Warmer temperatures are quickly approaching, which may seem like a welcome change for personal reasons, but in a processing line, the increased temperatures can wreak havoc on sensitive components found in an electrical control panel.
EXAIR Corporation will be hosting a FREE webinar titled “Intelligent Solutions for Electrical Enclosure Cooling” on May 23, 2018 at 2:00 PM EDT.
By attending this interactive session, you will learn the difference between the 3 most common NEMA ratings for electrical control panels found in an industrial setting, NEMA Type 12, 4 and 4X. We’ll provide examples of traditional, yet unreliable, methods of cooling and the concerns associated with using these types of devices.
Next we will explain how ignoring heat related issues can cause machines to shut down due to failed electrical components, resulting in lost production and increased maintenance costs, negatively affecting a company’s bottom line.
In closing, we’ll show how using an engineered, compressed air operated solution can reduce downtime by providing a low cost, maintenance-free way to cool and purge control panels with no moving parts.
Almost every industry uses compressed air in some capacity. It is often referred to as the “fourth utility” In an industrial setting, next to water, gas and electric. and in many cases, is the largest energy user in the plant. With an average cost of $ 0.25 per every 1000 Standard Cubic Feet used, compressed air can be expensive to produce so it is very important to use this utility as efficiently as possible. When evaluating the performance of a compressed air system, it’s important to look at the system as a whole.
When you operate point-of-use devices at a higher pressure than necessary to perform a certain job or function, you are creating “artificial demand”. This results in excess air volume being consumed, increasing the amount of energy being lost to waste. For example, plant personnel or operators increase the supply pressure in an effort to improve the end use devices performance. When there is a leak in the system, the line pressure will actually begin to drop and performance begins to deteriorate in other areas in the plant. This not only puts stress on the existing compressor but it also leads to the false idea that a larger or secondary compressor is needed.
Here’s a quick reference on how operating pressure can directly affect operating cost:
Our Model # 1101 Super Air Nozzle requires 14 SCFM @ 80 PSIG. Based on the average operating cost of $ 0.25 per 1000 SCF used, it would cost $ 0.21 per hour to operate this nozzle. (14 SCFM x $ 0.25 x 60 minutes / 1000 SCF = $ 0.21)
If you were able to use the same Model # 1101 Super Air Nozzle operating at only 40 PSIG, while still achieving the desired end result, the air demand would decrease to only 8.1 SCFM, reducing the hourly cost to $ 0.12. (8.1 SCFM x $ 0.25 x 60 minute / 1000 SCF = $ 0.12)
Leaks in a compressed air system can account for up to 30% of the total operational cost of the compressor, wasting thousands of dollars of electricity per year. Some of the more common places for a leak to occur would be at connection points such as valves, unions, couplings, fittings, etc.
In this table, you will see that a certain amount of air volume is lost through an orifice or opening. If you have several leaks throughout your facility, it isn’t gong to take long for the waste and high operating costs to quickly add up as well as potential increases in repair or maintenance costs for the existing compressor. The industry average shows that any leakage more than 10%, shows there are areas where operational improvements could be made in a compressed air system.
Stay tuned to our blog over the next few weeks as we will discuss how following a few simple steps can help optimize your current compressed air system, in many cases, reducing energy costs related to compressed air waste, leading to a more economical operation.
In the meantime, if you have any questions or would like to discuss a particular application or EXAIR product, give me a call at 800-903-9247.
Are you needing to move a thick fluid, move liquid farther or higher? Do you have a below grade sump or pit you’re looking to empty? Then EXAIR has the solution for you, enter the High Lift Reversible Drum Vac. Like the standard Reversible Drum Vac, the High Lift RDV is a compressed air operated, liquid only vacuum with no moving parts or motors that can fail, like those in traditional electrically powered vacuums. What separates the High Lift RDV from the traditional version is the higher vacuum it achieves which allows you to lift liquids up to 15′, move liquids up to 20′ and handle fluids with viscosity as high as 1400 centipoise.
The High Lift Reversible Drum Vac features a two-way pump constructed of stainless steel and a built-in safety relieve valve to avoid over pressurizing or over-filling the drum. Air consumption is minimal, at 43 SCFM @ 80 PSIG, while maintaining a low noise level of only 83 dBA. In “empty” mode, the HLRDV achieves a flow rate of 30 gallons per minute (water) to quickly empty the drum.
Systems are available in 30, 55 and 110 gallon capacities in 3 different variations:
The Standard Systems include the High Lift Reversible Drum Vac, shutoff valve, 20′ vacuum hose, standpipe, 90° quick release elbow and aluminum chip wand.
Deluxe Systems include all of the items shown above in the “Standard” System and adds a drum dolly, ABS plastic spill recovery kit, (2) extension wands, crevice tool, skimmer tool and a magnetic tool holder.
And Premium Systems include all of the items in “Deluxe” Systems and adds the drum with lock ring and lid, heavy duty aluminum tools and 20′ compressed air hose.
A little while back, I worked with a large eyeglass manufacturer on a sunglass lens cooling application. In their setup, they were dry cutting film-coated lenses with a router and after the lenses are cut, they are passed through several different rinse cycles and inspected for scratches or other damage. They were seeing a high number of reject parts and determined that the heat being generated by the tooling, was causing the irregularities. In an effort to alleviate the condition, they used a section of open flexible tubing to blow compressed air at the bit, which helped a little, but they were still concerned with the amount of scrap material.
I recommended they use our Model # 3825 Adjustable Spot Cooler System in the process. The Adjustable Spot Cooler incorporates a Vortex Tube to provide a temperature drop from the incoming supply air temperature. Using the temperature control valve, the exhausting air temperature and flow can be adjusted to fit the application. The system includes a flexible hose to focus the cold air to the desired area until re-positioned. The system also features a magnetic base that allows for easy mounting. By incorporating the filter separator included in the system, they can remove any moisture and/or contaminants in the air supply, relieving any concern with contamination or damage to the part.
If you have a cooling application you’d like to discuss or for help selecting the best product to fit your need, give me a call at 800-903-9247.
Daniel Bernoulli was born in Groningen, Netherlands on February 8, 1700 and was part of a large family heritage of famous mathematicians – His father Johann Bernoulli, one of the first founders of calculus, his uncle Jacob Bernoulli and his older brother Nicolous. When he was only 7 years old, Daniel began to take an interest in mathematics but his father convinced him that there was no financial gain to be had in mathematics and recommended he focus his studies in business instead. Reluctant at first, Daniel would take his father’s advice under the one condition, that his father would tutor him in calculus and his theories of kinetic energy.
At 13 years old, Daniel attended Basel University where he studied logic and philosophy completing his bachelor’s degree by the age of 15 and earning his master’s degree just 1 year later. Over the years, Daniel’s relationship with his father was strained as a result of him plagiarizing his father’s findings. Eventually, his father passed without reconciling with Daniel. At 24, Daniel became a Professor of Mathematics at a University in Venice but resigned from the position just 9 years later in 1733.
His most recognized mathematical contribution, Bernoulli’s principle, came in 1938 while performing energy conservation experiments, and he published the results in his book entitled Hydrodynamica. He discovered that when fluid travels through a wide pipe into a smaller, more narrow pipe, the fluid begins to move faster. He determined that the volume or amount of fluid moving through the pipe remains unchanged but will conform to the shape of the pipe or container as it flows. He concluded that the higher the pressure, the slower the flow of the liquid and the lower the pressure, the faster the liquid flow.
The same principle can be applied to air. As air moves around an obstruction or object, it follows the profile of the part and begins to speed up.
Take for example our Super Air Nozzles. The compressed air exits the nozzle through a series of jets which induces a low pressure around the profile of the nozzle, drawing in ambient air. This entrainment of air, up to 25 times or more, results in a high outlet flow at minimal compressed air consumption.
Many of the products offered by EXAIR incorporate this science which can lead to a more efficient operation by lowering compressed air demand ultimately reducing operating costs. To see how our products can help you save money while increasing process performance, contact an Application Engineer for assistance.
From now through May 31, 2018, we are offering a FREE Vac-u-Gun with any order for one of our Industrial Housekeeping Vacuum Systems. The Vac-u-Gun is a multi-purpose tool that can be used to vacuum or transfer material from one location to another or it can be used as a powerful blow gun to clean debris off of the surface of a part or workstation. There is no electricity required to operate and no moving parts to wear out, providing for a safe, maintenance free operation.
When choosing one of our vacuums, selection can be simplified depending on what type of media you are needing to pickup. Our systems are going to be either solids handling or liquid handling.
Our Chip Vac Systems are the ideal choice when looking to vacuum dry or damp debris left over from machining operations and delivers them to a standard open top steel drum. For more abrasive material, such as sand or steel shot used in sandblasting processes, the Heavy Duty Dry Vac provides superior wear resistance due to it’s proprietary hardened alloy construction.
Our Chip Trapper and High Lift Chip Trapper are also used in liquid applications but these systems incorporate a filter bag inside the drum to capture any suspended solids in the liquid so only clean fluid is pumped back into the reservoir or tank.
In dusty applications we offer the Heavy Duty HEPA Vac which uses the same vacuum as the HD Dry Vac but this system provides a higher level of filtration meeting HEPA requirements of 99.97% filtration at the 0.3 micron level.
All of these products are In-Stock, Ready To Ship.
To take advantage of the offer, you need to order using the promotional Model number. Ordering is easy – you can email the order to firstname.lastname@example.org or place your order online at www.EXAIR.com. If you’d rather place your order over the phone or have any technical questions about our products, you can call us at 800-903-9247 and one of our reps will be happy to assist.
I recently had a chat conversation with a customer who was looking to cool the tooling on his CNC router, mill and lathe in his small machine shop. During the machining process, as the tooling would begin to heat up, it would warp the bit, causing irregularities in the finished product. In some cases the tooling was getting so hot, it would actually break, creating a safety concern.
He had reviewed some of our cooling products and was thinking of using our Cold Gun in the application but was concerned with the air demand. The Cold Gun consumes 15 SCFM @ 100 PSIG and provides a 50°F temperature drop (from supply temperature) with 1,000 Btu/hr. of cooling capacity. The problem was that his compressor only produces a little over 9 SCFM. I explained that the existing compressor would in fact be undersized as it doesn’t produce enough volume to keep up with the demand of the Cold Gun.
Due to the limited amount of compressed air available, our Mini Cooler System, Model # 3808, would be the better solution. The Mini Cooler also provides a 50°F temperature drop with a little less cooling power, 550 Btu/hr., but this system only requires 8 SCFM @ 100 PSIG, falling within the existing compressor’s output capacity. The Mini Cooler also includes a magnetic base as well as flexible tubing to direct the cold air to the desired location, making it easy to move from machine to machine.
If you are considering an EXAIR product for an application or have additional questions about performance, contact an application engineer for assistance in making the best selection.