Growing up as a kid of the 80’s I remember wanting a Nintendo 64. This was very much a want due to the excellent advertising and having friends that got them when they first came out. So, like many kids of the times, I set forth to present my case to my parents and sell them on the benefits to me receiving this 64 bit wonder of the world. These benefits all revolved around me doing chores and “helping” to earn money to go towards the end goal. Thinking back now, I really should have started to learn more about negotiating earlier in life because my parents and older brother really made out on the deal. The point is, I had to make sure that they saw a return on their investment. Mainly, I would be entertained and they would get some stuff done around the house without complaints.
Well, flash forward to today and I still feel as though it is always an easy justification if I have supporting evidence of the benefits and even better, if there is some form of cost savings that will be had by spending money on a project or a tool. Often times the justification is the amount of time spent on a task. Well, here at EXAIR we completely embrace that justification culture and, in many cases, can provide you the information necessary to present to management or budget committee – the simple ROI your company will see when investing in EXAIR products. The best part is, this study is always free.
The way it works is pretty simple, we want to compare your current solution to our engineered products. EXAIR has a simple form that gets filled out (or you can call, e-mail or chat) explaining your application to us. We ask for a few key pieces of detailed information, and for you to send one of your current solutions (the nozzle, homemade device, or open tube for example). Then we run side by side tests in house to determine air consumption, noise, and force at the same pressure you are using at your facility. That’s right, this testing is all done here at EXAIR through our EXAIR Efficiency Lab. We document these performance characteristics and send a report showing a simple return on investment for you if you replace your device with an EXAIR engineered solution.
This information is then easily backed up by our 30 day guarantee on stock products. Get the EXAIR solution in, test it in your facility and see how the savings stack up. If there is anything that doesn’t stack up, you simply let us know and send the units back.
The entire Efficiency Lab and 30 day guarantee are offered to all of our customers that are within the US and Canada. If you would like to discuss what is possible for you and your team, please reach out to an Application Engineer.
If you’re a follower of the EXAIR Blog, you’re probably well aware that compressed air is the most expensive utility in an industrial environment. The average cost to generate 1000 Standard Cubic Feet of compressed air is $0.25. If you’re familiar with how much air you use on a daily basis, you’ll understand just how quickly that adds up. To make matters worse, many compressed air systems waste significant amounts of compressed air just through leaks. According to the Compressed Air Challenge, a typical plant that has not been well maintained will likely have a leak rate of approximately 30%!! Good luck explaining to your finance department that you’re carelessly wasting 30% of the most expensive utility. To make sure you get the most out of your compressed air system, it’s important to follow the Six Steps to Optimizing Your Compressed Air System.
Starting with Step 1: Measure the air consumption to find sources that use a lot of compressed air. In order to have an understanding of your compressed air usage across various processes and in your entire facility, you have to measure and produce a baseline. Without a measurement of usage, there’s no way to determine your actual costs or evaluate opportunities for savings. To do so, EXAIR offers a range of Digital Flowmeters from stock. The Digital Flowmeter provides a digital readout of the exact amount of compressed air being used. Many companies will install the DFM on each major leg of their air distribution system to allow for constant monitoring and provide a benchmark of compressed air usage.
Once you’ve measured your baseline, it’s time to explore another simple avenue of savings. Step 2 in the process is finding and fixing leaks in your current system. EXAIR offers our Model 9061 Ultrasonic Leak Detector to allow you to locate and fix any leaks within your distribution system. With an unmaintained system wasting on average 30% of the produced volume, this one seems like a no-brainer but is often overlooked. If you can hear the leak without the help of a device like the ULD, it’s a VERY bad leak. These should be located, tagged, and repaired ASAP!
After getting a baseline measurement of the air consumption in your facility of compressed air usage and locating and fixing leaks in your system, it’s time to begin implementing some changes. Step 3 of the 6 Steps to Optimizing Your Compressed Air System covers upgrading your blowoff, cooling, and drying operations using engineered compressed air products. EXAIR manufactures a variety of products that can help to ensure you’re using your compressed air in the best way possible. While it may seem simple, easy, and cheap to use something like an open-ended pipe or tube for blowoff, the fact of the matter is that the volume of air that these homemade solutions use quickly make them more expensive. Look no further than EXAIR when seeking a safe, efficient, and reliable engineered blowoff solution.
Step 4 may be the easiest of any of the others. TURN IT OFF! You can’t waste compressed air when it’s turned off. By strategically placing valves at various points throughout the distribution system, it allows you to isolate areas of the facility that may not require continuous compressed air usage. It isn’t exactly feasible to eliminate every single leak, so even if you’ve closely followed Step 3 it’s still beneficial to close some valves here and there to further reduce your consumption. In some applications, such as products traveling on a conveyor, it may be possible to utilize a product like EXAIR’s Electronic Flow Controller to ensure air isn’t wasted in between parts on the conveyor.
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. 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. They should be placed strategically to provide a source of compressed air to intermittent high-volume applications.
The last step, Step 6, discusses the use of pressure regulators at the point of use. Pressure regulators are available to control the air pressure within the system and throttle the appropriate supply of air to any pneumatic device. As the last of the six steps to optimizing your compressed air system, controlling air pressure so that you’re only consuming as much as necessary can have a dramatic impact. EXAIR sells a variety of systems that will include a suitably sized pressure regulator to ensure you’re operating as efficiently as possible.
Follow these 6 steps and make sure you get the most out of your compressed air system!
EXAIR not only has products that will reduce your air consumption, cost and noise levels but also has the tools to help you calculate the annual savings and Return on Investment (ROI). Sometimes you have the materials in house to make your own pneumatic tools so you get that piece of pipe in the maintenance crib, drill several holes and connect your compressed air. It works, your team is proud of the solution and everyone moves on to the next fire, right?
Several projects later you notice that your compressed air usage seems very high so a team is assembled and challenged with a cost savings program geared towards compressed air savings. EXAIR is the company that can help. We have Intelligent Compressed Air Products, Free Expert Technical Help and savings calculators that can be used to show the savings in your reports and presentations. EXAIR’s cost savings calculator will simplify the savings for each process you study and help your efforts in purchase justifications.
We have several examples of helping our customers save money such as this blog by one of our talented Application Engineers. You will realize more than cost savings as you should also see significant sound reductions and safety improvements as all of our products meet or exceed OSHA standard 29 CFR 1910.95 (a) which outlines allowable noise exposure for personnel and OSHA standard 29 CFR1910.242 (b) Dead End Pressure requirements.
When you begin compressed air cost savings program and have questions as to where to start, how to calculate and how to prepare your justifications please give EXAIR a call and talk with one of our many talented Application Engineers. EXAIR’s Intelligent Compressed Air products and Application Engineers will support all your efforts to decrease compressed air usage, reduce sound levels and increase the safety of your environment.
When discussing ROI, return on investment, for an industrial compressed air system it is necessary to understand what it costs to produce compressed air. Generally we calculate that it costs .25 cents to produce 1,000 SCF (Standard Cubic Feet) of compressed air here in the Midwest of the United States. For our example let’s consider a typical 250 HP industrial compressor running 24 hours per day/5 days per week for 52 weeks. This compressor can generate 374,400,000 SCF per year, using the industry standard utility cost for the Midwest of .25 cents per 1,000 SCF it will cost $93,600 to produce that volume of compressed air.
To avoid wasting money on compressed air generation it is extremely important to eliminate unintended or wasteful compressed air use in your plant. The two main offenders are leaks and open tube blow-offs. While soapy water is a good method for discovering leaks, EXAIR offers the Ultrasonic Leak Detector. This handy device allows leaks to be detected at distances of up to 20′ away! Also consider how safe and convenient it is to find leaks in overhead pipes while standing on the ground instead of on a ladder. Using a tool like this to do an entire system leak audit can easily result in many small leaks being identified and when fixed result in a large savings.
Now let’s look at what an open pipe or tube may consume. A single 1/4″ OD copper tube can use 33 SCFM @ 80 PSIG inlet pressure. Using the manifold pictured above as our example with 13 open tubes, each tube can consume 33 SCFM @ 80 PSI inlet pressure. With 13 open tubes running 24 hours a day, 5 days a week, 52 weeks per year equates to a total consumption of 160,617,600 SCF annually. If we installed the EXAIR model 1100 Super Air Nozzle using a simple compression fitting we would reduce the air consumption dramatically. The EXAIR 1100 Super Air Nozzle consumes 14 SCFM @ 80 PSIG inlet pressure, running 24 hours a day, 5 days a week, 52 weeks per year equates to a total consumption of 68,140,800 SCF annually. That change will save you 92,476,800 SCF annually which is equal to $23,119.20 and 24.7% of air compressor capacity! These calculations are all based on continuous running applications, if intermittent operation is possible consider the EXAIR Electronic Flow Control for even greater savings. The EXAIR Electronic Flow Control combines a photoelectric sensor with timing control that limits compressed air use by turning it off when no part is present
Open pipe blow offs also violate OSHA standard 29 CFR 1910.242(b) requirement for using compressed air for cleaning when pressurized above 30 PSIG. Not to mention they generally are louder than 90 dBA, which is the maximum allowable noise exposure without hearing protection under OSHA standard 29 CFR – 1910.95 (a). The EXAIR engineered Super Air Nozzle is a great way to avoid a OSHA fine.
A great product that will help you keep your fingers on the pulse of compressed air consumption and demand is by incorporating the EXAIR Digital Flow Meter. This handy item mounts directly to the pipe. The digital display shows the amount of compressed air being used in any leg of your distribution system. The Digital Flow Meter is offered in sizes for 1/2″ – 4″ Schedule 40 Iron Pipe and 3/4″ – 4″ Copper Pipe. It also is available with the Summing Remote Display that is prewired with a 50′ cable, it is powered by the Digital Flow Meter and with a push of the button will display either the current compressed air consumption, consumption for the previous 24 hours or the total cumulative usage.
The Digital Flowmeters are also available with wireless capability using the ZigBee mesh network protocol, data can be passed from meter to meter to extend the distance over which the wireless system can operate. Each meter has a range of up to 100′ (30 meters). Or you can opt for the USB Data Logger option. The USB Data Logger can store approximately 9 hours of readings if set to sample once every second or up to 2 years if sampled every 12 hours.
If you would like to talk about any of the quiet EXAIR Intelligent Compressed Air® products or our line of Optimization Products, feel free to contact me or any EXAIR Application Engineer.
Russ Bowman, CCASS
Application Engineer EXAIR Corporation Visit us on the Web Follow me on Twitter Like us on Facebook