The Value of Going Back to Where it All Began

This past week I was able to take part in one of the many incentives EXAIR offers to all of our team members, a volunteer day. EXAIR gives each employee the choice to go out into our community and choose an organization they connect with to volunteer for either a single 8-hour day or two 4-hour shifts. The past couple of years, I have reconnected with the director of the Mechanical Engineering Technology department at the University of Cincinnati where I received an undergraduate degree from to find out how I can get involved with the program and help the department that gave me the knowledge and understanding I use in my career. Much to my surprise, the first thing that came to mind for him was to be a judge at the College of Engineering and Applied Sciences Senior Tech Expo. This expo is where each student will showcase their Senior Design Project which they must complete in order to graduate. The judges are all alumni of their given programs and the students can elect to have their project be judged for various prizes that are donated by local companies and alumni. This was my third year judging for the MET department and there have been several of us that have networked and really get reminded of exactly where we were when we graduated and the amount of experience we lacked at the time.

There were 11 projects total in the MET discipline that were elected to be judged this year. We had 12 judges show up, so we broke into 4 teams. Three teams judged three projects while the remaining judged two larger scale projects. We judge the individuals/teams on different criteria like, communication skills, technical knowledge, presentation, complexity, marketability, and innovation. The projects my team evaluated were a hybrid system that would bolt onto an early 2000s Nissan Frontier and increase the vehicles’ efficiency, a team from the UC Battle Robotics Club, and a company-backed project to increase efficiency on vegetation mitigation equipment to better sustain power within the new equipment designs.

Each of these projects had great goals, highs, lows, oversights, learning points, and yet it was very great to see how truly vested each of these students had become in this project. They knew their subject inside and out and even when they had a pitfall come. This did not derail them, this took me back to when the team I was part of built a Basic Utility Vehicle as our project. We competed in a national competition with a vehicle which was fully funded by sponsorship we obtained and poured hours upon hours of work and sweat into it. The drivetrain which I designed did experience two different failures during our competition. Rather than loading up and taking a loss, we pushed through as a team, we made a new chain tensioner with parts from a hardware store, and found a judge with a welder nearby which permitted us to weld a broken attachment point back on. Ultimately, we took second place. A team of 4 students was only beaten by a team of 12 from Wisconsin. The experience I learned in that process and time during the competition truly taught me that if you are passionate about something you will make it happen. That’s the same level of passion I saw in each of the students that I interviewed during the judging cycle.

In the end, it really builds one of my favorite sayings, “You can’t teach experience.” Each of these students has experienced a lot, and yet they still have so much to learn. Without the volunteer program here at EXAIR, I may not have gotten to go back to my alma mater and participate as a judge for the Tech Expo. That’s an experience I have gained a lot from. Mainly, instead of asking judgmental questions, ask curiously. This often means asking open-ended questions that aren’t so pointed. This generally brings out more reasoning and explanation than one could expect and leads to a more comfortable discussion. These students all helped me to see that, and it let their passions shine straight through. Once the interviews were done, all the judges came together and dispersed $12,000 in prizes for various awards to these 11 projects within the Mechanical Engineering Technology Department. The passion I had for learning and projects still lives to this day. I still keep a list of ideas for EXAIR products that I am saving for rainy days or for the right time to test.

If you have a problem you can’t get past, need a curious question answered or need someone to share in your passion that involves industrial compressed air, moving, cleaning, cooling, coating, eliminating static, spraying, or conserving a resource, share it with us, we’ll be genuinely curious.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Pictionary Is Not What Should Come To Mind When Looking At Facility Drawings

Does anyone else remember the episode of Friends where they were playing Pictionary and no one could guess what Monica was drawing? No, well, honestly, that’s the scene I thought of when looking at some system drawings for compressed air setups. If you need a refresher, see the YouTube clip below.

1 – Pictionary | Friends

When trying to ensure you have a sustainable compressed air system within a facility, it is critical to ensure the layout is documented. This can be a very tedious task on existing systems that have been in place for years without any documentation, it doesn’t mean the idea should be lost. This can save considerable time and effort when looking at issues and or expansion of existing usage. The other point this can help greatly with is documenting and fixing leaks on your way to an optimized compressed air system.

Along that same line, I’ve seen numerous reports over the past decade that all point to improperly maintained filter drains in compressed air systems that account for a large percentage of the 30% total system leakage that facilities can see. So I want to educate on the different types of P&ID symbols used for regulators and filters on compressed air systems so that our readers can better their preventive maintenance plans and install checkpoints at each one of these on a routine schedule.

