Step 4 of the Six Steps to Optimizing your compressed air is to turn off your compressed air when it is not in use. This step can be done using two simple methods either by using manual controls such as ball valves or automated controllers such as solenoid valves. Manual controls are designed for long use and when switching on and off are infrequent. Ball Valves are one of the most commonly used manual shut offs for compressed air and other fluids.
Manual Valves allow for operators to turn on and off their system by hand. The full-flow ball valves range from ¼” NPT to 1 1/4” NPT in size and will not restrict flow. EXAIR also offers a manual foot pedal valve for hands-free operations. This ¼” NPT foot valve has a 3-way operation and works great if the operator has to use both hands in their process.
Solenoid Valves are a way to turn on and off the supply of compressed air electrically for automated systems. We offer solenoids in three different voltages; 110Vac, 240Vac, and 24Vdc. EXAIR has a large range of flows with ports ranging from ¼” NPT to 1” NPT. All models are UL listed and are CE and RoHS compliant.
By turning off your compressed air, whether it be with manual or automated controllers, a company can minimize wasted compressed air and extend the longevity of the air compressor that is used to supply the plants air. The longevity of the air compressor is increased due to reduced run time since it does not need to keep up with the constant use of compressed air. Other benefits include less use of compressed air and recouped cost of compressed air.
If you have any questions on how these easy to install accessories can help save you money give us a call! One of our application engineers will be happy to assist!
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.
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.
One way to use the Electronic Flow Control would be for Turning a Atomizing Spray nozzle on to coat your product. For example see the photo below where you could use the EFC to sense the pants coming down the line. Then turn the air supply on to spray a bleach solution to get the weathered look you are after. Once the pants pass the EFC will turn the nozzle off, replacing a manual operation awhile saving compressed air and your liquid solution!
Another use would be to tell when a hopper that is being filled by a Line Vac is empty or over filled. You can adjust the sensor and the control module to sense that the hopper is empty and it will turn the compressed air on to the Line Vac to then feed the hopper. Then set the timer module so it will run for the length of time it takes to fill the hopper. The other way would be to place the sensor at the top of the hopper and have it sense when the pile of media has reached the full level.
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
The Digital Flowmeter is available from stock for use on Schedule 40 pipe with sizes ranging from ½”-4” I.D. Sizes up to 8” for Schedule 40 and ¾”-4” for copper pipe are also available. Metric sizes are also available for 25mm, 40mm, 50mm, 63mm, 76mm, and 101mm. With a digital readout display, it’s easy to accurately monitor your compressed air usage throughout the facility. Creating a baseline of your usage will allow you to understand your compressed air demand, identify costly leaks, and replace inefficient air products.
The Digital Flowmeter installs in minutes with help from a drill guide and locating fixture to assist in mounting the Digital Flowmeter to the pipe. Two flow sensing probes are inserted into the drilled holes in the pipe. The meter then seals to the pipe once tightened. There is no need to cut, weld, or do any calibration once it is installed. With blocking rings also available, installation can be permanent or temporary. Below is a easy to follow video on how to install EXAIR’s Digital Flow Meter!
The newest addition to this product line is the Digital Flowmeter with wireless capability. Using a ZigBee® mesh network protocol, data is transmitted to an Ethernet connected gateway. This allows you to mount the Digital Flowmeter in areas that you may not be able to easily access and wirelessly monitor and graph the usage with the EXAIR Logger software. Take a peek at this video blog for a demonstration of the use of a wireless Digital Flowmeter software to compare an open pipe to an engineered Air Nozzle.
In addition to communicating wirelessly with the gateway, the Digital Flowmeters can “piggyback” off of each other to extend their range. Each meter has a range of 100’. Using multiple Digital Flowmeters within the same ZigBee® mesh network, data can be passed from meter to meter to extend the distance over which the meters can operate. These can be installed on each major leg of your compressed air system to continuously monitor usage throughout the facility.
If you’d rather go with a hard-wired data collection method, the Digital Flowmeter is also available with a USB Data Logger. Simply remove the Data Logger from the Digital Flowmeter and connect it to the USB port of your computer. The data can then be viewed directly in the accompanying software or exported into Microsoft Excel.
Two special flow meter options we now offer are the Pressure Sensing Digital Flowmeters, and the Hot Tap Digital Flowmeters!
Pressure Sensing Digital Flowmeters help by generating a pressure and consumption profile of a system can help to pinpoint energy wasters such as timer-based drains that are dumping every hour versus level based drains that only open when needed. Hot Tap Digital Flowmeters offer a way to install a flow meter on a pipe that is currently under pressure. It uses a series of valves and mufflers to maintain a safe working environment for the installer.
If you’d like to get a clear view of your compressed air usage, give us a call. An Application Engineer will be happy to work with you and get the proper Digital Flowmeters installed in your facility!