Opportunities To Save On Compressed Air

If you’re a regular reader of the EXAIR blog, you’re likely familiar with our:

EXAIR Six Steps To Optimizing Your Compressed Air System

This guideline is as comprehensive as you want it to be.  It’s been applied, in small & large facilities, as the framework for a formal set of procedures, followed in order, with the goal of large scale reductions in the costs associated with the operation of compressed air systems…and it works like a charm.  Others have “stepped” in and out, knowing already where some of their larger problems were – if you can actually hear or see evidence of leaks, your first step doesn’t necessarily have to be the installation of a Digital Flowmeter.

Here are some ways you may be able to “step” in and out to realize opportunities for savings on your use of compressed air:

  • Power:  I’m not saying you need to run out & buy a new compressor, but if yours is
    Recent advances have made significant improvements in efficiency.

    aging, requires more frequent maintenance, doesn’t have any particular energy efficiency ratings, etc…you might need to run out & buy a new compressor.  Or at least consult with a reputable air compressor dealer about power consumption.  You might not need to replace the whole compressor system if it can be retrofitted with more efficient controls.

  • Pressure: Not every use of your compressed air requires full header pressure.  In fact, sometimes it’s downright detrimental for the pressure to be too high.  Depending on the layout of your compressed air supply lines, your header pressure may be set a little higher than the load with the highest required pressure, and that’s OK.  If it’s significantly higher, intermediate storage (like EXAIR’s Model 9500-60 Receiver Tank, shown on the right) may be worth looking into.  Keep in mind, every 2psi increase in your header pressure means a 1% increase (approximately) in electric cost for your compressor operation.  Higher than needed pressures also increase wear and tear on pneumatic tools, and increase the chances of leaks developing.
  • Consumption:  Much like newer technologies in compressor design contribute to higher efficiency & lower electric power consumption, engineered compressed air products will use much less air than other methods.  A 1/4″ copper tube is more than capable of blowing chips & debris away from a machine tool chuck, but it’s going to use as much as 33 SCFM.  A Model 1100 Super Air Nozzle (shown on the right) can do the same job and use only 14 SCFM.  This one was installed directly on to the end of the copper tube, quickly and easily, with a compression fitting.
  • Leaks: These are part of your consumption, whether you like it or not.  And you shouldn’t like it, because they’re not doing anything for you, AND they’re costing you money.  Fix all the leaks you can…and you can fix them all.  Our Model 9061 Ultrasonic Leak Detector (right) can be critical to your efforts in finding these leaks, wherever they may be.
  • Pressure, part 2: Not every use of your compressed air requires full header pressure (seems I’ve heard that before?)  Controlling the pressure required for individual applications, at the point of use, keeps your header pressure where it needs to be.  All EXAIR Intelligent Compressed Air Product Kits come with a Pressure Regulator (like the one shown on the right) for this exact purpose.
  • All of our engineered Compressed Air Product Kits include a Filter Separator, like this one, for point-of-use removal of solid debris & moisture.

    Air Quality: Dirty air isn’t good for anything.  It’ll clog (and eventually foul) the inner workings of pneumatic valves, motors, and cylinders.  It’s particularly detrimental to the operation of engineered compressed air products…it can obstruct the flow of Air Knives & Air Nozzles, hamper the cooling capacity of Vortex Tubes & Spot Cooling Products, and limit the vacuum (& vacuum flow) capacity of Vacuum Generators, Line Vacs, and Air Amplifiers.

Everyone here at EXAIR Corporation wants you to get the most out of your compressed air use.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Airguns, OSHA, And You

Depending on the context, those may be three words you DON’T want to hear in the same sentence. Case in point…a caller I spoke with recently, who works at a large steel forging plant. During a recent inspection, management was surprised (and disappointed) to find out that, unbeknownst to them, some of their operators had modified some of their compressed air blow off devices.

These modifications left them in violation of both OSHA Standard 1910.242(b) (limit on outlet, or dead end pressure) and 1910.95(a) (limits noise level exposure.)  The OSHA inspector left them with an $8,000.00 fine, and a promise to return with an even higher one if the situation wasn’t corrected.

We discussed the ways their current devices were supplied, the conditions they were operating in, what they were used for…and why the operators had modified them.  Sadly, we found the devices were underperforming due to air supply issues – hoses that were too small in diameter and/or too long, with restrictive quick connect fittings.  And some of their modifications (drilling out the discharge) just exacerbated those problems.

Most of their applications were pretty typical – blowing flash, chips, oil, coolant, etc. from processed metal parts.  Typical enough that a couple of EXAIR Safety Air Guns would allow them to determine what they would need, by taking them around to various stations in the plant and trying them out.

