Not much in life is free anymore. So, make sure and take advantage of EXAIR’s upcoming FREE webinar at 2:00 PM ET on 10/17/2019. Not only are we providing it for free, but in this webinar we’ll be discussing how you can save money by reducing your compressed air consumption. Something for free, that will help save you money? Almost unheard of these days!!! Hosted by one of our highly-trained Application Engineers, Jordan Shouse, you’ll learn about four common ways that you can easily save air in your facility.
Compressed air is often referred to as the fourth utility in industry. When used improperly, compressed air is extremely expensive. Homemade devices such as open-ended and drilled pipes, inefficient air nozzles, leaks, etc. all contribute to increased energy costs. In addition to being wasteful, these devices are not safe and compliant with OSHA standards and regulations. By using an Intelligent Compressed Air Product, you’ll be both saving money and creating a safer environment for your operators.
In this webinar, you’ll gain an understanding of the places in your facility that are wasting the most compressed air. We’ll educate you on the various engineered solutions available from EXAIR to help eliminate unnecessary compressed air usage. You’ll gain the knowledge necessary to determine the best solution based on the application, sound level, compressed air usage, and compliance with OSHA safety requirements. You’ll also learn about the various solutions available to help understand and optimize your compressed air system. You can’t begin implementing a plan to reduce air consumption until you fully understand the usage in your own facility and processes. EXAIR’s line of Optimization products are ideal to help you gain a baseline measurement and begin implementing new products and processes that’ll only help add to your bottom line.
After the conclusion of the webinar will be a brief Q&A session where you can ask any questions you have about any of the topics covered. Unable to attend the webinar live? Don’t let that stop you from registering! Afterwards, each registrant will receive a link via e-mail where they’ll be able to access the full webinar at any time. Make sure and take advantage of this opportunity to gain some knowledge about the usage of your compressed air. You’ll be glad you did!
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!
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.
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.
Check the Air Supply
Check the plumbing
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.
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.
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:
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.
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.
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.