Tag: compressed air flow control

As margins get tighter and the cost of manufacturing climbs, industries are looking for ways to be more economical.  A big focus is on the compressed air system.  Compressed air is considered to be the “fourth utility” behind gas, water, and electricity.  Air compressors are necessary to run pneumatic systems, but they are the least efficient of the utilities.  For every $1.00 that is put into making compressed air, you only get roughly 5¢ of work from it.  So, it is very important to use this utility as efficiently as possible. 

One of the biggest problems affecting compressed air systems is leaks.  That quiet sound coming from the pipelines is costing your company a lot of money.  A study was conducted by a university to determine the percentage of air leaks in a typical manufacturing plant.  In a poorly maintained system, they found that 30% of the compressor’s capacity is lost through air leaks on average.  Just to let you know, the majority of companies do not have a leak prevention program, so they will fall into the “poorly maintained” category.  The chart below shows the amount of money that can be wasted by the size of the hole for larger leaks. Unlike a hydraulic system, compressed air is clean, so leaks will not be visible at the source.  You have to find them by other means.  There are four main methods to test your system for leaks.

Ultrasonic Leak Detector:  When you have small air leaks, the turbulent flow will emit an ultrasonic sound.  This method is the most direct way to find leaks in your system.  With the EXAIR Ultrasonic Leak Detector, it can pick up these high frequencies in the range of 20 kHz to 100 kHz, above human hearing.  This device makes the inaudible leaks audible.  Some other features of the model 9207 are a sensitivity adjustment button, a signal strength display, and a headphone volume button.  It has two attachments; the parabola attachment to locate leaks up to 20 feet (6.1 meters) away, and the tube attachment to define the exact location of the leaks. 

Digital Flowmeters:  With Digital Flowmeters, you can continuously watch for waste.  Air leaks can occur at any time within any section of your pneumatic system.  You can do systematic checks by isolating sections with the Digital Flowmeter and watching for a flow reading.  Another way to monitor your system would be to compare the results over time.  With the Digital Flowmeters, we have a couple of options for recording the air flow data.  We have a USB Datalogger for setting certain time increments to record the air flows.  Once the information is recorded, you can connect the USB to your computer, and with the downloadable software, you can view the information and export it into an Excel spreadsheet.  Once the information starts trending upward for the same process, you can focus your attention on finding the leak.  It can also serve as a preventive measure if a pneumatic system is starting to fail.

Pressure difference:  There are some equations that can be helpful in determining how severe the leaks are in the system.  One method would be to look at a pressure gauge.  For this method to work, you will have to estimate the total system volume, comprising secondary air receiver, piping, and air mains. After the compressor runs for a while to build to an operating pressure (P1).  Then, you have to block the system off and measure the time.  When it reaches a stopping point at pressure (P2), mark that time.  Use Equation 1 to measure the leakage rate, Q in CFM.  If the flow is more 10%

Equation 1:

Q = (V x (P1-P2)/T x 14.7) x 1.25

V = Volume (Ft³)

P1- Starting pressure (psig)

P2 = Ending pressure (psig)

T = Time (Minutes)

Compressor cycling time:  First start by shutting off all the points of use of compressed air products so that there’s no demand on the system. Then, start the compressor and record the average time it takes for the compressor to cycle on/off. The compressor will load and unload as the air leaks, causing a pressure drop from air escaping. The percentage of total leakage can be calculated by Equation 2.  The leakage rate will be given as a percentage of total compressor capacity lost. This value should be less than 10% for a well-maintained system.

Equation 2:

Leakage % = [(T) / (T + t)] * 100

Where:

T = loaded time (seconds)

t = unloaded time (seconds)

Compressed air leaks will rob you of performance, compressor life, and electrical cost.  It is important to have a leak prevention program to check for leaks periodically, as they can happen at any time.  I added some tips and tricks to help determine the severity of the leaks in your system.  The EXAIR Digital Flowmeters and Ultrasonic Leak Detector will help you accomplish this and optimize your compressed air system.  If you need more information, you can contact an Application Engineer at EXAIR.  Once you find and fix all your leaks, you can then focus on improving the efficiency of your blow-off devices with EXAIR products.  It will save you even more money. 

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

Photo: Soap bubbles and pencils by Carola68.  Pixabay license. 

The production of compressed air represents roughly one-third of the total energy expenses in an industrial setting. The Compressed Air Challenge indicates that approximately 30% of this compressed air is lost due to leaks. Consequently, nearly 10% of the energy costs incurred by the facility are squandered because of inadequate connections, malfunctioning air valves, and improper installations. Beyond financial waste, these leaks can lead to various operational inefficiencies. A reduction in system pressure can hinder the performance of end users, negatively impacting production efficiency. Additionally, this pressure drop may result in more frequent cycling of equipment, which can diminish the lifespan of compressors and other machinery. If leaks compromise the supply volume, it may create a false impression that additional compressor capacity is required, thereby escalating operating expenses.