My caller ordered a Model 1210 Soft Grip Safety Air Gun with a Zinc Aluminum Super Air Nozzle (our most popular for typical blow off applications,) and a Model 1260 Soft Grip Safety Air Gun with a High Force 1/2 NPT Zinc Aluminum Super Air Nozzle (the most powerful one available on the Soft Grip Safety Air Gun.)

Here’s Model 1210-6-CS, fitted with a Zinc Aluminum Super Air Nozzle on a 6″ Rigid Extension & Chip Shield.  All EXAIR Safety Air Guns are compliant with OSHA Standard 1910.242(b).

I feel pretty good about the chances of publishing a future blog about the success of this application.  If you want to keep up, I encourage to follow the EXAIR blog – there’s a link to the right to provide your email address – for more on this one, other applications, and a wealth of expert writings on how to get the most out of your compressed air system.

As always, if you’d like to discuss a particular compressed air application and/or product selection, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Refrigerant Compressed Air Dryer Systems

No matter what your use of compressed air entails, moisture is very likely an issue.  Air compressors pressurize air that they pull in straight from the environment and most of the time, there’s at least a little humidity involved.  Now, if you have an industrial air compressor, it’s also very likely that it was supplied with a dryer, for this very reason.

There are different types of dryer systems, depending on your requirements.

For practical purposes, “dryness” of compressed air is really its dew point.  That’s the temperature at which water vapor in the air will condense into liquid water…which is when it becomes the aforementioned issue in your compressed air applications.  This can cause rust in air cylinders, motors, tools, etc.  It can be detrimental to blow offs – anything in your compressed air flow is going to get on the surface of whatever you’re blowing onto.  It can lead to freezing in Vortex Tube applications when a low enough cold air temperature is produced.

Some very stringent applications (food & pharma folks, I’m looking at you) call for VERY low dew points…ISO 8673.1 (food and pharma folks, you know what I’m talking about) calls for a dew point of -40°F (-40°C) as well as very fine particulate filtration specs.  As a consumer who likes high levels of sanitary practice for the foods and medicines I put in my body, I’m EXTREMELY appreciative of this.  The dryer systems that are capable of low dew points like this operate as physical filtration (membrane types) or effect a chemical reaction to absorb or adsorb water (desiccant or deliquescent types.)  These are all on the higher ends of purchase price, operating costs, and maintenance levels.

For many industrial and commercial applications, though, you really just need a dew point that’s below the lowest expected ambient temperature in which you’ll be operating your compressed air products & devices.  Refrigerant type air dryers are ideal for this.  They tend to be on the less expensive side for purchase, operating, and maintenance costs.  They typically produce air with a dew point of 35-40°F (~2-5°C) but if that’s all you need, they let you avoid the expense of the ones that produce those much lower dew points.  Here’s how they work:

  • Red-to-orange arrows: hot air straight from the compressor gets cooled by some really cold air (more on that in a moment.)
  • Orange-to-blue arrows: the air is now cooled further by refrigerant…this causes a good amount of the water vapor in it to condense, where it leaves the system through the trap & drain (black arrow.)
  • Blue-to-purple arrows: Remember when the hot air straight from the compressor got cooled by really cold air? This is it. Now it flows into the compressed air header, with a sufficiently low dew point, for use in the plant.

Non-cycling refrigerant dryers are good for systems that operate with a continuous air demand.  They have minimal dew point swings, but, because they run all the time, they’re not always ideal when your compressed air is not in continuous use.  For those situations, cycling refrigerant dryers will conserve energy…also called mass thermal dryers, they use the refrigerant to cool a solution (usually glycol) to cool the incoming air.  Once the glycol reaches a certain temperature, the system turns on and runs until the solution (thermal mass) is cooled, then it turns off.  Because of this, a cycling system’s operating time (and cost) closely follows the compressor’s load – so if your compressor runs 70% of the time, a cycling dryer will cost 30% less to operate than a non-cycling one.

EXAIR Corporation wants you to get the most out of your compressed air system.  If you have questions, I’d love to hear from you.

Russ Bowman
Application Engineer
EXAIR Corporation
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Video: EXAIR Drum Vacs Selection For Solid Materials

EXAIR Corporation has engineered compressed air solutions for Industrial Housekeeping…among them, a full line of drum mounted vacuums for dry/solids cleanup.

