Tag: pneumatic control system

Since air compressors use a lot of electricity to make compressed air, it is important to use the compressed air as efficiently as possible. EXAIR has six simple steps to optimize your compressed air system. Following these steps will help you to cut electrical costs, reduce overhead, and improve your bottom line.

Step 1 – Measure the air consumption to find sources that use a lot of compressed air.  Information is important to diagnose wasteful and problematic areas within your compressed air system. To measure air consumption, flow meters can be used to find the volume or mass of compressed air per unit of time. Flow rates are very useful data points to find problems like leaks, over-use in blow-offs, waste calculations, and comparison analysis.

Step 2 – Find and Fix the Leaks.  One of the largest problems affecting compressed air systems is leaks.  That quiet little hissing sound from the pipe lines is costing your company a lot of money.  A study was conducted by a university to determine 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.  For a 100 hp compressor, you are losing 30 hp into the ambient air.  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 from one inaudible leak in hundreds of feet of compressed air lines.  EXAIR offers an Ultrasonic Leak Detector to find those inaudible leaks to fix.

Step 3 – Upgrade your blow-off devices with engineered products.  Here is a simple example.  A 1/4″ copper tube blow off can consume as much as 33 SCFM (934 SLPM) when supplied with compressed air at 80psig (5.5 bar).  It’ll give you a loud, strong blow off.  If you replace that copper tube with an engineered nozzle, a Model 1100 Super Air Nozzle, you can reduce that flow to just 14 SCFM (396 SLPM) at 80 PSIG (5.5 bar).  If you’re tracking your compressed air usage, you’ll see that replacing just one of them saves you 45,600 Standard Cubic Feet worth of compressed in one 5 day (8 hour a day) work week.  At $0.25 per 1,000 cubic feet of compressed air, that’s a savings of $11.40 per week.  Also, the noise level will be dropped to 74 dBA to make it comfortable when working nearby. 

Step 4 – Turn off your compressed air when not in use.  This step can be done using two simple methods, either by using manual controls such as ball valves or automated controllers such as solenoid valves.  Manual controls are designed for long use and when switching on and off are infrequent. Ball Valves are one of the most commonly used manual shut-offs for compressed air and other fluids.  The solenoid valves can be used for quicker shut-offs.  With the cost of compressed air, every bit counts.  If there are gaps in your operation, they can be triggered with different types of methods.  EXAIR does offer an Electronic Flow Control that has an optical eye and timing sequences to trigger solenoid valves to blow compressed air only when it is required. 

Step 5 – Install Secondary Receiver Tanks.  Compressed air receiver tanks are an integral part of many compressed air distribution systems. Compressed air is stored at a high pressure after drying and filtration. A secondary receiver tank is located on the floor for pneumatic equipment or systems. Think of a receiver tank as a “capacitor”.  It stores the energy within a system to be used in periods of peak demand, helping to maintain a stable compressed air pressure in your system. This improves the overall performance of the compressed air system and helps to prevent pressure swings.  Rather than having to pull from the compressor, a secondary receiver tank can be sized to provide the short-term volume of air for a particular application.

Step 6 – Control the Air Pressure.  People tend to overuse their compressed air for many blow-off applications.  This can create excessive waste, overwork your air compressor, and rob other pneumatic areas.  With Pressure Regulators, they give you control to set the operating pressure.  By simply turning down the air pressure, less compressed air is used.  As an example, a model 1100 Super Air Nozzle uses 14 SCFM (396 SLPM) of compressed air at 80 PSIG (5.5 bar).  If you only need 50 PSIG (3.4 bar) to satisfy the blow-off requirement, then the air flow for the model 1100 drops to 9.5 SCFM (269 SLPM).  You are now able to add that difference of 4.5 SCFM (127 SLPM) back into the compressed air system. If we use the average rate of $0.25/1000 cubic feet to make compressed air, this would be a savings of $135.00/year with an 8-hour shift.  And, if you have many similar blow-off devices, you can see how this can really add up.

It is important to review and monitor your compressed air system.  You can cut your energy consumption, improve efficiency, and save yourself money.  The six steps above will help to diagnose the overall “health” of your compressed air system. EXAIR does carry some of these products to help you measure and analyze.  You may have questions about the Six Steps to Optimize Your Compressed Air System, and an Application Engineer at EXAIR will be happy to help. 

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

When we talk with customers about their EXAIR Products, we also discuss the quality of their compressed air. Many of our products have no moving parts and are considered maintenance-free when supplied with clean, dry compressed air. One of the most critical aspects of a compressed air distribution system is the dryer.

No matter where you are in the world, the atmospheric air will contain water vapor. Even in the driest place in the world, McMurdo Dry Valley in Antartica, there is some moisture in the air. As this air cools to the saturation point, also known as dew point, the vapor will condense into liquid water. The amount of this moisture will vary depending on both the ambient temperature and the relative humidity. According to the Compressed Air Challenge, a general rule of thumb is that the amount of moisture air can hold in a saturated condition will double for every increase of 20°F. In regions or periods of warmer temperatures, this poses an even greater problem. Some problems that can be associated with moisture-laden compressed air include:

• Increased wear of moving parts due to removal of lubrication.
• Formation of rust in piping and equipment.
• It can affect the color, adherence, and finish of paint that is applied using compressed air.
• Jeopardizes processes that are dependent upon pneumatic controls. A malfunction due to rust, scale, or clogged orifices can damage products or cause costly shutdowns.
• In colder temperatures, the moisture can freeze in the control lines.

In order to remove moisture from the air after compression, a dryer must be installed at the outlet of the compressor. It is recommended to dry the compressed air to a dew point at least 18°F below the lowest ambient temperature to which the distribution system or end use is exposed. A dew point of 35-38°F is often sufficient and can be achieved by a refrigerated dryer (Best Practices for Compressed Air Systems). This makes the refrigerant dryer the most commonly used type in the industry.

A refrigerant dryer works by cooling the warm air that comes out of the compressor to 35-40°F. As the temperature decreases, moisture condenses and is removed from the compressed air supply. It’s then reheated to around ambient air temperatures (this helps to prevent condensation on the outside of distribution piping) and sent out to the distribution system.

With your air clean and dry at the point of use, you’re making sure you get the most lifespan out of EXAIR’s point-of-use Intelligent Compressed Air Products.

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

X: @EXAIR_TD

As margins get tighter and the cost of manufacturing climbs, industries are looking for ways to be more economical.  A big focus is on the compressed air system.  Compressed air is considered to be the “fourth utility” behind gas, water, and electricity.  Air compressors are necessary to run pneumatic systems, but they are 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 biggest problems affecting compressed air systems is leaks.  That quiet sound coming from the pipelines is costing your company a lot of money.  A study was conducted by a university to determine the percentage of air leaks in a typical manufacturing plant.  In a poorly maintained system, they found that 30% of the compressor’s capacity is lost through air leaks on average.  Just to let you know, the majority of companies do not have a leak prevention program, so they will fall into the “poorly maintained” category.  The chart below shows the amount of money that can be wasted by the size of the hole for larger leaks. Unlike a hydraulic system, compressed air is clean, so leaks will not be visible at the source.  You have to find them by other means.  There are four main methods to test your system for leaks.

Ultrasonic Leak Detector:  When you have small air leaks, the turbulent flow will emit an ultrasonic sound.  This method is the most direct way to find leaks in your system.  With the EXAIR Ultrasonic Leak Detector, it can pick up these high frequencies in the range of 20 kHz to 100 kHz, above human hearing.  This device makes the inaudible leaks audible.  Some other features of the model 9207 are a sensitivity adjustment button, a signal strength display, and a headphone volume button.  It has two attachments; the parabola attachment to locate leaks up to 20 feet (6.1 meters) away, and the tube attachment to define the exact location of the leaks. 

Digital Flowmeters:  With Digital Flowmeters, you can continuously watch for waste.  Air leaks can occur at any time within any section of your pneumatic system.  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 a 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 spreadsheet.  Once the information starts trending upward for the same process, you can focus your attention on finding the leak.  It can also serve as a preventive measure if a pneumatic system is starting to fail.

Pressure difference:  There are some equations that can be helpful in determining how severe the leaks are in the system.  One method would be to look at a pressure gauge.  For this method to work, you will have to estimate the total system volume, comprising secondary air receiver, piping, and air mains. After the compressor runs for a while to build to an operating pressure (P1).  Then, you have to block the system off and measure the time.  When it reaches a stopping point at pressure (P2), mark that time.  Use Equation 1 to measure the leakage rate, Q in CFM.  If the flow is more 10%

Equation 1:

Q = (V x (P1-P2)/T x 14.7) x 1.25

V = Volume (Ft³)

P1- Starting pressure (psig)

P2 = Ending pressure (psig)

T = Time (Minutes)

Compressor cycling time:  First start by shutting off all the points of use of compressed air products so that there’s no demand on the system. Then, start the compressor and record the average time it takes for the compressor to cycle on/off. The compressor will load and unload as the air leaks, causing a pressure drop from air escaping. The percentage of total leakage can be calculated by Equation 2.  The leakage rate will be given as a percentage of total compressor capacity lost. This value should be less than 10% for a well-maintained system.

Equation 2:

Leakage % = [(T) / (T + t)] * 100

Where:

T = loaded time (seconds)

t = unloaded time (seconds)

Compressed air leaks will rob you of 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.  I added some tips and tricks to help determine the severity of the leaks in your system.  The EXAIR Digital Flowmeters and Ultrasonic Leak Detector will help you accomplish this and optimize your compressed air system.  If you need more information, you can contact an Application Engineer at EXAIR.  Once you find and fix all your leaks, you can then focus on improving the efficiency of your blow-off devices with EXAIR products.  It will save you even more money. 

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

Photo: Soap bubbles and pencils by Carola68.  Pixabay license.