Optimizing Your Current Compressed Air System Is Simple

A few weeks ago, we posted a blog discussing how artificial demand and leaks can lead to poor performance and expensive waste.  Today, I’d like to review how following a few simple steps can help optimize your current compressed air system and reduce compressed air usage.

The first step you want to consider is measuring the air usage in the system. To do this, you want to start at the compressor and check individual leads to each drop point to a blowoff device, record your findings to track the demand. By measuring your compressed air usage, you can locate the source of high usage areas and monitor the usage on each leg of the system. If the demand exceeds the supply, there is potential for problems to arise, such as lowered pressure and force from compressed air operated devices leading to irregular performance.

Digital Flowmeter with wireless capability

EXAIR’s Digital Flowmeters are designed to measure flow continuously and accurately to give you real-time flow measurements of your compressed air system to help identify problems areas.

Step 2 is to locate the source of waste. Again, compressed air leaks can result in a waste of up to 30% of a facility’s compressor output. A compressed air leak detection and repair program can save a facility this wasted air. Implementing such a program can be used as a way for a facility to “find” additional air compressor capacity for new projects. Whenever a leak occurs, it will generate an ultrasonic noise.

Model # 9061 Ultrasonic Leak Detector

Our Ultrasonic Leak Detector is designed to locate the source of ultrasonic sound emissions up to 20’ away. These ultrasonic sound emissions are converted to a range that can be heard by humans. The sound is 32 times lower in frequency than the sound being received, making the inaudible leaks, audible through the included headphones and the LED display gives a visual representation of the leak.

The 3rd step involves finding the source of noisy and wasteful blowoffs, like open pipes or homemade blowoffs, and replacing them with an energy efficient, engineered solution. By replacing these devices, you are not only reducing the amount of waste but also improving operator safety by complying with OSHA safety requirements.

Model # 9104 Digital Sound Level Meter

EXAIR’s Digital Sound Level Meter is an easy to use instrument that measures and monitors the sound level pressure in a wide variety of industrial environments. The source of loud noises can be quickly identified so that corrective measures can be taken to keep sound levels at or below OSHA maximum allowable exposure limits.

The easiest way to reduce compressed air usage and save on operating expense is to turn off the compressed air to a device when it isn’t needed, step 4 in the process. Not only will this save money, in many cases, it can also simplify a process for the operator.

 

Sizes from 1/4″ NPT up to 1-1/4″ NPT are available

A simple manual ball valve and a responsible operator can provide savings at every opportunity to shut down the air flow.

 

120VAC, 240VAC or 24VDC

 

For automated solutions, a solenoid valve can be operated from a machine’s control. For example, if the machine is off, or a conveyor has stopped – close the solenoid valve and save the air.

 

 

Model # 9040 Foot Valve

A foot pedal valve offers a hands free solution to activate an air operated device only when needed, such as being implemented in an operator’s work station.

 

EFC – Electronic Flow Control

For even more control, you can use a device like our EFC or Electronic Flow Control. This helps minimize compressed air usage by incorporating a programmable timing controlled (0.10 seconds to 120 hours) photoelectric sensor to turn off the compressed air supply when there are no parts present. It is suited for NEMA 4 environments and can be easily wired for 100-240VAC.

 

 

Step 5, intermediate storage. Some applications require an intermittent demand for a high volume of compressed air. By installing a receiver tank near the point of high demand, there is an additional supply of compressed air available for a short duration. This will help eliminate fluctuations in pressure and volume.

Model # 9500-60

EXAIR offers a 60 gallon, ASME approved vertical steel tank with mounting feet for easy installation near high demand processes.

Many pneumatic product manufacturers have a certain set of specifications regarding performance at stated input pressures. In many applications, or in the case of using a homemade blowoff device like open pipe, these wouldn’t necessarily require the full rated performance of the device or full line pressure. Controlling the air pressure at the point-of-use device will help to minimize air consumption and waste, step 6.

Pressure Regulators permit easy selection of the operating pressure

By simply installing a pressure regulator on the supply side, you can start off at a low pressure setting and increase the pressure until the desired result is achieved. Not only will this help to conserve energy by only using the amount of air required for the application, it also allows you to fine tune the performance of the point-of-use device to match the application requirements.

If you have any questions, please contact an application engineer at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

A Unique Application for the Ultrasonic Leak Detector

Here on the EXAIR blog we post a ton of different applications for our products. We typically see similar applications each day and write about them so that you may identify potential points in your various processes that may benefit from an engineered compressed air solution. Many of these are typical blowoff or cooling applications that we see day in and day out. Sometimes, though, we see some applications that are outside the realm of typical operation. This can sometimes require the manufacturing of a specialized part or just getting a little creative with a stock product.

Our distributor in Argentina recently contacted me about a unique application for an Ultrasonic Leak Detector. The Model 9061 Ultrasonic Leak Detector is a hand-held instrument that allows you to locate costly leaks in a compressed air distribution system. As pressurized air exits a small orifice, an ultrasonic sound that is above human hearing is created. The Ultrasonic Leak Detector is able to pick up on these sound emissions and can convert it to an audible range that is able to be heard by the human ear. Typically, this product is used in conjunction with a leak prevention program to help save money and compressed air by identifying leaks in the distribution system.

ultrasonic_2
Model 9061 ULD detecting a leak

The customer is a manufacturer of plastic bottles used to hold a wide variety of different personal care products. The bottles were molded in two separate pieces, then brought together and sealed. After the two pieces of the bottle were sealed, they had to test each one to ensure that they remained watertight. Their current method involved filling the cavities with water and inspecting for leaks.

While this method was effective, when a leak was present water would get all over the machine and floor and needed to be cleaned up. This to them was considered a nuisance and they began to explore alternative methods of checking the seals on the bottles. They found EXAIR’s Ultrasonic Leak Detector and wondered if they could use it to detect leaks on the bottles if they were to pressurize them with compressed air instead of filling them with water. We’ve handled similar applications in the past, this one here a customer used the ULD to detect leaks from poor welds on the roof of buses. They ordered one for testing and were very pleased with the results. The ULD had no problem detecting leaks in the bottles and allowed them to eliminate the mess and annoyance associated with using water.

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Operator testing for leaks using the ULD

Just because you can’t find a particular application in our Application Database on the website or here on the blog, doesn’t mean that it can’t be done! With our unconditional 30 day guarantee for all stock products you have plenty of time to test it out in your specific application. If for any reason it won’t work for you, just send it back and we’ll try something else.

If you have a unique application that could be served by an Intelligent Compressed Air Product, give us a call. Trust me when I say we absolutely LOVE tackling a new and exciting challenge with a creative solution!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

Do You Need 30 Days for Testing?

Not long ago while checking out of a motel my laptop bag that was attached to the handle on my suitcase fell forward and the impact shattered the screen on the laptop.  Upon turning the computer on I realized that a new screen was in order.

I waited until I arrived at home and found what I thought to be the correct monitor and quickly ordered it.  It arrived two days later and I painstakingly took the laptop apart and exposed the mounting frame.  The removal of the broken screen and the installation of the new was not too difficult but the cable connector was less than robust and was very tight.  Carefully I worked it back and forth and it came free.

Installation and reassembly went quickly and then I powered up the machine.  I was only greeted with a series of very loud and annoying beeps.  At that point I shut it down and called the company I purchased the screen from and described the issue.  They determined that the resolution of the screen was incorrect for my laptop and that I needed a different model.  They said I could return the incorrect one and upon inspection receive a credit less the return shipping.  At that point I ordered the correct screen and packaged up the wrong one and dropped it off at the parcel delivery service.

The new model arrived and it installed easily and worked perfectly.  I waited patiently and never did see a refund so I called the company and they said that it was an oversight on their end and that it would be corrected within 48 hours.  Sure enough they issued the credit and money was credited back to my account with one exception, the 40% restocking fee!

I can tell you that EXAIR is not that way!  If you order the wrong item or are not satisfied for any reason and the item was purchased within the last 30 days we will facilitate the return and ZERO restocking fee. There are a multitude of reasons our customers would want to take advantage of our 30 day guarantee and we make it a simple transaction if you need to take advantage of it too. Testing is one reason a customer would use this 30 days, other customers may have ordered incorrectly or released product inadvertently, they may have wanted a small sample for a meeting or demonstration at a customers location.

30 day money back guarantee
EXAIR Guarantee

If you want to discuss any EXAIR product, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
Send me an email
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Six Steps To Optimizing Your Compressed Air System – Step 1: Measure

“To measure is to know – if you cannot measure it, you cannot improve it.”
-Lord Kelvin, mathematical physicist, engineer,and pioneer in the field of thermodynamics.

This is true of most anything. If you want to lose weight, you’re going to need a good scale. If you want to improve your time in the 100 yard dash, you’re going to need a good stopwatch. And if you want to decrease compressed air consumption, you’ll need a good flowmeter. In fact, this is the first of six steps that we can use to help you optimize your compressed air system.

Six Steps To Optimizing Your Compressed Air System

There are various methods of measuring fluid flow, but the most popular for compressed air is thermal mass air flow.  This has the distinct advantage of accurate and instantaneous measurement of MASS flow rate…which is important, because measuring VOLUMETRIC flow rate would need to be corrected for pressure in order to determine the true compressed air consumption.  My colleague John Ball explains this in detail in a most excellent blog on Actual (volume) Vs. Standard (mass) Flows.

So, now we know how to measure the mass flow rate.  Now, what do we do with it?  Well, as in the weight loss and sprint time improvements mentioned earlier, you have to know what kind of shape you’re in right now to know how far you are from where you want to be.  Stepping on a scale, timing your run, or measuring your plant’s air flow right now is your “before” data, which represents Step One.  The next Five Steps are how you get to where you want to be (for compressed air optimization, that is – there may be a different amount of steps towards your fitness/athletic goals.)  So, compressed air-wise, EXAIR offers the following solutions for Step One:

Digital Flowmeter with wireless capability.  This is our latest offering, and it doesn’t get any simpler than this.  Imagine having a flowmeter installed in your compressed air system, and having its readings continually supplied to your computer.  You can record, analyze, manipulate, and share the data with ease.

Monitor your compressed air flow wirelessly over a ZigBee mesh network.

Digital Flowmeter with USB Data Logger.  We’ve been offering these, with great success, for almost seven years now.  The Data Logger plugs into the Digital Flowmeter and, depending on how you set it up, records the flow rate from once a second (for about nine hours of data) up to once every 12 hours (for over two years worth.)  Pull it from your Digital Flowmeter whenever you want to download the data to your computer, where you can view & save it in the software we supply, or export it directly into Microsoft Excel.

From the Digital Flowmeter, to your computer, to your screen, the USB Data Logger shows how much air you’re using…and when you’re using it!

Summing Remote Display.  This connects directly to the Digital Flowmeter and can be installed up to 50 feet away.  At the push of a button, you can change the reading from actual current air consumption to usage for the last 24 hours, or total cumulative usage.  It’s powered directly from the Digital Flowmeter, so you don’t even need an electrical outlet nearby.

Monitor compressed air consumption from a convenient location, as well as last 24 hours usage and cumulative usage.

Digital Flowmeter.  As a stand-alone product, it’ll show you actual current air consumption, and the display can also be manipulated to show daily or cumulative usage. It has milliamp & pulse outputs, as well as a Serial Communication option, if you can work with any of those to get your data where you want it.

With any of the above options, or stand-alone, EXAIR’s Digital Flowmeter is your best option for Step One to optimize your compressed air system.

Stay tuned for more information on the other five steps.  If you just can’t wait, though, you can always give me a call.  I can talk about compressed air efficiency all day long, and sometimes, I do!

 

Digital Sound Level Meter Identifies Harmful Noise in the Workplace

slm-newlabel EXAIR offers the model 9104 Digital Sound Level Meter.  It is an easy to use instrument for measuring and monitoring the sound level pressures in and around equipment and other manufacturing processes.

Sound meters convert the movement of a thin membrane due to the pressure waves of sound into an electric signal that is processed and turned into a readable output, typically in dBA.  The dBA scale is the weighted scale that most closely matches the human ear in terms of the sounds and frequencies that can be detected.

 

To protect workers in the workplace from suffering hearing loss OSHA has set limits to the time of exposure based on the sound level.  The information in the OSHA Standard 29 CFR – 1910.95(a) is summarized below.

OSHA Noise Level

The Digital Sound Meter can be used to monitor and measure sound levels of manufacturing processed such as blowoffs for cooling or drying.  Many blowoffs, especially open or drilled pipes are very inefficient and can be identified as a source of excessive noise, outside the OSHA exposure ranges.  Once the noise violators are identified, a review can be done and the implementation of engineered solutions such as Super air Nozzles or Super Air Knives can be investigated. Keeping harmful noise levels in check benefits everyone involved.

The EXAIR Digital Sound Level Meter is an accurate and responsive instrument that measures the decibel level of the sound and displays the result on the large optionally back-lit LCD display. There is an “F/S” option to provide measurement in either ‘slow’ or ‘fast’ modes for stable or quickly varying noises. The ‘Max Hold’ function will capture and hold the maximum sound level, and update if a louder sound occurs.

Certification of accuracy and calibration traceable to NIST (National Institute of Standards and Technology) is included.

There is an informative Video Blog, presented by @EXAIR_LE that can be found here.

If you have questions about the Digital Sound Level Meter, or would like to talk about any of the quiet EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Twitter: @EXAIR_BB

FREE EXAIR Webinar – November 2nd, 2017 @ 2:00 PM EDT

On November 2, 2017 at 2 PM EDT, EXAIR Corporation will be hosting a FREE webinar titled “Optimizing Your Compressed Air System In 6 Simple Steps”.

During this short presentation, we will explain the average cost of compressed air and why it’s important to evaluate the current system. Compressed air can be expensive to produce and in many cases the compressor is the largest energy user in a plant, accounting for up to 1/3 of the total energy operating costs. In industrial settings, compressed air is often referred to as a “fourth utility” next to water, gas and electric.

Next we will show how artificial demand, through operating pressure and leaks, can account for roughly 30% of the air being lost in a system, negatively affecting a company’s bottom line. We will provide examples on how to estimate the amount of leakage in a system and ways to track the demand from point-of-use devices, to help identify areas where improvements can be made.

To close, we will demonstrate how following six simple steps can save you money by reducing compressed air use, increasing safety and making your process more efficient.

CLICK HERE TO REGISTER

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

The Cost of Compressed Air Leaks Create the Need to Find and Fix

Leaks can cost you

As margins get tighter and cost of manufacturing climbs, industries are looking into other areas to be more economical.  A big focus today is in the compressed air systems.  Compressed air is considered to be the “forth” utility behind gas, water, and electricity.  It is a necessary system to run pneumatic systems, but it is the least efficient of the utilities.  For every $1.00 that is put into making compressed air, you only get roughly 5¢ of work from it.  So, it is very important to use this utility as efficiently as possible.

One of the largest problems affecting compressed air systems is leaks.  That quiet little hissing sound coming from the pipe lines is costing the company much money.  A university study was conducted to find the percentage of air leaks in a typical manufacturing plant.  In a poorly maintained system, they found on average that 30% of the compressor capacity is lost through air leaks.  In relation to the amount of electricity required to make compressed air, for every ten power plants producing electricity, there is one power plant producing electricity just for air leaks.  A majority of companies do not have a leak prevention program; so, many of these companies have poorly maintained systems. This creates a large amount of waste caused by simple air leaks.  To put a dollar value on it, a leak that you cannot physically hear can cost you as much as $130/year.  That is just for one inaudible leak in hundreds of feet of compressed air lines.  For the leaks that you can hear, you can tell by the chart below the amount of money that can be wasted by the size of the hole.  Unlike a hydraulic system, compressed air will not leave a tell-tale sign of a leak. You have to locate them by some other means.

**Note 1

Most leaks occur where you have threaded fittings, connections, hoses, and pneumatic components like valves, regulators, and drains.  The Optimization products from EXAIR are designed to help optimize your complete compressed air system.  The most effective way is to find and eliminate air leaks, and EXAIR has two products that can help do this.  The Ultrasonic Leak Detectors can find the air leaks, and the Digital Flowmeters can monitor your system for air leaks.  With both of these products included in a leak prevention program, you will be able to keep your compressed air system running optimally and reduce the wasted cost in air leaks and overusing the air compressor.

EXAIR Ultrasonic Leak Detector:

When a leak occurs, it emits an ultrasonic noise caused by turbulence.  These ultrasonic noises can be at a frequency above that which is audible for human hearing.  The EXAIR Ultrasonic Leak Detector can pick up these frequencies and make the leaks audible.  With three sensitivity ranges and LED display, you can find very minute leaks in your compressed air system.  It comes with two attachments; the parabola to locate leaks up to 20 feet away, and the tube attachment to define the exact location in the pipe line.  Once you find a leak, it can be marked for fixing.

EXAIR’s Digital Flowmeter w/ USB Data Logger

EXAIR Digital Flowmeter:

With the Digital Flowmeters, you can continuously monitor for waste.  Air leaks can occur at any time within any section of your pneumatic area.  You can do systematic checks by isolating sections with the Digital Flowmeter and watching for a flow reading.  Another way to monitor your system would be to compare the results over time.  With the Digital Flowmeters, we have a couple of options for recording the air flow data.  We have the USB Datalogger for setting certain time increments to record the air flows.  Once the information is recorded, you can connect the USB to your computer, and with the downloadable software, you can view the information and export it into an Excel spread sheet.  We also offer a wireless capability option with the Digital Flowmeters.  You can have multiple flow meters communicating through a gateway to monitor and record the flow information onto your computer system.  If you find that the flow starts trending upward for the same process, then you know that you have a leak.  It can also give you a preventive measure if your pneumatic system is starting to fail.

Compressed air leaks will rob you in performance, compressor life, and electrical cost.  It is important to have a leak prevention program to check for leaks periodically as they can happen at any time.  The EXAIR Ultrasonic Leak Detector and the Digital Flowmeters will help you accomplish this and optimize your compressed air system.  Once you find and fix all your leaks, you can then focus on improving the efficiency of your blow-off devices with EXAIR products and save yourself even more money.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

 

**Note 1: Chart was published by Compressed Air Challenge in April 1998 – Rev. 0