If you’d like to find out more, please give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Upgrade Blowoff Applications with Engineered Products to Increase Safety and Efficiency

At EXAIR, it’s our business to make sure that you get the most out of your compressed air system.  We’ve got a Six Step plan to help you do just that, and one of those steps is the topic of today’s blog:

We have a couple of ways to help with step #1.  You can use a Digital Flowmeter to measure your total compressed air usage, and take advantage of our Efficiency Lab service to determine the consumption of individual compressed air devices that may be running up the total.  Based on our performance tests of those devices, we can recommend suitable EXAIR Intelligent Compressed Air Products to replace them with, along with the expected reductions in air consumption & noise levels…quieter is always better too.

We’re going to skip right over Step #2…just for now…but if you can’t wait, click on the picture above for more on finding & fixing leaks.

Once you get our recommended replacements in (I mean, why wouldn’t you?), they’re going to be part of your compressed air system, so naturally, we want to make sure you get the most out of them as well.  Key considerations are suitable supply lines, and proper installation.

In the case of a Super Air Nozzle or Air Jet, these are oftentimes one and the same.  They’re all small enough, and lightweight enough, to be adequately supported by compressed air piping (assuming the piping is adequately supported,) metal tubing (via a compression fitting adapter,) or even mounting solutions like our Stay Set Hoses.

Just a few ideas for installing an EXAIR Super Air Nozzle

Sometimes, though, you need a firm, vibration-resistant mounting…that’s where we recommend our Swivel Fittings.  A hex retainer tightly locks the ball in position, but allows for easy repositioning when loosened.  They come in standard NPT sizes from 1″ NPT down to 1/8″ NPT, and we even have them for the M4, M5, and M6 metric threads for our Atto, Pico, and Nano Super Air Nozzles.

Typical threaded fittings are limited in the angles you can achieve. EXAIR Swivel Fittings provide 50° of adjustability.

Even a highly efficient blow off needs to be aimed well in order to do its job well.  If you’d like to discuss how to get the most out of your compressed air system – or our products – give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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6 Primary Benefits of Cabinet Coolers (Vortex Tube Enclosure Coolers)

First off, I want to dispel any notion that there might be something that’s NOT great about EXAIR Cabinet Cooler Systems.  Are there other methods to provide effective cooling to an electrical panel?  Of course there are, and frankly, if one particular method was clearly superior in any & every situation, the makers of that one would have put all the others out of business by now.  But for now, let’s consider:

1. Simplicity: Cabinet Cooler Systems need compressed air to work.  That’s it.  Supply them with clean, moisture free air, and they’ll run darn near indefinitely, maintenance free. What could be easier?

2. Control:  Continuous Operation systems have their place (more on that in a minute,) but in most cases, Thermostat Control is preferred, for a couple of reasons:

  • Most electrical and electronic components have a rated maximum operating temperature of 104°F (40°C).  Maintaining the air temperature at a reasonable level less than that is all you need…any lower, and you’re just wasting energy, no matter what method of cooling you use.  Our Thermostats are preset at 95°F (35°C) to ensure heat protection, while limiting operating costs.
  • There is such as thing as “too cold.” Particularly sensitive instrumentation & controls may exhibit varied behavior at different temperatures.
  • Our bimetallic probe-type thermostats are ideal for controlling air temperature.  They have much faster response time than other mechanical styles, meaning the system won’t keep running once it’s cool enough, and it starts running as soon as it starts getting too hot.  They’re also easy to reset, if the preset of 95°F (35°C) is not suitable for particular specific needs.
  • If constant monitoring, or frequent changes in control temperature are desired, the ETC Electronic Temperature Control offers these benefits, via a quick response thermocouple and pushbutton operation.

3. Environmental concerns: No matter where a panel is located in your plant, and what it might be exposed to, EXAIR Cabinet Cooler Systems will keep the environment out of that panel:

  • NEMA 12 Cabinet Cooler Systems are oil tight, dust tight, and rated for indoor duty.
  • NEMA 4 systems provide the same protection as NEMA 12, and are additionally splash resistant, and are rated for indoor/outdoor duty.
  • NEMA 4x systems offer NEMA 4 protection, and are made of stainless steel for corrosion resistance.
  • HazLoc Cabinet Coolers are UL Classified & CE Compliant.

    HazLoc Cabinet Cooler Systems also maintain NEMA 4 or 4X integrity, and are for use with classified enclosure purge & pressurization systems in hazardous locations:

    • Class I Div 1, Groups A, B, C and D
    • Class II Div 1, Grouds E, F and G
    • Class III

4. Dependable protection: In most cases, the less moving parts something has, the more reliable it is.  With NO moving parts, EXAIR Cabinet Cooler Systems absolutely prove this out:

  • Unlike refrigerant-based systems, there are no filters to clean, no coils to foul or corrode, and no electric motors to burn out.
  • No potential contaminants from outside air ever enter the enclosure…all the cold air comes from your compressed air supply, through an Automatic Drain Filter Separator fitted with a 5 micron particulate element and a centrifugal separator for moisture removal.

