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.
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.
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.
Information is important to diagnose wasteful and problematic areas within your compressed air system. To measure air consumption, flow meters are used to find the volume or mass of compressed air per unit of time. Flow rates are very useful data points to find problems like leaks, over-use in blow-offs, waste calculations, and comparison analysis.
There are many different types of flow meters. Many of them entail a breakdown of your current compressed air lines by cutting, welding, or dismantling for installation. This will add cost in downtime and maintenance staff. But, not with the EXAIR Digital Flowmeters. In this blog, I will share the features and benefits of the Digital Flowmeters including options for you to start measuring and optimizing your compressed air system in Step 1.
Overall, it only takes a few minutes to install and start measuring. The installation kit comes with a drill bit and a drill guide to properly locate the two holes on the pipe. The Digital Flowmeter uses a clamp to mount to the pipe and to seal the area around the probes. Once it is powered, the unit is ready to measure the air flow inside the pipe with a large LED display. The display can be customized to show flow readings in three different units; SCFM, M3/hr or M3/min; and, it can display the Daily Usage and Cumulative Usage. This will require that the compressed air line is discharged, or pressure free. However, there are Hot Tap digital flowmeters available for installing on pressurized compressed air lines.
To get started, the EXAIR Digital Flowmeter is a thermal dispersion device that can accurately measure compressed air flows. They use two sensing probes for comparative analysis. One probe is a temperature sensing probe, and the other is a flow-sensing probe. By comparing these, the Digital Flowmeter can measure precisely the mass air flow without needing to be recalibrated. They are a cost-effective, accurate, and simple way to measure compressed air flows.
EXAIR stocks a large volume of Digital Flowmeters to ship same day for U.S. and Canadian customers. We also offer a 30-day unconditional guarantee to try them out. We stock meters for pipe diameters from ½” NPT to 4″ NPT Schedule 40 black pipe. EXAIR can also offers flow meters up to 8″ NPT black pipe; copper pipes with diameters from 3/4″ to 4″, and aluminum pipes with diameters ranging from 40mm to 101mm. If you have another type of piping for your compressed air system, you can give us the material, O.D. or I.D., and wall thickness. We may still be able to get a Digital Flowmeter for you.
For measuring, all the units come standard with a 4 – 20mA analog output. Per your request, we can change this signal to a serial output for RS-485 or Ethernet connections. What more can we offer with the EXAIR Digital Flowmeter? Options. Options upgrade the flow meters to better suit your application. Here is a list below:
Wireless Capability: Our latest Digital Flowmeter now has wireless capabilities. They use a Zigbee® communications to pick up flow readings from other flow meters and the Gateway. The Gateway can detect over 100 Digital Flowmeters in your facility. From the Gateway, the information is transferred through a LAN. You can record and analyze the flow information from each meter on the network with our EXAIR® Logger Software. You can set limits to send warnings when your compressed air system is using too much or too little of compressed air. This technology makes it very easy for measuring your compressed air system in the entire facility without having to be there.
When you need to analyze your pneumatic components, flow is an important point in diagnosing the overall “health” of your compressed air system. The EXAIR Digital Flowmeter can give you that important data point. With optimization, you can cut your energy consumption, improve pneumatic efficiencies, and save yourself money. This blog is an overview of Step 1 of six steps. You may have more questions; and, that is great! You can find them in other EXAIR blogs, or you can contact an Application Engineer at EXAIR.
A major benefit to utilizing compressed air is the speed at which it can be shut off and re-energized for use – in fact, this can be done instantaneously. Shutting down the supply of compressed air to an application while it is not needed can drastically reduce the compressed air consumption of the process. This is an easy remedy that can produce significant savings.
Think about a place where you have a compressed air blow off with spaces between the parts or dwell times in conveyor travel. What about break times, do operators continue to keep the air on when they leave for a break or even worse, for the day?
Step number four in EXAIR’s Six Steps to Optimization is:
A simple manual ball valve and a responsible operator can provide savings at every opportunity to shut down the airflow. But an automated solution is a no-brainer and can provide significant savings.
For a more automated approach, you can add a solenoid valve that would tie into your existing PLC or e-stop circuit, into your compressed air supply lines to aid in turning the compressed air on and off.
For an automated on/off solution can be found by using the EXAIR EFC (Electronic Flow Control). The EFC is made to accept 110V or 220V AC, and convert it to 24V DC to operate a sensor, timer, and solenoid valve. Its multiple operating modes allow you delay on, delay-off, and delay on/off among others. The operating mode can then be set to the specific time necessary for a successful application.
The spaces between parts can be turned into money saved. Every time you reach the end of a batch run, the EFC can turn the air off. You can also add solenoid valves and run them from your machine controls. If the machine is off, or the conveyor has stopped – close the solenoid valve and save the air. The modes are all defined in the video below.
So, take a look, or even better a listen, around the plant and see what you can find that could benefit from turning the air off; even if it is just for a moment it will help put money back into your bottom line.