When a leak occurs, it generates ultrasonic noise due to turbulence, often at frequencies above 20 kHz, which are inaudible to the human ear. The EXAIR Ultrasonic Leak Detector, model 9207, is designed to detect these frequencies and convert them into audible sounds through a technique known as “heterodyning.” This device features a signal strength indicator and a bar graph display, enabling the identification of even the smallest leaks. It includes two attachments: a parabolic microphone for detecting leaks from distances of up to 20 feet, and a tube attachment for pinpointing the exact location of a leak among multiple connections within a pipe. Once a leak is identified, it can be marked for repair.

The ULD is equipped with attachments designed to minimize background noise commonly encountered in industrial settings, featuring “+” and “-” buttons for precise adjustments to the meter’s sensitivity. This latest model enhances leak detection capabilities in difficult-to-access locations and adheres to the IEC 61326-1 standard, ensuring its functionality in the typical electromagnetic environments present in industrial facilities.

In most industrial facilities, huge amounts of savings can be realized rather easily by implementing a leak protection program. If you have questions about introducing the Ultrasonic Leak Detector to your leak protection program, please do not hesitate to reach out.

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

Manufacturing environments present numerous hazards for both companies and their employees on a daily basis. Among these risks, the potential dangers posed by high-decibel machinery and equipment are often underestimated. The Digital Sound Level Meter from EXAIR serves as a user-friendly tool designed to measure and monitor sound pressure levels across diverse industrial settings.

The Digital Sound Level Meter from EXAIR is both precise and responsive, effectively measuring sound decibels and presenting the results on a large LCD screen. This display features a backlight button for enhanced visibility. Additionally, the device includes an F/S response time button, allowing users to select between slow response for stable noise measurements and fast response for fluctuating noise levels. The “Max Hold” function enables users to set a specific decibel threshold, providing alerts when this level is surpassed. Furthermore, the Digital Sound Level Meter is certified by the NIST (National Institute of Standards and Technology) for initial calibration, ensuring its accuracy and reliability.

If you have any questions about the Digital Sound Level Meter by EXAIR, or any EXAIR product or application, please feel free to reach out to our team of Application Engineers for assistance.

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

Compressed air leaks and ineffective blow-offs can result in significant electricity wastage annually, impacting your organization’s production expenses and overall profitability. In numerous facilities, leakage can represent as much as 30% of the total system capacity costs associated with compressed air.

Since 1983, we have been dedicated to offering products that are efficient, safe, and effective. Our ambition extended beyond mere manufacturing; we aimed to enhance our customers’ compressed air systems as well. This vision led to the creation of our Optimization product line. These products serve a dual purpose: they emphasize the significance of conserving compressed air, enhancing safety, and streamlining processes, while also optimizing the performance of your compressed air system to maximize its potential.

EFC: The EFC is engineered to conserve compressed air. In instances where a blowing or cooling process is intermittent, it is advisable to deactivate the compressed air supply when not needed. This compact, timed PLC employs a photoelectric sensor to facilitate this action with a compressed air supply. By reducing the consumption of compressed air, significant cost savings is achieved.

Digital Flowmeter: Measuring flow enables numerous optimization opportunities. The Digital Flowmeter effectively displays and logs the flow rate within your compressed air system. Additionally, it assists in leak detection, troubleshooting pneumatic issues, and utilizing the collected data for preventive maintenance. When comparing EXAIR products to open pipes or competing solutions, the air savings become apparent, allowing for a straightforward calculation of the payback period, typically within weeks. EXAIR also provides various recording options, including wireless, serial, or USB Datalogger types, facilitating continuous 24/7 monitoring of your compressed air system.

Digital Sound Level Meter: This instrument is utilized for assessing sound levels. To ensure safety, OSHA established time-based decibel limits for workplace environments. The Digital Sound Level Meter is calibrated according to NIST standards to provide precise noise measurements. Inadequate nozzles on air guns or exposed pipes for blow-offs may lead to non-compliance with OSHA standard 29CFR 1910.95(a), potentially incurring fines. EXAIR products are engineered to comply with this regulation.

Ultrasonic Leak Detector: Numerous compressed air systems experience leaks, which, if undetected, can significantly diminish the system’s overall capacity and lead to substantial financial losses. Such leaks may represent up to one-third of the total compressed air output. The ULD is capable of identifying these leaks, thereby enhancing system efficiency and promoting the optimal functioning of your compressor.

If you would like to discuss our Optimization products, or any of our EXAIR products, please do not hesitate to contact an Application Engineer. We are always happy to help!

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