Optimizing Your Current Compressed Air System Is Simple

A few weeks ago, we posted a blog discussing how artificial demand and leaks can lead to poor performance and expensive waste.  Today, I’d like to review how following a few simple steps can help optimize your current compressed air system and reduce compressed air usage.

The first step you want to consider is measuring the air usage in the system. To do this, you want to start at the compressor and check individual leads to each drop point to a blowoff device, record your findings to track the demand. By measuring your compressed air usage, you can locate the source of high usage areas and monitor the usage on each leg of the system. If the demand exceeds the supply, there is potential for problems to arise, such as lowered pressure and force from compressed air operated devices leading to irregular performance.

Digital Flowmeter with wireless capability

EXAIR’s Digital Flowmeters are designed to measure flow continuously and accurately to give you real-time flow measurements of your compressed air system to help identify problems areas.

Step 2 is to locate the source of waste. Again, compressed air leaks can result in a waste of up to 30% of a facility’s compressor output. A compressed air leak detection and repair program can save a facility this wasted air. Implementing such a program can be used as a way for a facility to “find” additional air compressor capacity for new projects. Whenever a leak occurs, it will generate an ultrasonic noise.

Model # 9061 Ultrasonic Leak Detector

Our Ultrasonic Leak Detector is designed to locate the source of ultrasonic sound emissions up to 20’ away. These ultrasonic sound emissions are converted to a range that can be heard by humans. The sound is 32 times lower in frequency than the sound being received, making the inaudible leaks, audible through the included headphones and the LED display gives a visual representation of the leak.

The 3rd step involves finding the source of noisy and wasteful blowoffs, like open pipes or homemade blowoffs, and replacing them with an energy efficient, engineered solution. By replacing these devices, you are not only reducing the amount of waste but also improving operator safety by complying with OSHA safety requirements.

Model # 9104 Digital Sound Level Meter

EXAIR’s Digital Sound Level Meter is an easy to use instrument that measures and monitors the sound level pressure in a wide variety of industrial environments. The source of loud noises can be quickly identified so that corrective measures can be taken to keep sound levels at or below OSHA maximum allowable exposure limits.

The easiest way to reduce compressed air usage and save on operating expense is to turn off the compressed air to a device when it isn’t needed, step 4 in the process. Not only will this save money, in many cases, it can also simplify a process for the operator.

 

Sizes from 1/4″ NPT up to 1-1/4″ NPT are available

A simple manual ball valve and a responsible operator can provide savings at every opportunity to shut down the air flow.

 

120VAC, 240VAC or 24VDC

 

For automated solutions, a solenoid valve can be operated from a machine’s control. For example, if the machine is off, or a conveyor has stopped – close the solenoid valve and save the air.

 

 

Model # 9040 Foot Valve

A foot pedal valve offers a hands free solution to activate an air operated device only when needed, such as being implemented in an operator’s work station.

 

EFC – Electronic Flow Control

For even more control, you can use a device like our EFC or Electronic Flow Control. This helps minimize compressed air usage by incorporating a programmable timing controlled (0.10 seconds to 120 hours) photoelectric sensor to turn off the compressed air supply when there are no parts present. It is suited for NEMA 4 environments and can be easily wired for 100-240VAC.

 

 

Step 5, intermediate storage. Some applications require an intermittent demand for a high volume of compressed air. By installing a receiver tank near the point of high demand, there is an additional supply of compressed air available for a short duration. This will help eliminate fluctuations in pressure and volume.

Model # 9500-60

EXAIR offers a 60 gallon, ASME approved vertical steel tank with mounting feet for easy installation near high demand processes.

Many pneumatic product manufacturers have a certain set of specifications regarding performance at stated input pressures. In many applications, or in the case of using a homemade blowoff device like open pipe, these wouldn’t necessarily require the full rated performance of the device or full line pressure. Controlling the air pressure at the point-of-use device will help to minimize air consumption and waste, step 6.

Pressure Regulators permit easy selection of the operating pressure

By simply installing a pressure regulator on the supply side, you can start off at a low pressure setting and increase the pressure until the desired result is achieved. Not only will this help to conserve energy by only using the amount of air required for the application, it also allows you to fine tune the performance of the point-of-use device to match the application requirements.

If you have any questions, please contact an application engineer at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

EXAIR’s EFC is THE Way to Save Compressed Air

waste

Compressed air is the most expensive utility for most industrial facilities. The energy costs associated with the generation of compressed air can be very high. Because of this, EXAIR manufactures a wide range of products geared towards reducing your overall compressed air consumption.

The best way to save compressed air is to simply turn it off when it’s not being used. This might seem pretty simple, but there may be processes in your facility where this couldn’t be achieved by just turning a valve. In applications where product is traveling along a conveyor, and must be dried, cooled, or blown off, there is likely some spacing in between the parts. It isn’t necessary to keep the blowoff running constantly if there’s periods of intermittent spacing. To help reduce the overall load on the air compressor, implementing a solution to shut the air off in between each part can have a dramatic impact. EXAIR’s Electronic Flow Control, or EFC, is designed to improve efficiency by reducing overall compressed air usage. It utilizes a photoelectric sensor that detects when the part is present. When it’s not, it triggers a solenoid valve to close and shut off the compressed air supply.

efcapp

 

Let’s take a look at an example that shows just how much air (and $$) an EFC can save. We had a manufacturer of car bumpers that was using a Model 112060 60” Super Ion Air Knife supplied at 40 PSIG to remove dust prior to a painting operation. The bumpers were moving at about 10’/minute and had 1’ of spacing in between each part. The bumpers are only under the blowoff for 10 seconds, while 6 seconds passed with no part present. With a (3) shift operation, this translates to 1,440 minutes of nonstop compressed air usage per day.

A 60” Super Ion Air Knife will consume 102 scfm at 40 PSIG. Their current method was using a total of 146,880 SCFM.

102 SCFM x 1,440 minutes = 146,880 SCF

With the EFC installed, the air was shut off for 6 seconds reducing the airflow by 37.5%. With the EFC installed, the compressed air consumption per day was reduced to 91,800 SCF.

146,880 SCF x .625 = 91,800 SCF

As a general rule of thumb, compressed air costs $0.25/1,000 SCF. By saving 55,080 SCF per day, this manufacturer was able to save $13.77 per day. Since this was a 24 hour/day shift running 7 day/week, total savings for the year came in at $5,012.28. This easily recoups the costs of the EFC and then begins to pay you in less than 6 months.

55,080 SCF x ($0.25/1,000 SCF) = $13.77

$13.77 x 7 days/week x 52 weeks/year = $5,012.28

The EFC models available from stock can accommodate flows up to 350 SCFM. For applications requiring more compressed air, EFCs with dual solenoids are also available. If you have an application in one or more of your processes where intermittent compressed air use could help save you money, give us a call. We’d be happy to take a look at the application and help determine just how quickly the EFC could start paying YOU!

Tyler Daniel
Application Engineer
E-mal : TylerDaniel@Exair.com
Twitter: @EXAIR_TD

Video Blog: The Monetary Benefits of an Engineered Solution

This video highlights the value and benefits of an engineered blow off solution.  We take a homemade open pipe blowoff and replace it with an EXAIR model 1100 Super Air Nozzle.  This air nozzle is then controlled through our Electronic Flow Controller, allowing for intermittent On/Off of the compressed air flow.  And, these solutions are wirelessly monitored via Zigbee network using our Wireless Digital Flowmeter.  Implementing these solutions results in a compressed air reduction of over 90%!!!

 

Full calculations along with supporting flow values (pulled from the same data shown in the video above) are shown below.

Screengrab of the flow values shown in the video above. Click for larger image.

The open pipe:

The first compressed air flow values to show up on the EXAIR Logger are for the open pipe blow off.  At 1 BAR operating pressure, this “solution” consumes 22.3 SCFM of compressed air.  At a cost of $0.25 for every 1,000 cubic feet of compressed air, this nozzle will cost $695.76 to operate 8 hours per day, 5 days per week, 52 weeks per year.

The engineered EXAIR Super Air Nozzle

Model 1100 EXAIR Super Air Nozzles consumes 4.7 SCFM at an operating pressure of 1 BAR – a reduction of 79% compared to the open pipe.  These savings prove out in terms of operating cost as well – $146.64 per year, compared to $695.76.

The engineered EXAIR Super Air Nozzle with Electronic Flow Control (EFC)

By controlling the “ON” time for this application with an EFC, we are only blowing for 32% of the time for each minute of operation which changes the required compressed air flow from 4.7 SCFM to a peak value of 1.5 SCFM. This control saves an additional 68% of compressed air flow.  And, these savings are compounded by eliminating the need for constant compressed air flow.  Total annual operating cost for the EXAIR 1100 Super Air Nozzle with Electronic Flow Control is just $46.80.

Implementing an engineered solution can have a TREMENDOUS impact on energy costs and operating costs in your facility.  Compressed air is the most expensive utility to produce and consume, making the impact of proper solutions of high value to any business.  Let us help you utilize engineered compressed air solutions in your facility by contacting an EXAIR Application Engineer today.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

EXAIR Leads the Way with Standards and Certifications

For over 34 years, EXAIR has been the industry leader in providing Intelligent Compressed Air Products to the industrial marketplace. While much of our focus is to ensure our products are engineered to provide optimal performance, we are also dedicated to manufacturing products that meet a wide range of standards and directives to promote safety in relation to plant personnel.

 

For instance, all of our compressed air operated products meet or exceed OSHA Standards 29 CFR 1910.242(b), requiring that the outlet pressure of an open pipe, nozzle, air gun, etc., when used for cleaning purposes, must remain below 30 PSI when dead-ended against the skin, as well as Standard 29 CFR 1910.95(a) as a way to protect workers from job related injuries related to dangerous sound levels of 90 dBA and higher.

 

 


Many of our products are also CE Compliant, meeting the mandatory requirements for products intended to be sold in the European Economic Area or “EEA”. For example our Electronic Flow Control and Electronic Temperature Control (ETC) meet the EU (European Union) Low Voltage Directive 2006/95/EC.

 

 

EXAIR electrically powered devices, like our Static Eliminators and Digital Flowmeters for example, comply with the “Restriction of Hazardous Substances” or RoHS Directive 2011/65/EU, including the amendment outlined in the European Commission decision L 214/65.

 

 

We are also committed to providing material that supports the conflict mineral free rule to help aid in the relief of illegal trade of exotic materials, like tungsten, gold, tin and tantalum in the DRC region. Using the CMRT 4.20 template, we document our supply resources to ensure we provide conflict free products, as outlined in Section 1502 of the Dodd-Frank Wall Street Reform and Consumer Protection Act.

 

Lastly, the European Union introduced the REACH program – Registration, Evaluation, Authorization and Restriction of Chemicals, as a method to register chemical substances being imported into the EU to protect people and the environment, per Regulation (EC) No 1907/2006 Title I, Article 3.  Also noted in the program, Title II, Article 7, they state that any product with a substance intended to be released under normal operating conditions, must be registered for quantities totaling more than 1 metric ton per year. Since EXAIR products do not intentionally release or contain any such substances, registration to meet the program is not required.

 

If you have any questions about any of these Standards or Directives or about which EXAIR products comply, please feel free to contact an application engineer for assistance. We’d be happy to help!

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Many Ways to $ave on Compressed Air Costs

Using compressed air in the plant is common for many types of processes.  Typical uses are drying, cooling, cleaning and conveying. Compressed air does have a cost to consider, and there are many ways to keep the usage and the costs as low as possible.  The first step is to use an EXAIR Intelligent Compressed Air Product, which has been engineered to provide the most performance while using the least amount of compressed air. The next step is to control the use of the air, to only have it on when needed.

EXAIR offers the EFC – Electronic Flow Control.  It offers the most comprehensive method to maximize the efficiency of compressed air usage.  It combines a photoelectric sensor with a timing control that operates a solenoid valve to turn on and off the air as required. With 8 different program types, an on/off mode that works with any process can be programmed ensuring that the minimum amount of compressed air is used.  You can use the online EFC Savings Calculator to see how quickly the savings add up!

EFCp4
EFC – Electronic Flow Control

Another method would be to use a solenoid valve with some other method of control. Depending on the process, the solenoid could be energized via a machine control output, or as simple as an electrical push button station. EXAIR offers solenoid valves in a variety of flow rates (from 40 to 350 SCFM) and voltages (24 VDC, 120 VAC and 240 VAC) to match the air flow requirements of the products we provide, while integrating into the facility and available supply voltages.

For control of the Cabinet Cooler Systems, the ETC – Electronic Temperature Control, uses a thermocouple to measure cabinet temperature and cycle the system on and off to maintain a precise cabinet temperature, and provides a digital readout of the internal temperatures and on the fly adjustment.  Also available is the Thermostat Control models, which utilize an adjustable bimetallic thermostat to control the solenoid valve, also cycling the unit on and off as needed to maintain a set cabinet temperature.

