Save Compressed Air with the EXAIR Electronic Flow Control

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
EXAIR EFC

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

Jordan Shouse
Application Engineer

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EXAIR Digital Flow Meters

A topic that we’ve talked about here on the EXAIR blog discusses the costs of compressed air and how to use it more efficiently. How can you determine the costs of your compressed air? The first step you’ll need to take is to put a number to how much compressed air you are currently using. In order to do that you’ll need a measurement tool such as the EXAIR Digital Flowmeter.

EXAIR Digital Flow Meters

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.

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Wireless output gives you the freedom to track air usage data from any computer!

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.

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Add a Data Logger for easy Value Tracking

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!

Jordan Shouse
Application Engineer

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Save Your Compressed Air Today with These Simple Methods

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.

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Thirteen Open Tube Blow-Offs

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
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6 Steps to Air Savings: Step 1 – Measure!

Six Steps to Optimizing Your Compressed Air System

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 20%!! Good luck explaining to your finance department that you’re carelessly wasting 20% of the most expensive utility. Step 1 of the 6 steps to optimizing your compressed air system is to measure the air consumption to find sources that consume a lot of air.

In order to have an understanding of your compressed air usage across various processes and in your entire facility, you have to measure. 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 in sizes from as small as ½” Schedule 40 iron pipe and up to 4” Schedule 40 pipe from stock. Larger sizes and pipes calibrated for use on copper or metric pipe are also available.

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.

Each meter has a built in LED display that provides the volume of air moving through the pipe in SCFM, m3/hr, or m3/min. Two small probes are inserted into holes in the pipe (drill guide kit w/ drill bit included) to detect the airflow. The unit seals to the pipe once the clamps are tightened. (If the DFM ever needs to be removed, EXAIR also offers blocking rings to seal off the holes) No cutting, welding, adjustments or calibrations are ever required.

In addition to the standard Digital Flowmeter itself, it’s also offered with wireless capability to transmit the data back to your PC, or via USB Data Logger. Both of these options will allow you to track usage over time and upload that data into an Excel spreadsheet.

EXAIR’s Digital Flowmeter w/ USB Data Logger

If you’re “flying blind” when it comes to understanding your costs of compressed air in your facility, this is the first step. Contact an EXAIR Application Engineer today to get started. We’ll be happy to help you identify areas where you could take advantage of simple savings.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD