Tag: compressed air optimization

Priorities of Work

Published on by Brian FarnoLeave a comment

Triage, priorities of work, MoSCoW Method, ABCdE, the list could go on and on. These are all methods to help you prioritize your day. I have blogged about my first career as a field service/training on CNC machines. This was something that I was baptized into. During the day-to-day here at EXAIR, and during GORUCK events, it became solidified in the way I approach almost any project and most of the days.

If you Google or use your favorite search engine for What are Priorities of Work, then you may get a list something like what is shown above. I’ve heard many of these over the years, but it wasn’t until one of the GORUCK events I was doing that it truly sank in that if I am not addressing the appropriate tasks first, then I wouldn’t have time for them later. When I was in machine tool, it meant evaluating all the issues preventing the customer’s machine from operating and making sure the longest lead time parts were ordered first, then the ancillary problems after. The goal was always to get the machine back up and running as fast as possible to get the customer back on schedule.

In endurance events, the priorities are to assess yourself, hydrate, if blister/skin care is needed, take care of those, and consume calories if needed. Then, take off your shoes and socks, lie down, elevate your feet, and sleep. Chatting and socializing can happen during, or it can wait until after.

Optimizing a compressed air blow off, reducing wasted compressed air, and maintaining the existing system can very often get knocked down on your priority list. The fact is, these priorities of keeping production moving and then ignoring subservient tasks can add up over time. This can then be the reason you are not able to keep production moving. That’s why here at EXAIR, we help you with a triaged list of priorities when it comes to maintaining your compressed air system.

The six steps to compressed air optimization are laid out to make it easy to check off the big-ticket items first and put the most back into your system. We can also help every step of the way with just a few clicks. Simply request a chat, reserve a video meeting with an Application Engineer, call, or email.

Brian Farno, MBA – CCASS
National Business Development Manager

BrianFarno@EXAIR.com
@EXAIR_BF

Turn it Down: Save Money by Reducing Compressed Air Pressure

Published on by Tyler DanielLeave a comment

If there’s one thing I’ve learned about compressed air, it’s that pressure is a lot like coffee. A little bit gets the job done, but too much just makes you jittery and costs you more than it should. The last step in our 6 Steps to Optimizing Compressed Air series is all about dialing that pressure back to where it actually needs to be. So why worry about pressure?

Compressed air is one of the most expensive utilities in your facility. For every couple of PSI you crank the system higher than necessary, your energy bill climbs right along with it. In most cases, your application doesn’t even need that extra pressure. It’s like using a fire hose to water a houseplant.

This is where pressure regulators come in. They’re simple devices, a knob, a spring, a diaphragm, but they’re doing some heavy lifting. Twist the knob, and the spring loads or unloads. That changes how much the diaphragm allows through, and suddenly you’ve got a steady, consistent downstream pressure without overfeeding your air tools or EXAIR products.

The real magic happens when you lower that setpoint. If your Super Air Knife is blowing water off parts just fine at 60 PSIG, why run it at 100 PSIG? Less pressure means less flow, and less flow means more savings. You’ll get the same result with a smaller demand on the compressor. That’s a win-win every plant manager can appreciate.

Now, before you start cranking down knobs all over the place, keep sizing in mind. Regulators need to be matched to the volume of air your application requires. If they’re undersized, you’ll experience droop, when the pressure drops off during demand spikes. EXAIR takes the guesswork out by offering properly sized regulators in kits with a lot of our products. We’ve already done the math so you don’t have to.

Turning down the pressure might be the last of the six steps to optimizing compressed air, but it’s one of the easiest changes to make and one of the fastest ways to save. A couple twists of the regulator could be all it takes to lighten the load on your compressor, cut operating costs, and keep your system running lean and efficient.

And if you’re not sure where to start, that’s what our Application Engineers are here for. Call us, chat with us, or shoot us an email. We’ll help you find the right pressure for your setup without the trial and error.

EXAIR is now partnering with EasyCAS by DirektIn software. This tool lets you actually measure and validate the savings you’re getting from steps like lowering pressure and implementing engineered solutions. No more guessing, you’ll have hard data showing how much air and money you’re saving.

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

X: @EXAIR_TD

Good Idea!!! Compressor Room Tips and Tricks

Published on by jasonkirbyLeave a comment

At EXAIR, we frequently discuss optimal strategies for utilizing compressed air on the demand side. This includes recommendations such as utilizing point-of-use filtration with our Filter Separators and adjusting pressure with our Pressure Regulators to maintain the lowest necessary pressure for effective operation. Adhering to these best practices maximizes the efficiency of our Intelligent Compressed Air Products. Equally crucial is the adoption of best practices on the supply side, particularly within the compressor room.

1. A centrally located compressor room is preferable, as it reduces pipe length and facilitates better noise management. Extended piping can result in pressure loss and a higher risk of leaks, which may incur significant expenses over time.

2. The compressor room must be designed to accommodate potential future expansion and facilitate straightforward maintenance. The Compressed Air Challenge advises maintaining a minimum clearance of 3 feet on all sides of the compressor to ensure accessibility and proper ventilation.

3. Basic preventative maintenance is crucial for ensuring the efficient operation of your compressor, which in turn helps to reduce costs. It is essential to regularly replace intake filters and service the lubricant to maintain optimal performance.

4. Regularly changing intake filters and maintaining a clean source of intake air will significantly enhance performance. Ideally, the inlet pipe should be sourced from an area outside the compressor room, or preferably from outside the building itself.

5. Proper ventilation is essential in the compressor room due to the considerable heat generated by air compressors. Allowing excessive heat accumulation can diminish the compressor’s efficiency, leading to higher utility expenses, premature degradation of lubricant, and potentially increased maintenance needs or compressor failure. Additionally, utilizing this heat as an energy source for facility heating, hot water services, or pre-heating processes can enhance the overall efficiency of compressed air production.

Air Compressor and Storage Tanks

Adhering to these principles for your compressor room will maximize the efficiency of your equipment. Furthermore, by integrating EXAIR intelligent compressed air products, you can ensure a stable and dependable supply of compressed air.

If you would like to discuss your compressor room 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

Compressed Air System Optimization – Where Do Receiver Tanks Fit?

Published on by Tyler DanielLeave a comment
SixSteps

The 5th step in the 6 steps to optimizing your compressed air system highlights the use of intermediate storage of compressed air near the point of use. Secondary, or intermediate Receiver tanks are installed in the distribution system to provide a source of compressed air close to the point of use, rather than relying on the output of the compressor.

Compressed air receiver tanks are an integral part to many compressed air distribution systems. Compressed air is stored at a high pressure after drying and filtration, but just upstream of point of use devices. The receiver tank is charged to a pressure higher than what is needed by the system, creating a favorable pressure differential to release compressed air when needed.

Think of a compressed air receiver tank as a “battery”. It stores the compressed air energy within a system to be used in periods of peak demand, helping to maintain a stable compressed air pressure. This improves the overall performance of the compressed air system and helps to prevent pressure drop.

receiver_tank

They can be strategically placed to provide a source of compressed air to intermittent high volume compressed air applications. Rather than having to pull from the compressor, a receiver tank can be sized to provide the short-term volume of air for a particular application. In a previous post, we’ve highlighted how to calculate the necessary receiver tank based on the air consumption and duration of the application.

EXAIR offers from stock a 60-gallon receiver tank designed specifically for these higher-usage intermittent types of applications. Model 9500-60 can be installed near the point of high demand so that you have an additional supply of compressed air available for a short duration. The tank comes with mounting feet and is designed to stand up vertically, saving floor space. The tank meets American Society of Mechanical Engineers (ASME) pressure vessel code.

Just this past Spring, EXAIR hosted a live webinar where we discuss how to size, install, and implement secondary storage in your plant’s distribution system. If you missed it, check it out here on our website hosted by my colleague, Russ Bowman.

If you have an application in your facility that’s draining your compressed air system, a receiver tank could be the ideal solution. Give us a call and one of our Application Engineers will be happy to help evaluate your process and determine the most suitably sized receiver tank.

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