5. Selection:  Cooling capacities range from 275 Btu/hr to 5,600 Btu/hr, and they’re all in stock, ready for immediate shipment.

6. Special considerations:  “Customized” usually means high prices and long lead times. Not so for a number of EXAIR Cabinet Cooler System options:

  • This NEMA 4 Dual Cabinet Cooler System protects a critical equipment panel on a hot roll steel line.

    High Temperature systems are available from stock, for installation in areas where the ambient temperature can exceed 125°F (52°C,) all the way up to 200°F (93°C.)

  • Continuous Operation Systems aren’t the only way to constantly keep environmental contaminants out…Non-Hazardous Purge (NHP) systems combine the efficiency of Thermostat Control by always passing a small amount of air flow, to provide a slight positive pressure, even when the temperature is lower than the Thermostat set point.  This way, the Cabinet Cooler System only operates to maintain appropriate cooling, but the panel is still protected all the time.
  • When additional protection from harsh and corrosive environments is needed, or when specified by strict facility requirements (I’m looking at you, Food, Pharma, and Nuclear Plants,) our NEMA 4X Cabinet Cooler Systems can be provided in Type 316 Stainless Steel construction, from stock.

6.5 Simplicity, part 2:  Not only are they simple to operate…

  • They install, in minutes, through a standard knockout in the top of your enclosure.

    Side Mount Kits maintain NEMA 4/4X Splash Resistance.
  • If there’s no room on top, or if it’s just more practical, you can put them on the side of the panel using a Side Mount Kit.
  • Don’t know which one to pick, or need help determining your heat load?  Then use our Cabinet Cooler System Sizing Guide.  There’s one in the catalog that you can fill out and fax or email to us, or you can find it on our website under the “Features” tab on any Cabinet Cooler product page…just fill in the blanks and click “Submit.”  Or, you can always simply call in the data to an Application Engineer.  We can calculate your heat load in just a minute or so, and we do it over the phone all the time.

If you’d like to find out more about heat protection for your electrical or electronic panels, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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EXAIR Reversible Drum Vac Fills A 55 Gallon Drum in 90 Seconds Flat, And Empties It Just As Fast

There are a few ways to get the liquid out of a drum:

  • You can use a pump.  Some pumps are even made to mount straight onto the lid of the drum.
  • You can siphon the liquid out, if you can get the drum higher than where you want to put the liquid.  And if you have the time.
  • You can turn the drum over.  I used to do field service in chemical plants…some of them had drum handlers on fork trucks that could pick up and tilt the drum to pour the liquid out.  Some of them pushed the drum over and simply let the liquid spill into a pit or below-grade sump.

But pumps break down.  Siphoning is finicky and slow.  I’m loath to knock the skills of the fork truck operator that can pour out a drum like a sommelier pours a fine wine.  And I’ll never forget the first time I saw an operator half-roll/half-dance a drum to the edge of that pit and let the liquid dump as he dropped it precisely where he wanted it…however, even in the context of the inner recesses of a chemical plant, it was simple, but inelegant.

EXAIR has an engineered solution that preserves the simplicity, though: the Reversible Drum Vac.  Thread the standpipe into the bung connection and the RDV itself into the vent, and that drum is now a two-way pumping system, able to be emptied via a 10 foot long Vacuum Hose in as little as a minute and a half.  Turn the knob on the RDV to switch modes, and you can fill that same drum just as fast.

With a simple turn of the knob, the Reversible Drum Vac can fill or empty a 55 gallon drum in 90 seconds!

 

 

 

 

 

 

The EXAIR Reversible Drum Vac Systems come with a variety of configurations and options:

  • Made to fit an existing 30, 55, or 110 closed top steel drum in good condition.
  • Mini Reversible Drum Vac System comes with a 5 gallon drum.
  • Deluxe Systems add a Drum Dolly and a set of tools.
  • Premium Systems add a drum (30, 55, or 110 gallon,) an upgrade to Heavy Duty Aluminum Tools, and a 20ft compressed air supply hose with shutoff valve and pressure gauge.
  • High Lift Reversible Drum Vacs generate a suction head of 180″H2O for maximum lift.  They’re also specified for higher viscosity liquids.

Below is a great video that showcases just how easy it is to from installing the Reversible Drum Vac to using the Reversible Drum Vac and just how fast the RDV operates.

If you’re looking for a fluid handling solution for liquids in drums, give me a call and we’ll talk about which Reversible Drum Vac System is right for you.

Russ Bowman
Application Engineer
EXAIR Corporation
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