ETC CC
ETC – Electronic Temperature Control

There are several manual methods that can be used to control the compressed air.  A simple valve can be used to turn the air off when not needed, whether at the end of the work day, at break time, or whenever the air isn’t required.  We offer several options, from a foot controlled valve, to a magnetic base with on/off valve, to a simple quarter turn ball valve.

footpedalvalve (2)dualstand (2) manual_valves (2)

 

To discuss your processes and how an EXAIR Intelligent Compressed Air Product can control the air supply and save you money, feel free to contact EXAIR and myself or one of our other 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

 

 

There’s More Than 1 Way To Blow Some Air

Just today I spoke with a customer who is threading the ends of pipes and needs to blow the coolant and chips out of the threads.   The pipes range from 4″ to 9 – 5/8″ Diameters.  They are all threaded then fed into a trough and pushed down line to the next operation.

PEO ACWA
A machine with an out-feed roller conveyor similar to the pipe threading machine mentioned.

The photo above is not the exact machine but you can see where if this was used to process piping the different diameter pipes would all sit at the same level.  One option could be to use a Super Air Wipe  for this application but then the smaller diameters would not pass through the center of the Air Wipe, instead they would pass through the bottom half of the airflow which may not give optimal performance. Instead, I suggested to use 4 of our 6″ Super Air Knife kits and 2 of our Electronic Flow Control units.

 

2 - 110006 - 6" Aluminum Super Air Knives coupled together w/  a 110900 SAK Connector Kit
2 – 110006 – 6″ Aluminum Super Air Knives coupled together w/ a 110900 SAK Connector Kit

I  suggested that we make two pairs of knives for this blowoff setup by coupling two of the 6″ Super Air Knives together.  Once they are coupled together like is shown above, we could mount the two coupled air knives vertically along the trough and blowing at a 45° angle toward the center of the conveyor.  The plumbing of the two bottom knives will be to one EFC while the top two knives will be plumbed to the other.    The sensors will then be set up at two different heights, lower knives to sense the bottom of the pipe and the upper knife sensor will be set just above the bottom 6″ knife.

The reason for using 4 – 6″ Super Air Knives and 2 EFCs instead of 2 – 12″ Super Air Knives and 1 EFC is to save the most compressed air possible.   By enabling them to turn the top two 6″ Super Air Knives off automatically when they are running below a 6″ diameter pipe.  Then when a larger pipe is processed the top knives will also kick on with the lower knives and provide a uniform blowoff of the product.

So if you have multiple sizes of product being processed on the same line and don’t think any one solution will work, contact us and see if we can’t come up with our own recipe.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Machine image courtesy PEO ACWA Creative Commons

 

The 4th Step to Compressed Air Savings

EXAIR’s Electronic Flow Controller (EFC) is a stand alone timing and control product for compressed air. The EFC combines a photo electric sensor, solenoid, and timing control to turn off compressed air, when a part is not present. The timing control comes with 8 different settings for delaying the opening of valve, delaying the closing of the valve, setting an interval, continuously operating or some combination of these settings. This flexibility makes it a great option for someone who is looking to control any compressed air device to conserve compressed air. It is a great option for a company that is implementing the Six Steps to Optimizing your Compressed Air System. The EFC is designed to implement the 4th step – turning compressed air off when it is not in use.

EFCp4

The EFC is certainly valuable when controlling EXAIR’s Long Super Air Knife. Here is an example: An automotive company blows off a 55″ tall body panel. A 60 inch Super Air Knife will use 174 SCFM of compressed air at 80 PSIG of inlet pressure. The body panels come by at a rate of two parts every minute, but each body panel is only in the air stream of the air knife for 20 seconds. This means for 20 seconds of every minute the air knife is running without doing any work. To stop wasting compressed air an EFC can be setup to open the solenoid for 20 seconds after the body panel passes the photoelectric sensor. This will save one third of the 174 SCFM or 58 SCFM. Typical industrial cost of compressed air is $0.25 per 1,000 SCF. This automotive plant runs 24 hours per day. The EFC would save 83,520 SCF of compressed air over 24 hours, which costs the automotive company $20.88. Over 250 working days in a year the EFC will save $5,220. This is huge savings for simple fast installation that can be installed in any intermittent compressed air application.

The EFC is a great solution for controlling your compressed air usage.  The ROI for the EFC can be huge depending on the size of your compressed air usage, but in all cases, it is a key step to developing a efficient compressed air system.

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com