The Blog of all Blogs: A Quick Resource of Blogs that we Blogged

EXAIR started writing Blogs in 2008. Since then, we have written well over 2000 Blogs. There is a ton of information in our Blog section on the website. There is most likely a Blog or 10 written about nearly each one of our products. These are primarily written by application engineers that know a thing or two about our products. There are also many application Blogs, that may be very relatable to what you are doing. When you journey to our Blog page (or simply click Blog form EXAIR.com), simply type in a key word or two in our search bar. This search bar is located just below the first row of published Blogs on the right hand of the screen, here is a screenshot of that section (right). You can also choose to follow our blog here as well.

As application engineers, we get asked questions every day. Many of these questions are best answered in one (or more) of these 2000+ Blogs. Many times a picture or video can answer your questions much more precisely than a quick conversation or an email. Many times we will send you a blog link to help. Drawing from my own experience, and asking the other Application Engineers for their lists, I wanted to put our most referenced blogs in one helpful location. I’ve categorized these the best that I can, and hopefully this will be a useful resource for you today, and in the future.

OPTIMIZING YOUR COMPRESSED AIR SYSTEM

Six Steps to Optimizing Your Compressed Air System

This is one of the key sections to our blogs. One of our main goals is to help you optimize your system. Here are 6 blogs that go into detail on each of these key points:

  1. Six Steps to Optimization: Step 1 – Measure the Air Consumption
  2. Six Steps to Compressed Air Optimization: Step 2 – Find and Fix Leaks.
  3. Six Steps to Compressed Air Optimization: Step 3 – Use Efficient and Quiet Engineered Products
  4. Six Steps to Optimizing Compressed Air: Step 4, Turn it Off When Not in Use
  5. Installing Secondary Receiver Tanks: Step 5 in Optimizing Your Compressed Air System
  6. Six Steps to Optimization: Step 6 – Control the Air Pressure at the Point of Use to Minimize Air Consumption

INDUSTRIAL HOUSEKEEPING

This is a product line that has a lot of maintenance questions, probably because these products are used to clean up dirt, and where there is dirt, there can be problems, clogs and leaks:

One of the most common questions we have concerns the Reversible Drum Vacuum (RDV) refurbishment Blog. The RDV is used on the Reversible Drum Vac, and the Chip Trapper products. We offer a refurb service for a fee, but most of the time you can do this on your own by watching and following this blog: Cleaning the Reversible Drum Vac

The Chip Trapper has two very popular blogs as well: Finding and Fixing Chip Trapper Vacuum Leaks as well as Cleaning the Chip Trapper’s Directional Valve

CABINET COOLERS

  1. Calculating Heat loads for Cabinet Coolers
  2. Finding the correct internal temperature of your Electrical Cabinet – don’t use a temp gun
  3. Thermostat & Solenoid Valve
  4. How To Install An EXAIR NEMA 4 or 4X Cabinet Cooler® System
  5. EXAIR Side Mount Kits for NEMA Type 4-4X Cabinet Cooler® Systems
  6. Cold Air Distribution Kit Installation
  7. Installing A Dual Cabinet Cooler Hardware Kit
  8. How to identify your Cabinet Cooler

VORTEX TUBES

  1. Vortex Tubes for Dummies
  2. Adjusting the Vortex Tube
  3. Vortex Tube Cold Fraction – effects on flow and temperature
  4. Application: Creating Freeze Seals for water lines

SUPER AIR KNIVES

  1. Application: Bottle Drying with Super Air Knife (instead of blower)
  2. Application: Super Air Knives drying automotive parts
  3. How to position and mount your Air Knife
  4. Which Air Knife should you choose?
  5. Super Air Knife Plumbing Kits
  6. Maximizing Super Air Knives with Shims

LINE VACS / CONVEYOR SYSTEMS

  1. Why Line Vacs need ambient air
  2. How to drill out Line Vac Generator Holes for increased performance
  3. Application: Conveying Coffee Beans

AIR AMPLIFIERS

  1. Super Air Amplifier Ratios explained
  2. Air Amplifier vs Fan – for cooling
  3. Application: Super Air Amplifier evacuating smoke or fumes

AIR ATOMIZING SPRAY NOZZLES

  1. Choosing the right Atomizing nozzle
  2. No-Drip Nozzle repair video
  3. Atomizing Nozzle identification
  4. Application: Atomizing Spray nozzles and Gummy Bears

SAFETY AIR GUNS

  1. Putting the Safe in Safety Air Guns
  2. Safety Air Gun Accessories, Extensions, Chip Shields and more
  3. Chip Shield sizes and selections

GEN 4 STATIC ELIMINATORS

  1. Changing the Gen 4 Power Supply Fuse
  2. Replacing the rocker switch on a Gen 4 Power Supply
  3. Changing the high power cord on the Gen 4 Ion Air Cannon
  4. Application: Solving Static and Print quality in food packaging

E-VAC VACUUM GENERATORS

  1. How to build a custom E-Vac System
  2. Choosing the right size Vacuum Cups

ACCESSORIES – FILTERS AND REGULATORS

  1. Filter Separator and Pressure Regulator with coupling kit installation 
  2. Rebuilding an Automatic Drain Filter Separator 
  3. Overview of EXAIR accessories

CALCULATIONS AND MORE

  1. Calculating SCFM at any pressure
  2. ROI Calculations with EXAIR products
  3. Do you need a receiver tank?
  4. EXAIR’s Calculator Library
  5. EXAIR’s OSHA compliance

OPTIMZATION – EFC, FLOWMETERS, AND ULTRASONIK LEAK DETECTORS

  1. EFC – Application: Candy Company saves big money with EFC
  2. Flowmeter – How to install a Hot Tap Flowmeter
  3. Flowmeter – Moving and or using Block-Off rings

There are many more blogs and videos at your disposal. This is just a recap of many of our most used, most viewed and most helpful for the day-to-day conversations that happen here at EXAIR. If you have ideas for new blogs – we would love to hear that as well. Please feel free to reach out at any time for more information on any of our intelligent compressed air products.

Thank you for stopping by,

Brian Wages

Application Engineer

EXAIR Corporation
Visit us on the Web
Follow me on Twitter

Cover photo by clker-free-vector-image licensed by Pixabay

How Much $$$ are Compressed Air Leaks Costing You?!

All compressed air systems will have some amount of leakage. It is a good idea to set up a Leak Prevention Program.  Keeping the leakage losses to a minimum will save on compressed air generation costs, and reduce compressor operation time which can extend its life and lower maintenance costs.

The Compressed Air Challenge estimates an individual compressed air leak can cost thousands of dollars per year when using $0.07/kWh.

  • 1/16″ diameter hole in excess of $700/year
  • 1/8″ hole in excess of $2900/year
  • 1/4″ hole in excess of $11,735 per year

There are generally two types of leak prevention programs:

  • Leak Tag type programs
  • Seek-and-Repair type programs

If you walk through your facility, how many leaks can you hear? These are only the REALLY bad ones!!  So if we know that a large amount of compressed air is leaking, what do we do about it? ? A proper leak prevention plan is the key to success. Since these leaks are impossible to see and some cannot even be heard, you need a tool to help assist you. EXAIR’s model 9061 Ultrasonic Leak Detector is the right tool for the job. When compressed air leaks through a pipe, it creates an ultrasonic signature due to turbulence. While this sound is not always detectable by the human ear, this meter will allow you to locate leaks up to 20’ away by converting the ultrasonic signature into an audible sound.

The first step will be locating the leaks using an Ultrasonic Leak Detector and tagging them throughout the facility. Don’t let this overwhelm you!! If you have a larger facility, break it up into sections that can be completed in 1 day. This will allow you to decide which areas of the plant should be looked at first. Once you’ve located and tagged all of the leaks, rate them under two separate criteria so that you can prioritize what to fix first. Rate them based on the difficulty that it will take to fix them and also by the severity of the leak. Those that are severe yet easy to fix would make sense to begin fixing first. Those that may require a period of shutdown can be planned to fix at a more appropriate time.

9061 ULD

When you’ve had the opportunity to fix them, don’t just forget about it. When new piping is installed, new lines are added, or anything involving compressed air is installed there is the potential for new leaks to develop. Set this as one of your regular PM activities and complete your own compressed air audit once a year. Implementing the process and maintaining it are the keys to your success.

If you have questions about developing a leak program or how to use the Ultrasonic Leak Detector, give us a call. An Application Engineer will be happy to help with the process and recommend some other methods to save on your compressed air supply.

Jordan Shouse
Application Engineer

Send me an Email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

The Sixth Sense: Pressure Sensing Digital Flowmeters

Pressure profiles and flowrates of a compressed air system are essential parts in understanding and maintaining an industrial compressed air system. Understanding what the pressure is coming out of the compressor, what it is in your header system, and then down into the drops of your machines and points of use are all beneficial to building an efficient compressed air system. Of course, this will take some monitoring.

In a perfect system, the compressor outlet pressure and the point of use line pressure will be the same. Due to factors such as friction loss, unregulated demands (leaks), and inefficient pipe sizing, it is difficult to produce in a real life scenario. This results in a pressure drop across the compressed air system, a decline in pressure from the compressor outlet to the end use devices. Understanding the full pressure and flow layout of a system can be used to zero in on artificial demand on the system which is a result of a leaks or inefficient use of compressed air.

The Pressure Sensing Digital Flowmeters provide the ability to see both the flow on a pipe as well as the operating pressure. When coupled with other items such as our Wireless Communication network they can easily be setup to generate alerts to operators as well. This would look like a message stating that operating pressure has dropped and that would result in the operator halting production to determine the cause. While a production halt is less than desirable, a crashed machine or loss of clamping a part due to pressure drop can be worse.

Pressure Sensing Port on the Pressure Sensing Digital Flowmeter gives the added benefit of tracking more information.

By using the Pressure Sensing Digital Flowmeters you will be able to build a pressure profile throughout your system. This can all build back into an efficient compressed air system by tying directly into the information gathered for the overall system.

For instance, If a compressor set point is 90 psig, and at the point of use you are seeing 70 psig, you have a 20 psig drop in piping, fittings and/or artificial demand. If the operator needs 80 psig to maintain their process then that means someone will want to bump the compressor set point to 100 psig to compensate. First off, that pressure drop should never be present in a system as it is excessive. Second, if this is a positive displacement compressor then for every 2 psig added, the compressor itself will increase by 1% of energy demand from the drives.

If you would like to dig into your system and start building a pressure/flow profile to start off your path to an optimized system, please contact an Application Engineer.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Find It, Tag It, Fix It: Addressing Parasitic Draw

Leeks, and not the compressed air kind!

Leaks, and not the kind you see on a cooking show, are never good. Before you comment, yes I know the vegetable is spelled leek, that’s just the strength of my dad jokes. The point of this post is actually discussing leaks, mainly of the compressed air variety. All leaks cost. I recently found a leak within my home which was accounting for around a 20% increase in my water bill. Sad to say that it took a few months to locate, and solve the issue. Over the years, I’ve seen many facilities deal with common leak problems like being unable to leave their compressed air pipes energized over night because the parasitic draw will drain the entire system. That’s a problem!

Burst pipes and leaks are ALWAYS costly!

If the leaks are present when nothing is being utilized, then that means parasitic draw is happening on the system. This is when energy that is being converted into compressed air isn’t used but instead, leaking out to atmospheric conditions. These parasitic draws are not always easy to locate, so over the years I’ve had to help a few customers address this problem. One in particular stands out, so I am going to share how we honed in on the leak and ultimately gave them days without a shutdown.

The conversation all started with a customer asking about how our Digital Flowmeters work, and if they could be used to determine which production line is using the most air, and more importantly why their production line shuts down for low air pressure. After I explained how we would select their infeed pipe size as well as size a meter that would fit each machine infeed, we got to talking about the shut down sequence.

The approach they took to solving the issue was to first capture the flowrate of the entire system and then to evaluate the flowrates of each segment of their plant. From there, we would install flowmeters on the higher usage sectors, and drill down to each machine for the finite analysis. They could then go through all the other production lines and generate a full facility consumption profile. To start, they found one packaging line that was using a considerably higher volume of air throughout their first shift than any other line and than any other shift.

Once they started breaking down the high demand production line they found one leg of the production line which had a spike in usage at the same time every day. The trick was they couldn’t find a machine with high usage, that is until they traced all of the piping and found a filter bag house on the roof that had been added to the line at some point. This wasn’t documented and had a piece of pipe that had failed causing an open dump during the cleaning cycle every day at 2:30 in the afternoon.

This was all made possible by setting up multiple flowmeters with wireless capabilities so they could document and compare the usages between machines and production lines ultimately giving them a considerable amount of production time back into the day by fixing a broken pipe that caused daily shutdowns.

If you would like to discuss how to layout a compressed air monitoring system in your facility or the best way to track down the cause of some leaks and high compressed air demand, contact an Application Engineer.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

1 – Leeks on shelf – Jeffery Martin, CC0, via Wikimedia Commons – retrieved from – https://commons.wikimedia.org/wiki/user:Veronicasgardentracker