  • At treatment equipment (dryers, filters, etc.)
  • Various points across the distribution system
  • Check pressure differentials against manufacturers’ specifications. If high pressure drops are noticed, this indicates a need for service.

After taking the necessary measurements, you should sum the recorded pressure drops and subtract this total from your compressor’s operating range. The resulting value represents the actual operating pressure at the point of use.

If your distribution system is correctly sized and the pressure drops across your equipment are within acceptable limits, any pressure drop observed at the point of use suggests a lack of sufficient air volume. This issue may stem from restrictive fittings or inadequately sized air lines, hoses, or tubes. It is essential to ensure that the point of use product is installed in accordance with the manufacturer’s specifications for compressed air.

If you have questions about pressure drops, or anything regarding EXAIR and our products, please do not hesitate to reach out.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

Sound Power vs Sound Pressure

Published on by Al WooffittLeave a comment

Noise levels or sound levels are an important consideration in many industrial settings. Noise exposure can cause irreparable damage if the necessary safety precautions are not taken. OSHA standard 29 CFR – 1910.95 (a) addresses this very concern.

But when discussing sound levels, there are two terms that frequently come up – Sound Power, and Sound Pressure. So, what’s the difference?

Sound Power (measured in watts) refers to the rate at which sound energy (measured in decibels) is emitted, reflected, transmitted, or received over time. On the other hand, sound pressure is the local pressure change from ambient atmospheric pressure caused by a sound wave. From these definitions, we can see that sound power is what creates the sound wave, while sound pressure is the result of what we perceive after the sound wave reaches our ears.

A good way of conceptualizing this is to imagine a light bulb. Light bulbs use electricity to produce light, which means the power needed (also measured in Watts) to make the bulb shine is similar to sound power. The brightness of the light produced (measured in lumens) corresponds to sound pressure. Sound pressure is essentially what we hear or refer to as sound. This is what gets measured because it can be harmful to our hearing. If the sound pressure is too high and the ear is exposed for too long, it can lead to permanent damage, hence OSHA’s regulation mentioned above. This regulation is the result of testing performed to determine what time thresholds at which permanent damage to human hearing will occur due to exposure over a period of time. The higher the sound pressure level, the less exposure time necessary to produce irreparable damage. Within this regulation is included a time weighted chart that OSHA follow for noise exposure issues that serve as the metric by which they determine if a company is in compliance. If not, they may recommend engineering changes, work process changes or require the use of PPE (hearing protection) if the other types of controls cannot be implemented.

If you would like a way to measure noise levels in your facility, EXAIR has the perfect product – EXAIR’s Digital Sound Level Meter. We have a video blog covering its benefits and operation here.

Generally speaking, compressed air-generated noise within a facility can be rather prevalent and loud. So, if you would like to discuss how EXAIR’s quiet and efficient compressed air products can help reduce noise levels in your facility, then give us a call!

Al Wooffitt
Application Engineer

Send me an Email
Find us on the Web
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Twitter: @EXAIR_AW