If you are evaluating your compressed air system and trying to come up with a preventive maintenance plan, then each one of these symbols should be on a preventative check routine in order to ensure they are not a contributing factor to compressed air waste within your facility.

If you want to discuss other ways to optimize your compressed air system or other P&ID symbols used for pneumatic system components, reach out to any of the team here, and we will help you with your current situation.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

1 – Friends, Pictionary|Friends – Retrieved from https://www.youtube.com/watch?v=yP2bX0ctoFs – published – 10/1/2023

Coandă Profiles

Here at EXAIR, Coandă is a household name that can be heard on any given day multiple times throughout the day. The Coandă effect is fairly easy to visualize with a ligthweight ball and some high velocity airflow. Take the video below for example. This 2″ Super Air Amplifier on a stand powered at 40 psig at the inlet easily lifts this hollow plastic ball and then suspends the ball due to the Coandă effect.

If you were able to see the airflow, you would see it impacting the surface of the sphere at all different points then following the profile of the sphere until it colides with itself and is forced to separate off the surface. The turbulent flow on the top is creating a downward pressure as well. The science behind this was all found and showcased by Henri Coandă. He showcased this with a propulsion device which used a domed hood with airflow to follow the curvature of the dome then exit off the sharp edge or where the separate air streams began to recombine causing a turbulent / low pressure area depending on the angle.

This stream of air following a surface begins to pull in all surrounding and impacted air molecules from around the stream which is called entrainment. This is a key factor for EXAIR products and one reason the Coandă profiles are a key characteristic to obtaining the peak performance and efficiency out of a compressed air product.

As the high velocity air stream exits the EXAIR model 1100 Super Air Nozzle the ambient air is entrained around the fins and angled surfaces of the nozzle.

Many EXAIR products utilize the Coandă principle to improve their efficiencies and performance. Below you can see the EXAIR product families containing Coandă profiles within their design which increases the ambient air entrainment resulting in an amplified air blowoff.

Super Air Wipes, Super Air Knives, Super Air Nozzles and Super Air Amplifiers use the Coanda principle to become some of the most efficient compressed air blowoff products available.

If you would like to discuss how the Coandă profile and EXAIR Intelligent Compressed Air Products® can help your process, please give us a call.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Consider these Variables When Choosing Compressed Air Pipe Size

Here on the EXAIR blog we discuss pressure drops, correct plumbing, pipe sizing, and friction losses within your piping system from time to time.   We will generally even give recommendations on what size piping to use.  These are the variables that you will want to consider when selecting a piping size that will suit your need and give the ability to expand if needed.

The variables to know for a new piping run are as follows.

  • Flow Rate (SCFM) of demand side (products needing the supplied compressed air)
  • System Pressure (psig) – Safe operating pressure that will account for pressure drops.
  • Minimum Operating Pressure Allowed (psig) – Lowest pressure permitted by any demand side point of use product.
  • Total Length of Piping System (feet)
  • Piping Cost ($)
  • Installation Cost ($)
  • Operational Hours ( hr.)
  • Electical Costs ($/kwh)
  • Project Life (years) – Is there a planned expansion?

An equation can be used to calculate the diameter of pipe required for a known flow rate and allowable pressure drop.   The equation is shown below.

A = (144 x Q x Pa) / (V x 60 x (Pd + Pa)
Where:
A = Cross-Sectional are of the pipe bore. (sq. in.).
Q = Flow rate (cubic ft. / min of free air)
Pa = Prevailing atmospheric absolute pressure (psia)
Pd  = Compressor discharge gauge pressure (psig)
V = Design pipe velocity ( ft/sec)

If all of these variables are not known, there are also reference charts which will eliminate the variables needed to total flow rate required for the system, as well as the total length of the piping. The chart shown below was taken from EXAIR’s Knowledge Base.

Piping
Airflow Through 1/4″ Shed. 40 Pipe

Once the piping size is selected to meet the needs of the system the future potential of expansion should be taken into account and anticipated for.   If no expansion is planned, simply take your length of pipe and start looking at your cost per foot and installation costs.    If expansions are planned and known, consider supplying the equipment now and accounting for it if the additional capital expenditure is acceptable at this point.

The benefits to having properly sized compressed air lines for the entire facility and for the long term expansion goals makes life easier.   When production is increased, or when new machinery is added there is not a need to re-engineer the entire system in order to get enough capacity to that last machine.   If the main compressed air system is undersized then optimal performance for the facility will never be achieved.   By not taking the above variables into consideration or just using what is cheapest is simply setting the system up for failure and inefficiencies.   All of these considerations lead to an optimized compressed air system which leads to a sustainable utility.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF