EXAIR Optimization Products: Ultra Sonic Leak Detector Overview

Ultrasonic Leak Detector

The Ultrasonic Leak Detector is a hand-held, high quality instrument that can locate costly leaks in a compressed air system.  When using the Ultra Sonic Leak Detector, you only need to aim it in the direction of the suspected leak and if a leak is present an audible tone can be heard through the supplied headphones and the LED will light.  This can be accomplished from up to 20′ away!

If you are not maintaining your compressed air system you can easily waste up to 30% of your compressor’s output through leaks.  We all know compressed air is expensive, so mitigating wasteful leaks should be high on your to do list!

 

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EXAIR Ultrasonic Leak Detector

What is Ultrasound

Since most compressed air leaks emit only Ultra Sonic sound it would be next to impossible to find a leak by listening for them since the sound is above the human thresh hold.   That is where the EXAIR Ultrasonic Leak Detector comes in.  Its sensitivity is is adjustable with 3 settings X1, X10 and X100 along with an on/off thumb wheel for fine sensitivity adjustments.  The Ultra Sonic Leak Detector also comes with both a parabola or tubular extension to aim the unit and block out extraneous background noise.

If you have an application where you need to find an ultrasonic noise, you can speak with an Application Engineer to see if the model 9061 Ultrasonic Leak Detector could help.

If you would like to discuss the Ultra Sonic Leak Detector or any EXAIR product, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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Troubleshooting 101: Super Air Knife

Yesterday, I was working with a customer on troubleshooting a Super Air Knife. He had brought the knife into EXAIR’s demo room so I was able to verify a few items very easily.  When trouble shooting air knives there are no moving parts, so it is very small list of items to check.

  1. Check the Air Supply

  2. Check the plumbing

  3. Check the inside of the Air Knife for debris

The customer had a 36″ Super Air Knife ,and he was seeing some weak spots in the air flow as well as a gradient in flow from one side of the knife to the other.  The first thing I did was to install a pipe tee with a pressure gauge in both ports on the bottom of the knife.  This would allow me to monitor the pressure we were supplying to the knife to calculate the air consumption and ensure the our piping was not starving the knife for air.

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Feeding the knife with equal pressure from both sides, is necessary for any air knife 24 inches or longer. The customer immediately noticed that the flow from the knife lost any sort of gradient, once it was fed in (2) locations. Still the air knife exhibited a spot in the flow where air velocity significantly decreased.  Since we were getting correct pressure and supplying enough air, we decided to remove the cap from the Super Air Knife.  Under the cap we found a variety of debris and one dreaded piece of PTFE plumbing tape. The plumbing tape was suppose to prevent air leaks throughout the compressed air system, but a piece had become lodged in the air gap of the Super Air Knife preventing air flow through a small portion of the Super Air Knife.  As you can see, once we followed a few simple steps to ensure proper installation of the Super Air Knife, it was quick and easy to narrow down what caused the lack of performance. This is yet another reason to make sure you have clean and dry compressed air, as well as use a point of use filter separator.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

Compressed Air Calculations, Optimization, and Tips

EXAIR uses our blog platform to communicate everything from new product announcements to personal interests to safe and efficient use of compressed air. We have recently passed our 5 year anniversary of posting blogs (hard for us to believe) and I thought it appropriate to share a few of the entries which explain some more of the technical aspects of compressed air.

Here is a good blog explaining EXAIR’s 6 steps to optimization, a useful process for improving your compressed air efficiency:


One of the Above 6 steps is to provide secondary storage, a receiver tank, to eliminate pressure drops from high use intermittent applications. This blog entry addresses how to size a receiver tank properly:

Here are 5 things everyone should know about compressed air, including how to calculate the cost of compressed air:

These next few entries address a common issue we regularly assist customers with, compressed air plumbing:

In a recent blog post we discuss how to improve the efficiency of your point of use applications:

Thanks for supporting our blog over the past 5 years, we appreciate it. If you need any support with your sustainability or safety initiatives, or with your compressed air applications please contact us.  

Have a great day,
Kirk Edwards
@EXAIR_KE

Improve Your Compressed Air System: Improve Point of Use Applications

While compressor controls and efficiency are an important part of any comprehensive compressed air audit, so too, are your point of use applications. Many times these point of use locations are quickly and inexpensively improved. The first step is to identify which area of your system you would like to improve first. Certainly you will have that “problem area”, the part of the plant you know is using compressed air more than it should. This area of your plant is usually outfitted with open tubes that have the ends crimped down as a homemade nozzle or the operators are using blow-guns with commercial grade nozzles or worse yet, no nozzle at all. It’s the area of the plant that may require hearing protection due to the loud hissing of air or where that pipe with drilled holes was the quickest and cheapest fix for the application (or so you thought).

Document these areas of the plant and address these points of use by measuring the current consumption. Many times, we find, the volume of air provided by open tubes, inefficient nozzles and drilled pipes is much more than is required for the application.  Accurate compressed air measurement will be important to properly calculate the compressed air cost and savings. These points of use can be retrofitted or optimized in a couple of ways. First, you can retrofit open tubes by placing a compression fitting and engineered air nozzle on it. This will both reduce the air consumption and noise levels within the plant. Drilled pipes have holes, or slots, along the length to provide a wide area blow off. These applications can show dramatic improvement by using compressed air knives or air amplifiers which are engineered to reduce air consumption, reduce noise and maintain OSHA Compliance for dead end pressure. The second way to improve these end use applications is to install pressure regulators and lower the end use pressure which will result in lower air use.

Don’t let these end use applications go unchallenged, just because they were this way when you joined the firm does not mean they should not, or cannot be improved upon. If you get the right folks involved and keep them updated about the actions or changes you are making, you will find advocates for the projects. Remember that quantifying the savings is key so don’t start without measuring how much air you are currently using at these problem areas. Flow meters on each leg of your system or at specific high use areas of the plant will prove invaluable to providing data expressed in dollars of savings to those making decisions within your firm. The compressed air supply side personnel will also be helpful in locating or prioritizing where to start saving compressed air. Keep employees and management informed of savings and improvements and the savings ball will have more potential to keep on rolling.

Remember:

  • Measure – baseline the current conditions of compressed air use with flow meters
  • Upgrade – retrofit inefficient open blow offs, commercial grade nozzles, drilled pipes etc. with engineered  and intelligent compressed air products
  • Control air pressure – lower pressure results in lower air consumption

If you would like any assistance or support to improve your compressed air system, we’re here to help.

Kirk Edwards
Application Engineer
@exair_ke