Taking Yourself Out Of Your Comfort Zone

During the warmer Ohio weather months, April through October, my blog posts may include information about taking my motorcycle to some road course tracks (and now even a cold month or two).  I take my bike to open track days where (mostly) amateur riders can get on a proper race course. There are people on the track for the first time and people who race professionally.   They will generally divide the riders into several groups, Novice, Intermediate or Advanced.  The control riders/coaches at the track will help you to determine what group you should ride in and then help you throughout the day.   Below is a video of a control rider that is also a professional rider at Mid Ohio Sports Car Course.  (Don’t mind the music, it’s not my cup of tea either.)

For the novice group there are classes after each session, as well as skills practiced in every session.  This is to help teach the beginning track rider that the same habits you use on the street are not meant for the track, as well as how to be as safe as possible while being on the track.  This is the most watched and controlled group due to the fact it generally has the most riders and they are all the newest to the track.

For intermediate group there are optional classes and you just run your own pace.  They step up the skill level by not enforcing you to focus on a skill during each session or requiring you to go to a class after each session of the day.  The pace is considerably faster than novice and the only ways to get instruction are to either ask a control rider for it or if they see something to help you with they will generally stop you and coach you on how to do it better.

The final group is advanced, or race class.  This has the same elements as a professional race minus the grid at start-up.   There aren’t really any passing rules and the control riders are mainly all professional racers or former racers who can still make your head spin as they fly past you.  Similar to the intermediate group the only way you will get help is to ask for it.

For the past two years I have been running in the intermediate group and it is a serious meat grinder.  You will have people in there that are fast enough to be in advanced group, but are too scared.  As well as having people who let their ego and pride tell them they don’t need to learn anything from a novice class and should really be in novice learning as much as they can.  I stayed in Novice for over the first year of track riding that I had done.   Some people choose to never leave the novice group because that is exactly where they are comfortable.  They don’t want to worry about the other classes and are perfectly fine with not even being the fastest person in Novice.  This is perfectly acceptable for some, but I had to push myself out of my comfort zone in order to really enjoy the entire experience.  Even though I have been to the track several times now I am always out of my comfort zone in intermediate because there are always new people showing up and you never know when you will running with a group that should be racing, or a group that should be getting coached in novice.

Here at EXAIR we have customers that could fit into each of these groups also.   The customer who doesn’t know what an engineered solution is and doesn’t understand the cost of compressed air.  The intermediate user who has used some of our products in the past but is encountering new issues and knows that we can help lead them in the right direction.  As well as the advanced users who know exactly what they need and sometimes even request a special unit to fit their exact needs.

No matter the case, we can help as well as coach even the most advanced users of our products on how to use compressed air better.  If you are reading this and you don’t know the difference between a Super Air Nozzle and an open pipe, then give us a call.  We will help teach you the differences as well as make sure you understand the need for engineered solutions on your compressed air system.  It may be out of your comfort zone for the first few calls but we will make sure you get to the level you want to be so you get back into your comfort zone.

Brian Farno
Advanced Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Engineered Solutions Are Cost Effective

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One of the easiest ways to solve a blow off application is to install an open pipe or tube; it’s generally quick and available. They are easy to make, mainly you just need some pipe, maybe a hacksaw and hammer, and a way to hook them up to your compressed air system.  They will provide a good amount of force but at the cost of safety, noise level, and air consumption. That’s right: it will cost you in SAFETY, NOISE EXPOSURE and COMPRESSED AIR CONSUMPTION. I’m going to go out on a limb here (not really) and wager there are a number of folks in any organization unwilling to pay those costs – if you are willing, you may want to reconsider.

I have been to many manufacturing facilities where they have used copper line to bend into a tight space and then pump 85 psi into the pipe in order to try and blow a piece of lint out of a roller or to keep trim from getting caught in a pulley system.  In some cases I have seen 3/8″ ID pipe to keep dust and lint out of a pulley.

This is not needed at all.   The estimated flow through a 3/8″ ID tube that is around 3′ long would be roughly 109 SCFM when powered at 85 psig.   All to keep dust off and loose fiber out of a certain area.  The reason they plumbed this large of a piece of tubing into the area was simple, it’s what they had and it worked great (words from the maintenance worker). For additional reference, our 91 SCFM air nozzle produces 4.5 pounds of force which seems a bit of overkill when you can blow dust away with your breath.

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In one instance I looked over the material and scrap they were trying to keep from getting to the outer workings of the machine I made the recommendation for them to utilize a model 1100SSW, –  a 1/4 NPT Stainless Steel Super Air Nozzle w/ Swivel Fitting.   This would give them flexibility to target the right area through the swivel and require them to change the existing tubing out to a schedule 40 threaded pipe, or use a compression style fitting.

By replacing the single nozzle, the customer was able to reduce compressed air consumption in just this single blow off point from 109 SCFM at 85 psig to 14 SCFM at 80 psig inlet pressure.  This single replacement equates to saving 95 SCFM, or $11.40 per 8 hour shift that the blowoff is operated.   If the customer operated this blowoff 24 hours a day it would take a mere 4 days to pay the unit back in air savings.

The above savings do not include the benefit of being able to reduce the overall operating pressure of the compressed air system feeding this application to 80 psig, instead of 85 psig. In case you weren’t aware, if you lower the pressure value where your compressor shuts off, say from 85 psig to 80 psig, it will save an estimated 2.5% of drive energy for their air compressor.   Depending on the type and size of the compressor this could amount to a substantial savings.  This system pressure reduction will also lower the operating pressure of any leaks that may be within the system which will also be another amount of savings.  All of this is from simply replacing open pipe with an engineered nozzle.

This was just one area where the quick and easy way turned out to be the costly and dangerous path.  The best part about our engineered solution is they are all in stock, ready to ship same day.  This means you can find the problem today, have a solution waiting to be installed tomorrow.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF