Leaks and Why They Matter

Leaks can be discussed quite frequently around industrial environments. These can be refrigerant leaks, water leaks, gas leaks, even information leaks. All of these leaks have one thing in common, they all cost the company money in the end. I often think about several classic cartoons when I hear about leaks being fixed as they are found. They can become a little overwhelming like the “Squirrel” from the movie Ice Age 2.

1 – Ice Age 2 – Scrat – Mission Impossible

When it comes down to it, not many leaks create good results, that is why I want to take a second and educate on the costs your facility may be seeing from compressed air leaks. The leaks within an industrial environment can often account for up to 30% of the total compressed air generated.

So let’s take a look at that, the cost of compressed air is derived from the kWh cost the facility pays to the utility company. Here in the Midwest the average cost is around $0.08 / kWh. The equation to convert this to cost per cubic foot of compressed air is shown below. This formula assumes that the compressor generates four standard cubic feet of compressed air per horsepower of compressor. Again this is an industry acceptable assumption.

The size of a leak will determine how much compressed air is wasted, most of these leaks are not even to the audible range for the human ear which leads them to be undetected for long periods of time. A leak that is equivalent to a 1/16″ diameter orifice can result in an annual loss of more than $836.50 USD. While the scale of this number when compared to the annual revenue of a company may be small, the fact remains that this single leak would more than likely not be the only one. This isn’t the only way leaks will cost money though.

Leaks can also generate false demand which can result in pressure drops on a system. When the pressure on a production line drops this could result in unscheduled shutdowns. Often, when a pressure drop is observed the quick answer is to increase the header pressure which causes even more energy to be utilized and even more compressed air will be pushed out of these leaks. That increase in system pressure comes at a price as well. When increasing a system pressure by 2 psi the compressor will consume an additional percent of total input power. This again will hit the bottom line and result in lower efficiency of operation for the facility.

If you hear that distinct hiss of compressed air leaks when you are walking through your facility, or even if you don’t hear the his and you know that a leak detection action plan is not being practiced and want to find out the best ways to get one in place, contact us. We are always willing to help you determine how to lower the leaks in your facility as well as reduce the system pressure required to keep your lines up and running by implementing engineered solutions at the point of use.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

1 – Ice Age 2 – Mission Impossible Scrat – retrieve from YouTube – https://www.youtube.com/watch?v=S-HniegbnFs

 

Battling Heat Transfer

If you haven’t read many of my blogs then this may be a surprise. I like to use videos to embellish the typed word. I find this is an effective way and often gives better understanding when available.  Today’s discussion is nothing short of benefiting from a video.

We’ve shared before that there are three types of heat transfer, more if you go into sub-categories of each. These types are Convection,  Conduction, and Radiation. If you want a better understanding of those, feel free to check out Russ Bowman’s blog here.  Thanks to the US Navy’s nuclear power school, he is definitely one of the heat transfer experts at EXAIR.  If you are a visual learner like myself, check out the video below.

The Application Engineering team at EXAIR handles any call where customers may not understand what EXAIR product is best suited for their application. A good number of these applications revolve around cooling down a part, area, electrical cabinet, or preventing heat from entering those areas.  Understanding what type of heat transfer we are going to be combating is often helpful for us to best select an engineered solution for your needs.

Other variables that are helpful to know are:

Part / cabinet dimensions
Material of construction
External ambient temperature
If a cabinet, the internal air temperature
Maximum ambient temperature
Desired temperature
Amount of time available
Area to work with / installation area

Understanding several of these variables will often help us determine if we need to look more towards a spot cooler that is based on the vortex tube or if we can use the entrained ambient air to help mitigate the heat transfer you are seeing.

If you would like to discuss cooling your part, electrical cabinet, or processes, EXAIR is available. Or if you want help trying to determine the best product for your process contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Video Source: Heat Transfer: Crash Course Engineering #14, Aug 23, 2018 – via CrashCourse – Youtube – https://www.youtube.com/watch?v=YK7G6l_K6sA

EXAIR VariBlast Safety Air Gun

Air guns can be found in nearly any industrial facility that has a compressed air system within it.  From the maintenance department to the production floor, operators potentially use these for anything from, cleaning up work areas,  to blowing product out of a troubled spot in a process. Handheld blowoffs are often overlooked as a means to increase efficiency yet they are often observed as a means to increase safety.

Generic commercial air gun w/ cross cut hole in the nozzle

When evaluating efficiency the length of use for a handheld blowoff is often variable from operator to operator as well as changes even from each use.  Often, operators have several different uses throughout their day that require different levels of force needed to complete the job.  Most safety air guns don’t offer a variable force.  This means operators are full-force for all applications. This means full air consumption whenever that gun is used. EXAIR’s VariBlast Compact Safety Air Gun can help to give operators the adjustability they need.

CE compliant, VariBlast Compact Safety Air Gun saves air and increases safety.

The VariBlast Compact Safet Air Gun is available from stock with over a dozen options of different Super Air Nozzles as the end defector of the Safety Air Gun.  These are any nozzle up to a 1/8″ NPT thread size.  To couple with these engineered nozzles, we offer stock length extensions up to 72″ (1829 mm)  in length. This makes many applications that are hard to reach easily managed by the operators.

Different Length Extensions To Suit Nearly Every Application

To couple with the extensions and make sure the VariBlast Compact Safety Air Guns all meet or exceed OSHA standards for operator safety, we offer a Chip Shield accessory as well.

Chip Shields

If you would like to discuss how to lower the demand placed on your air compressor from blowoffs and want to better experience what true variability as well as what an engineered blowoff is capable of, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Back To The Basics: Process Improvement Basics

We understand that it is more important than ever to realize savings within manufacturing processes. EXAIR can reduce compressed air consumption and provide simple ROI in a matter of weeks in MANY cases.

In the hustle and bustle of the daily grind wherever you are, there are certain processes that become muscle memory for you and certain processes that just work and don’t need any attention. Whether it be a login process for your computer network, the number of steps it takes to fill your coffee cup, or the compressed air applications in your facility.

You know what I am talking about, these items begin to get glanced over and often become overlooked. When going through process improvements or troubleshooting, it is easy to overlook processes which are not causing trouble or that have become “acceptable” because they are producing. EXAIR firmly believes compressed air applications are ripe for improvement, and our product lines are built to replace inefficient compressed air products with engineered and efficient solutions.

When evaluating a process for improvement creating a baseline is the necessary start. With this, we can then start to draw a realistic target of where the process needs to be in order to be optimized and document the changes from our starting baseline.

Much like the 6 Steps to Compressed Air Optimization, which starts with measuring compressed air consumption to provide a baseline.  Sometimes, this may require the installation of a Digital Flowmeter, others it may include taking advantage of our Efficiency Lab service for us to get a baseline of what air consumption and other key performance indicators are for your application.

Looking to “go green?” We can help.

Once we have the baseline and a target, we can then begin to design an improvement process. Whether this is implementing better controls for the air, such as pressure regulators, or implementing controllers such as the Electronic Flow Control, it may even be simply installing an engineered solution.  Once an improvement has been implemented we can then go on to the next testing phase to again gather data to see how much air was saved from the baseline.

EXAIR’s Free Efficiency Lab

Once the performance of the new process is determined then we can take the new cost of ownership numbers and give a simple return on investment back to determine what the actual savings by implementing these process improvements have amounted to.

The below example is from a customer who had already improved their static elimination application by using our Super Ion Air Knife instead of a homemade pipe with drilled holes. They further optimized the application with our Electronic Flow Control.

If you would like to talk through methods for process improvement or how we can help you determine these costs, please reach out.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF