EXAIR Cabinet Cooler System Meets High Demands Of Sea Duty

I joined the Navy, right after high school, to get out of Ohio, see the world, and never come back. “My recruiter said” (if you are considering military service, those can be famous last words, just so you know) that I would be a good candidate for Nuclear Power School, so I took the test. As a math & science nerd scholar, I qualified for admission easily.  About halfway through Nuke School, I volunteered for submarines.  My decision was based in no small part on the sea stories of our instructors, the strong reputation of better food, and my deep appreciation for the movie “Operation Petticoat.”

Upon graduation, I was assigned to a new construction Trident submarine.  I did not see the world…I saw the Electric Boat shipyard in Groton, Connecticut, and Naval Submarine Base King’s Bay, Georgia.  Hilarity occasionally ensued, but never in the context of that movie I so adored.  I moved back to Ohio (on purpose) soon after my enlistment was up.  The food WAS good…I can unreservedly vouch for that.

In the new construction environment of the shipyard, I became quite familiar, and developed a deep respect for, the high level of attention paid to the materials and workmanship that a seagoing vessel demanded…not to mention, one with a nuclear reactor on board.  Reliability and durability are obviously key factors.

I had the pleasure recently of assisting an electrical contractor who was looking for a cooling solution for a new Variable Frequency Drive enclosure installation on a cement barge.  The ship’s engineer (a Navy veteran himself) had told the contractor that his priorities were reliability, durability, and dust exclusion.  He couldn’t have made a better case for an EXAIR Cabinet Cooling System.

Based on the specified heat load of the VFD, the size of the enclosure, and its location, a Model 4380 Thermostat Controlled NEMA 12 Cabinet Cooler System, rated at 5,600 Btu/hr, was specified.  This equipment is internal to the ship; had it been exposed to the elements, a NEMA 4X system would have been presented.

Up to 2,800 Btu/hr cooling capacity with a single Cabinet Cooler System (left) or as much as 5,600 Btu/hr with a Dual system (right.)

EXAIR Cabinet Cooler Systems have no moving parts to wear, no electric motor to burn out, and no heat transfer surfaces (like a refrigerant-based unit’s fins & tubes) to foul.  Once it’s properly installed on a sealed enclosure, the internal components never see anything but cold, clean air.

If you have a need to protect an electrical enclosure in aggressive environment, give me a call.  With a wide range of Cabinet Cooler Systems to meet a variety of needs, we’ve got the one you’re looking for, in stock and ready to ship.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

Troubleshooting Vortex Tube Performance

image-2

This Vortex Tube was not operating properly when initially connected to compressed air

One of the fun parts of Application Engineering at EXAIR is explaining the operation of Vortex Tubes to our customers.  Sometimes they’re described as a “reverse tornado” inside of a tube, spinning a pressurized airstream and converting it into a hot and cold flow.  Other times we describe it through the generation of two vortices with differing diameters, and the difference in diameters results in one vortex shedding energy in the form of heat.

But, no matter the way we explain their operation, we always stress the importance of proper compressed air plumbing.  If the compressed air piping/hoses/connections are not properly sized, performance problems can arise.  (This is true for any compressed air driven device.)

This fundamental came to light when working with one of our customers recently.  They were using a medium sized Vortex Tube to provide spot cooling in an enclosed space, but were not seeing the flow and temperature drop they knew to be possible with an EXAIR Vortex Tube.  And, after looking at installation photos of the application, the root cause was quickly spotted.

image-2-with-arrow

The red arrow in the bottom right corner of this image shows the beginnings of a reduction in compressed air supply.

I noticed what looked to be a very small hose connected to the inlet of the Vortex Tube in the image above.

image-1-with-circle

In this additional image, the small compressed air line is in full view. This was the root cause for performance problems in this application.

After further inspection of another photo, the small diameter tube was in full view.  This small hose serves as a restriction to compressed air flow, which in turn limits both flow and operating pressure of the downstream devices.  What that meant for this application, was poor performance from the Vortex Tube, all stemming from this reduction in piping size.

When looking to find the root cause of a performance issue with a compressed air driven unit, things aren’t always as easy as they were with this application.  A visual inspection is always a good idea, but if everything looks correct, here is a list of troubleshooting steps to consider:

  1. Check for quick-disconnects in the plumbing system.  Quick-disconnects are great from an operator’s perspective, but they can wreak havoc on compressed air flows due to small inside diameters and air volume restriction.
  2. Determine the operating pressure at the device.  This is imperative.  In order to make proper decisions to correct the performance concern, good information is required.  Knowing what is happening at the device is crucial for proper understanding.  There may be 100 PSIG at the main compressed air line, but only 60 PSIG at the device due to plumbing problems. A pressure gauge at the inlet of the compressed air product can provide this information.
  3. Check that the compressed air system has enough volume to properly supply the device.  A compressed air driven unit without the correct volume of compressed air is just as bad as having a lack of pressure.
  4. Check for leaks.  The US Department of Energy estimates that 20-30% of compressor output in industrial facilities is lost as leaks.  If your system and devices aren’t operating as they’re supposed to, check for leaks.  They may be contributing to the poor performance.  (Don’t know where your leaks are coming from?  Use our Ultrasonic Leak Detector!)

Fortunately for this customer, after improving the size of this tubing performance was on par with our published specifications and this customer was back in operation.  If you have a question about how to improve the utilization of the compressed air devices in your application, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

EXAIR Super Air Knives Can Make Everything Better…Even Popcorn!

You know the drill.  In almost any container of popcorn…whether it’s a movie theater bucket, a microwave bag, a stovetop pan (if you’re old school,) or a campfire popper (if you camp with class)…there’s always going to be some un-popped kernels.  And if you don’t pay particular attention to them, they might just activate your dental plan.

This is, unfortunately, an unavoidable inconvenience when dealing with freshly popped popcorn.  For a company that makes pre-packaged popcorn-based snacks, though, un-popped kernels are a real quality issue.  I just had the pleasure of helping a caller with this very issue: although they had a sifter device in place that took care of an awful lot of un-popped kernels, they still had enough getting through to merit a closer look.  Since the popcorn already passed through the sifter on a conveyor, the idea was to “float” the popped kernels across a short break in the conveyor, and let the un-popped kernels fall through.

After a short discussion of their needs, I recommended a Model 110224 24″ Aluminum Super Air Knife Kit. By using the Pressure Regulator (included with the kit) to dial in the air flow, they’re able to keep the popped deliciousness moving on for packaging, and let the dental hazards to fall through, where they’re sent back for another attempt at proper popping. So, they’re not only improving the quality of their product, they’re doing everything possible to make sure no kernel goes un-popped.

Super Air Knife Kits include a Shim Set, Filter Separator, and Pressure Regulator…everything you need to solve your application!

At EXAIR, we’re all about safety when it comes to compressed air use in industrial and commercial settings.  Now one of our products is helping protect peoples’ teeth while they’re eating popcorn snacks!  If you’d like to talk about how an EXAIR Intelligent Compressed Air Product might be able to make things better for you, give me a call.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

 

Super Air Knives Used as a Non-Contact Barrier in a Non-Woven Application

An overseas customer manufactures a 2.2 meter wide non-woven material.  In one of their processes, the media would travel through a spray booth to apply a water-based surfactant.  The surfactant was atomized and blown onto the top and bottom of the material.  The spray booth was equipped with a fume hood to capture any excess mist.  The material would then travel out of the spray booth and into the oven to dry.

Area between Spray Booth and Oven

Area between Spray Booth and Oven

Because they were running at a speed of 160 m/min, a draft was being created as the media was exiting the spray booth.  This draft was strong enough to overcome the vacuum pressure from the fume collection system.  This would allow the excess mist to escape the spray booth.  It was then collecting on the surface of the oven and floor outside the containment area.  This created a safety issue as well as a large mess.

In looking at the problem area, the dimension of the opening of the spray booth was 2.65 meters by 300 mm.  To blow a good curtain of air to contain the mist, we needed to have a laminar flow to create that “wall”.  I recommended two pieces of a model 1102108 Super Air Knife Kits.  At 108” (or 2.74m) long, they are the longest Super Air Knives in the market.  With a steady flow of air along the entire 2.74 meter length, it can generate that curtain of air across the entire opening of the spray booth.  The laminar flow was key as they did not want to disturb the spraying nozzles inside the booth.

The Super Air Knife Kit also comes with a filter, a regulator, and a shim set.  With the included shim set, the force can be changed dramatically by using a different thickness of shim.  Since they did not need much force to keep the mist inside the spray booth, they opted to put a thinner shim inside the Super Air Knife.  This would reduce the amount of compressed air needed, and with a regulator, the customer could “dial” in the correct amount of force to create the proper air barrier.  The Super Air Knives were mounted above and below the material to blow directly across the opening of the spray booth.  Any fine mist that would come in contact with the air would be deflected back into the spray booth.  With the extra mist removed from the process, the fume extraction system could then perform its duties the way it was intended. With air being used to create that barrier, it did not disrupt the structure of the material or the surfactant on its surface.

Super Air Knife

Super Air Knife

If you require a non-contact barrier for your application, EXAIR Super Air Knives could be your solution.  For this customer, we were able keep the work place safe and mess-free.

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

Offshore Pipe Welding Cooled with Series of EXAIR Super Air Nozzles

atoll_air-cooling-interpass-1

EXAIR model 1122 Flat Super Air Nozzles used to provide cooling blow off.

One of the services we provide to our customers, is assistance in selection of the most suitable product solution for their application.  For most applications we have solutions readily available from stock, though that wasn’t the case in the solution shown above.

atoll_air-cooling-interpass-6

This unique blow off solution cools welds on 450mm (18″) pipes.

This configuration of model 1122 Flat Super Air Nozzles is used to cool pipe welds in an application located off the coast of France.  Pipes with an OD of 450mm (~18”) are welded together, and in order for the welds to be of the highest quality, they must be cooled.  To cool the welds, this customer needed to blow ambient temperature air over the pipes.

atoll_air-cooling-interpass-9

Closeup of nozzles used in this application

Initially, we explored a Super Air Wipe solution.  A Super Air Wipe can provide a full 360° blow off for this pipe, but there was an aspect of the application which led to a better solution through nozzles; an irregularity in position of the pipe.

atoll_air-cooling-interpass-8

Another view of the 1122 Flat Super Air Nozzles

The diameter of the pipes in this application is relatively constant, but there is some fluctuation in position as the pipe is moved.  If using a Super Air Wipe, this could mean contact with a precision machined surface, resulting in a change to the performance of the unit.  But, what if we could find a way to allow the blow off solution to have some “flex”.

swivels

Flat Super Air Nozzles with swivels provide the unique solution needed for this application.

“Flex” in this solution is provided through the use of EXAIR model 9053 swivel fittings, shown above with red circles, each used to mount an 1122 Flat Super Air Nozzle (16 of each).  These allow for proper placement of the nozzles, and also for movement if anything should ever contact the blow off solution.

An additional benefit of the EXAIR 1122 nozzles used in this application, is the ability to exchange shims inside the nozzle to increase or decrease the amount of force delivered from the nozzle.

Understanding the critical requirements of the customer led to this semi-custom solution using EXAIR Super Air Nozzles.  If you‘d like to explore an EXAIR blow off solution for your application, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

EXAIR Atomizing Spray Nozzles Make It Nice & Foggy In Greenhouses

Fog. Nobody likes driving in it. It’s downright perilous to sailing vessels on the open water, but especially those near the shore, or other watercraft. Flights get delayed or cancelled, stranding travelers in airport terminals far from home, and keeping many from pressing matters that necessitated the speed of an airline flight in the first place.  Oh, and it’s ALWAYS where the bad guy is hiding in the movies.  You can tell by the ominous low-string music that starts playing right before things get real nefarious.

You know who LIKES fog, though?  Greenhouse operators.  Their plants get plenty of water to sustain their growth from the well-irrigated soil, but the leaves & petals can wither and get discolored if the humidity isn’t kept at a high level.

The same is true for the parts of a greenhouse that folks don’t see when they’re selecting the annuals to plant on the next nice spring weekend (which we should be coming up on quite soon here!) – like the seed germination chambers.  I had the pleasure of helping a greenhouse operator recently, who needed to replace some old, and malfunctioning, nozzles in one of their germination chambers.  They were interested in the extremely fine mist that our Atomizing Spray Nozzles produce.  After some experimentation with a couple of different flow rates & patterns, they determined that the Model AW1020SS (Wide Angle Round Pattern, Internal Mix) Atomizing Spray Nozzles provided optimal results.

The fine, atomized mist (left) produced by the EXAIR AW1020SS (right) optimizes the seed germination in this chamber.

The fine, atomized mist (left) produced by the EXAIR AW1020SS (right) optimizes the seed germination in this chamber.

As the fogging systems in their other chambers start to fail, they’ve been replacing them with the AW1020SS’.  We shipped them two earlier this week.

With (90) distinct models to choose from, we’ve got the solution to your liquid spraying application.

EXAIR Atomizing Spray Nozzles offer an incredibly wide range of flow rates, patterns, and adjustability to suit most any application that requires a fine liquid mist.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

Compressed Air Has Tremendous Power! Use It Safely

Just the other day, not far from here, a demolition crew at a shuttered factory and a local homeowner got this message, loud & clear, when the crew inadvertently cut into a still-pressurized compressed air cylinder.  It launched, like a missile (an apt description, given the fact that real missiles operate on this exact same principle) some 1,500 feet, across the neighborhood, and into the bedroom of a house, three blocks away.  Here’s what the local news reported on it:

Now, before you go turn your air compressor off and vent your system, let’s look at just a couple of other incredible dangers we place ourselves in close proximity to every day:

Driving a car: I came to work this morning in a 3,500lb mass of metal, plastic, and glass, hurtling at speeds of up to 65 miles per hour (that’s my story and I’m sticking to it.)  This would be an insane thing to do, were it not for:

*The engineering, design, and maintenance that makes the vehicle safe to operate,

*The training, experience, and periodic re-licensing required to maintain driving privileges,

*The upkeep of roadways, bridges, traffic signals, etc., and

*The monitoring and enforcement of traffic safety measures by our law enforcement officers.

Operating electrically powered devices:  if you’re reading this on a computer screen, you’re likely surrounded by objects that are connected directly to 120 volts of alternating current electricity.  That stuff will stop your heart.  Thank goodness all that current is contained, isolated, and grounded to keep it out of our bodies, even when we have to touch the controls to turn those devices on & off.

Food: Don’t even get me started on the hazards of ingesting plant & animal product that used to live outside and was processed for transport hundreds, or sometimes thousands, of miles away.  It’s a wonder any of us have made it this long.  Well, except for the development and rigorous implementation of food safety and sanitation practices & policy.

Working with compressed air is no different.  A typical plant compressed air system will operate at about 100psig.  That literally means that there is ONE HUNDRED POUNDS OF FORCE being exerted on EACH AND EVERY SQUARE INCH of the inside of the pipes, hoses, tanks, etc., in the system.  If you don’t keep it under control, you can have some serious problems.  Fortunately, there are simple, straightforward, and easily accessible ways to do that.

This is not going to be a comprehensive guide, but let’s start with:

Design: Your piping and components have to be the proper pressure rating.  We’ve got some good piping information on our websiteAlso, keep your vehicle well maintained, periodically check your electric devices for frayed cables, and look at your meat packages’ labels for a USDA stamp and “use by” date.

Our Compressed Air Piping web page is a valuable resource for safety AND efficiency (left.) Don't rely on smell or color; food package labels are your best indication of food safety (right.)

Our Compressed Air Piping web page is a valuable resource for safety AND efficiency (left.) Don’t rely on smell or color; package labels are your best indication of food safety (right.)

Controls: Make sure you’re using your compressed air safely.  OSHA Regulation 1910.242(b) governs the use of compressed air when used for cleaning purposes…it limits you to no more than 30psi of downstream, static pressure at the discharge of your blow off device.  EXAIR Intelligent Compressed Air Products comply with this regulation, by design.  Also, watch your speed on the highway, don’t plug too many strands of Christmas tree lights in to one outlet, and always cook chicken to an internal temperature of at least 165F (73.9C)

EXAIR Super Air Nozzles are fully OSHA Compliant - certificated available upon request (left.) Your power strip and Christmas tree light strands should both be labeled with their amperage ratings. Check these to make sure you don't overload the circuit (right.)

EXAIR Super Air Nozzles are fully OSHA Compliant – certificate available upon request (left.) Your power strip and Christmas tree light strands should both be labeled with their amperage ratings. Check these to make sure you don’t overload the circuit (right.)

Personal Protective Equipment: Any time you’re working with compressed air, you should be wearing eye protection and using appropriate chip guards to keep flying debris from coming back at you.  Certain applications may require more safeguards…check with your compliance coordinator or supervisor to make sure.  Also, don’t shift out of ‘park’ without your seat belt fastened, take care to unplug any appliance before servicing it, and don’t skimp on a decent pair of oven mitts if you plan on making a lot of baked goods.

EXAIR Safety Air Guns can be fitted with Chip Shields for OSHA Compliance (left.) Oven mitts come in all shapes & sizes - it would be illogical to reach for that lasagna without them (right.)

EXAIR Safety Air Guns can be fitted with Chip Shields for OSHA Compliance (left.) Oven mitts come in all shapes & sizes – it would be illogical to reach for that lasagna without them (right.)

EXAIR has been making quiet, efficient, and safe compressed air products for 34 years now.  If you ever have any questions about the safe use of compressed air, give us a call and ask for an Application Engineer.  No; compressed air isn’t safe, in and of itself…but it CAN be used safely…and that’s the important part.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

 

ef2d_star_trek_oven_mitt picture courtesy of Cozinhando Fantasias

d2590-1 picture courtesy of US Department of Agriculture

Holiday fire safety – Power strip overloaded picture courtesy of State Farm

Creative Commons Attribution 2.0 Generic License

%d bloggers like this: