Tag: compressed air plumbing

Plumb it Right for Full Performance!

Published on by Jordan T ShouseLeave a comment

Many times when we provide the air consumption of an EXAIR product, we get a response like…. “I’ve got plenty of pressure, we run at around 100 PSIG”. While having the correct pressure available is important, it doesn’t make up for the volume requirement or SCFM (Standard Cubic Feet per Minute) needed to maintain that pressure. We commonly reference trying to supply water to a fire hose with a garden hose, it is the same principle, in regards to compressed air.

When looking to maintain an efficient compressed air system, it’s important that you use properly sized supply lines and fittings to  support the air demand (SCFM) of the point-of-use device. The smaller the ID and the longer the length of air supply line, it becomes more difficult for the air to travel through the system. Undersized supply lines or piping can sometimes be the biggest culprit in a compressed air system as they can lead to severe pressure drops or the loss of pressure from the compressor to the end use product.

Take for example our 18″ Super Air Knife. An 18″ Super Air Knife will consume 52.2 SCFM at 80 PSIG. We recommend using 1/2″ Schedule 40 pipe up to 10′ or 3/4″ pipe up to 50′. The reason you need to increase the pipe size after 10′ of run is that 1/2″ pipe can flow close to 100 SCFM up to 10′ but for a 50′ length it can only flow 42 SCFM. On the other hand, 3/4″ pipe is able to flow 100 SCFM up to 50′ so this will allow you to carry the volume needed to the inlet of the knife, without losing pressure through the line.

Pipe size chart for the Super Air Knife

Another problem area is using restrictive fittings, like quick disconnects. While this may be useful with common everyday pneumatic tools, like an impact wrench or nail gun, they can severely limit the volumetric flow to a device requiring more air , like a longer length air knife.

1/4″ Quick Connect

For example, looking at the above 1/4″ quick disconnect, the ID of the fitting is much smaller than the NPT connection size. In this case, it is measuring close to .192″. If you were using a device like our Super Air Knife that features 1/4″ FNPT inlets, even though you are providing the correct thread size, the small inside diameter of the quick disconnect causes too much of a restriction for the volume (SCFM) required to properly support the knife, resulting in a pressure drop through the line, reducing the overall performance.

If you have any questions about compressed air applications or supply lines, please contact one of our application engineers for assistance.

Jordan Shouse
Application Engineer

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Why Start a Leak Prevention Program?

Published on by Jordan T ShouseLeave a comment

All compressed air systems will have some amount of leakage. It is a good idea to set up a Leak Prevention Program.  Keeping the leakage losses to a minimum will save on compressed air generation costs, and reduce compressor operation time which can extend its life and lower maintenance costs.

The Compressed Air Challenge estimates an individual compressed air leak can cost thousands of dollars per year when using $0.07/kWh.

  • 1/16″ diameter hole in excess of $700/year
  • 1/8″ hole in excess of $2900/year
  • 1/4″ hole in excess of $11,735 per year

There are generally two types of leak prevention programs:

  • Leak Tag type programs
  • Seek-and-Repair type programs

Of the two types, the easiest would be the Seek-and-Repair method.  It involves finding leaks and then repairing them immediately. For the Leak Tag method, a leak is identified, tagged, and then logged for repair at the next opportune time.

A successful Leak Prevention Program consists of several important components:

  • Document your Starting Compressed Air Use – knowing the initial compressed air usage will allow for comparison after the program has been followed for measured improvement.
  • Establishment of initial leak loss – See this blog for more details.
  • Determine the cost of air leaks – One of the most important components of the program. The cost of leaks can be used to track the savings as well as promote the importance of the program. Also a tool to obtain the needed resources to perform the program.
  • Find the leaks – Leaks can be found using many methods.  Most common is the use of an Ultrasonic Leak Detector, like the EXAIR Model 9061.  See this blog for more details. An inexpensive handheld meter will locate a leak and indicate the size of the leak.

    Model 9061
    Model 9061
  • Record the leaks – Note the location and type, its size, and estimated cost. Leak tags can be used, but a master leak list is best.  Under Seek-and-Repair type, leaks should still be noted in order to track the number and effectiveness of the program.
  • Plan to repairs leaks – Make this a priority and prioritize the leaks. Typically fix the biggest leaks first, unless operations prevent access to these leaks until a suitable time.
  • Record the repairs – By putting a cost with each leak and keeping track of the total savings, it is possible to provide proof of the program effectiveness and garner additional support for keeping the program going. Also, it is possible to find trends and recurring problems that will need a more permanent solution.
  • Compare and publish results – Comparing the original baseline to the current system results will provide a measure of the effectiveness of the program and the calculate a cost savings. The results are to be shared with management to validate the program and ensure the program will continue.
  • Repeat As Needed – If the results are not satisfactory, perform the process again. Also, new leaks can develop, so a periodic review should be performed to achieve and maintain maximum system efficiency.

An effective compressed air system leak prevention and repair program is critical in sustaining the efficiency, reliability, and cost effectiveness of an compressed air system.

If you have questions about a Leak Prevention Program or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer
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Twitter: @EXAIR_JS

Proper Compressed Air Supply Plumbing Equals Success

Published on by Tyler DanielLeave a comment

EXAIR manufactures and stocks Super Air Knives in lengths ranging from 3”-108”. They’re designed to dramatically reduce compressed air usage when compared to similar blowoffs while still maximizing both force and flow. With an air entrainment ratio of 40:1, it’s the ideal solution for a variety of applications that necessitate a wide, laminar sheet of high velocity airflow.

I recently worked with a customer who makes wooden pallets. They were using a Model 110048 48” Super Air Knife to remove sawdust from the pallets prior to stacking them. When the grooves are cut into the pallet to accommodate the forks from a forklift or pallet-jack, there’s a good amount of sawdust that remains on the pallet. They would prefer to not have sawdust all over the finished pallets that they send to customers, so they looked towards a Super Air Knife to provide a curtain of air capable of removing that sawdust just prior to stacking them.

They purchased the Model 110048, but after installing it they didn’t get the level of force they had been hoping for. After some initial discussions, we identified that the issue lied with the plumbing of the air supplied to the knife. A 48” Super Air Knife will need to be fed with compressed air to (3) of the ¼ NPT air inlets. This ensures that an adequate volume of air is fed to the full length of the knife, keeping a consistent airflow.

Not only had they been plumbing compressed air to just (1) air inlet, but they were also using a restrictive quick-disconnect fitting. The I.D. of a quick connect fitting restricts the overall volume of air that can be passed through it. Length of the pipe or hose is also critical as the diameter of the pipe will need to be larger for longer runs or greater volumes. Accompanying any Super Air Knife is our Installation & Maintenance Guide which outlines the necessary requirements for each available length that we have available as well as how many air inlets need to be supplied with compressed air.

SAK pipe sizing

To confirm that air supply was the issue, they installed a pressure gauge directly at the air inlet to the knife. Line pressure was around 90 PSIG, but when they opened the valve and supplied air to the knife the pressure gauge dropped all the way to 35 PSIG. We’ve talked about pressure drop before here on the EXAIR Blog, the only way to confirm this is to take a pressure reading directly at the air inlet.

They removed the quick disconnect fitting, increased to a 1/2″ supply hose in place of 1/4″, and plumbed compressed air to each end and the center air inlet. On all Super Air Knives, compressed air inlets are available on either end as well as on the bottom. After fixing their plumbing, they noticed a dramatic increase in both force and flow and the pressure directly at the air inlet increased to 85 PSIG. The sawdust was easily blown off of the pallets and the customer was pleased that their pallets were free of sawdust.

sak pallet

At EXAIR, we stand by our products with the Unconditional 30 Day Guarantee. If you’ve just purchased a new product and aren’t seeing the results that you were hoping for give us a call. Our highly-trained team of Application Engineers is ready and standing by to investigate the application and provide support to help make sure you’re getting the most out of our products. Most of the times the solution is simple, but we won’t be satisfied until we find a resolution!

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

Starting a Leak Prevention Program

Published on by Leave a comment

Since all compressed air systems will have some amount of leakage, it is a good idea to set up a Leak Prevention Program.  Keeping the leakage losses to a minimum will save on compressed air generation costs,and reduce compressor operation time which can extend its life and lower maintenance costs.

SBMart_pipe_800x

There are generally two types of leak prevention programs:

  • Leak Tag type programs
  • Seek-and-Repair type programs

Of the two types, the easiest would be the Seek-and-Repair method.  It involves finding leaks and then repairing them immediately. For the Leak Tag method, a leak is identified, tagged, and then logged for repair at the next opportune time.  Instead of a log system, the tag may be a two part tag.  The leak is tagged and one part of the tag stays with the leak, and the other is removed and brought to the maintenance department. This part of the tag has space for information such as the location, size, and description of the leak.

The best approach will depend on factors such as company size and resources, type of business, and the culture and best practices already in place. It is common to utilize both types where each is most appropriate.

A successful Leak Prevention Program consists of several important components:

  • Baseline compressed air usage – knowing the initial compressed air usage will allow for comparison after the program has been followed for measured improvement.
  • Establishment of initial leak loss – See this blog for more details.
  • Determine the cost of air leaks – One of the most important components of the program. The cost of leaks can be used to track the savings as well as promote the importance of the program. Also a tool to obtain the needed resources to perform the program.
  • Identify the leaks – Leaks can be found using many methods.  Most common is the use of an Ultrasonic Leak Detector, like the EXAIR Model 9061.  See this blog for more details. An inexpensive handheld meter will locate a leak and indicate the size of the leak.

    ULD_Pr
    Using the Model 9061 Ultrasonic Leak Detector to search for leaks in a piping system
  • Document the leaks – Note the location and type, its size, and estimated cost. Leak tags can be used, but a master leak list is best.  Under Seek-and-Repair type, leaks should still be noted in order to track the number and effectiveness of the program.
  • Prioritize and plan the repairs – Typically fix the biggest leaks first, unless operations prevent access to these leaks until a suitable time.
  • Document the repairs – By putting a cost with each leak and keeping track of the total savings, it is possible to provide proof of the program effectiveness and garner additional support for keeping the program going. Also, it is possible to find trends and recurring problems that will need a more permanent solution.
  • Compare and publish results – Comparing the original baseline to the current system results will provide a measure of the effectiveness of the program and the calculate a cost savings. The results are to be shared with management to validate the program and ensure the program will continue.
  • Repeat As Needed – If the results are not satisfactory, perform the process again. Also, new leaks can develop, so a periodic review should be performed to achieve and maintain maximum system efficiency.

In summary – an effective compressed air system leak prevention and repair program is critical in sustaining the efficiency, reliability, and cost effectiveness of an compressed air system.

If you have questions about a Leak Prevention Program or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer
Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_BB