Control Air Pressure at the Point of Use with EXAIR’s Pressure Regulators

In any application necessitating the use of compressed air, pressure should be controlled to minimize the air consumption at the point of use. Pressure regulators are available to control the air pressure within the system and throttle the appropriate supply of air to any pneumatic device. As the last of the six steps to optimizing your compressed air system, controlling air at the point of use can often be overlooked. To help you achieve this, EXAIR offers a line of point of use pressure regulators to make sure you’re operating at the optimal pressure for your application.

Pressure regulators utilize a control knob that is turned to either increase/decrease tension on a spring. The spring puts a load on the diaphragm which separates internal air pressure from the ambient pressure. Typically made of a flexible rubber material, these diaphragms react very quickly to changes in the air supply. By either increasing or decreasing the flow of air based on the load on the diaphragm, downstream pressure remains fairly constant.

Regulator Internal

While one advantage of a pressure regulator is certainly maintaining consistent pressure to your compressed air devices, using them to minimize your pressure can result in dramatic savings to your costs of compressed air.

As pressure and flow are directly related, lowering the pressure supplied results in less compressed air usage. EXAIR recommends operating your Intelligent Compressed Air Products at the minimum pressure necessary to achieve a successful application. If you notice a desirable result at a pressure of 60 PSIG, or even less, there’s no need to run full line pressure. In-line point of use pressure regulators are the simplest and most reliable way to allow you to dial down the pressure to any compressed air operated product. For example, a Model 110012 Super Air Knife will consume 42 SCFM when operated at 100 PSIG. When the pressure is reduced to 60 PSIG, this drops to just 27.6 SCFM. That’s a 34% reduction in compressed air usage, just by dialing down the pressure at the point of use!

When selecting a pressure regulator for your application, it’s critical that it is appropriately sized to supply adequate volume to the point of use devices downstream. Doing so, minimizes the risk of experiencing “droop”. Droop is a decrease in outlet pressure from the specified setting due to an increase in flow rate.  Droop occurs when the demand at the point of use exceeds the volume of air that the regulator can supply. By ensuring the pressure regulator is rated to deliver sufficient volume of air, you’ll reduce the chances of experiencing droop. EXAIR offers pressure regulators in kits along with many of our products, we’ve done the hard part for you and made sure they’re properly sized!

If you’re looking for ways to help lessen the demand on your compressor, EXAIR’s team of Application Engineers will be happy to help. Reach out to us via phone, chat, or e-mail and see for yourself just how easy it can be to start saving compressed air!

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

EXAIR Super Air Knives: Controlling the Force

EXAIR has been manufacturing Intelligent Compressed Air® products since 1983.  In the beginning, the Standard Air Knives and Full Flow Air Knives were very effective at that time.  But as leaders in this market, EXAIR did not want to stop there.  We were able to engineer a more efficient and more powerful air knife, the Super Air Knife.

Super Air Knife has 40:1 Amplification Ratio

Bernoulli’s principle explains how a high velocity fluid can generate a low pressure.  The EXAIR Super Air Knife creates a high velocity air stream to produce a low pressure to entrain ambient air.   What does this mean for you?  It will save you much money by using less compressed air.  The mass of the ambient air is added into the air stream to give a strong blowing force.  The Super Air Knife has an amplification ratio of 40:1. For every 1 part of compressed air, 40 parts of ambient air is drawn into the blowing air stream.  Ambient air is free, and compressed air is expensive.  EXAIR was able to engineer a design to use the Bernoulli’s principle to make one of the most efficient air knives in the market place.    In this blog, I will discuss how you can change the air usage and force of the EXAIR Super Air Knives.

We manufacture and stock the widest range in lengths and materials.  To start, EXAIR has Super Air Knives ranging from 3” to 108” (76mm to 2,743mm) in three different materials; aluminum, 303 stainless steel, and 316/316L stainless steel.  There is no-one else in this industry that can manufacture to those lengths.  EXAIR also offers Super Air Knives in PVDF material with Hastelloy hardware for chemical resistant applications from 3” to 54” (76mm to 1,372mm).  Depending on the application requirement, temperature, chemical resistance, and OSHA and FDA regulations, we probably will have one on the shelf for you.  If EXAIR does not have it, we can make special air knives in different lengths and materials to best fit your application.

Pressure Regulators

To adjust the force and air usage a Pressure Regulator is a very helpful tool. The regulator would be considered a fine adjustment for the Super Air Knife.  With the laminar flow, the force is very consistent across the entire length; so, you can “dial” in the exact force.  EXAIR always recommends to use the least amount of pressure to “do the job” because this will save you even more money.  For the coarse adjustment, EXAIR Super Air Knives have replaceable shims.  So, you can increase or decrease the gap to get a variety of force ratings.  The Aluminum version uses colored plastic shims for visual verification.  They come stock with a 0.002” (0.05mm) red shim installed.  We have other thicknesses in our Shim Sets which includes a 0.001” (0.03mm), 0.003” (0.08mm), and a 0.004” (0.10mm) colored as amber, green, and tan respectively.

The Stainless Steel Super Air Knives come with a stainless steel shim for higher temperatures and chemical resistance.  Stock units have the 0.002” (0.05mm) thickness as well.  The Shim Sets come with three additional 0.002” (0.05mm) shims to stack.  EXAIR does have the ability to manufacture other thicknesses in stainless steel.  Similarly, the PVDF Super Air Knives use a PTFE shim for maximum chemical resistance.  It is also 0.002” (0.05mm) thick, and there are three more shims in the Shim Set.

This unique feature of using shims allows for the most flexibility in creating forces for different applications ranging from a blast to remove rocks from a conveyor to a breeze for light duty work.

We can include the pressure regulator, filter, and Shim Sets in our standard kits.  It will make our Super Air Knives a more complete system that is properly sized.  With the today’s cost in making compressed air, it is important to do it as efficiently as possible.  And with the Pressure Regulator and Shim Sets available, you can control the blowing force and air usage.  From now until December 31st, EXAIR is having a promotion.  You will receive a model 1210 Safety Air Gun for free, a $91.00 value, with qualified purchases.  (Check it out HERE).  If you have any questions about the Super Air Knife or if you would like to discuss an application, you can contact an Application Engineer at EXAIR.   We will be glad to help you.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Compressed Air: Only as Intelligent as Your Accessories

How often have you seen a compressed air system functioning at 100% efficiency? Do you have the right accessories to provide a source of clean air at the proper pressure? Even with the right accessories, have they been maintained in good working order? Chances are that some of your components are in fact in need of attention such as a clogged filter, improper regulator or maybe undersized hoses. Your air compressor is only as intelligent as the weakest component in your system.

This is why you need to make sure all of your EXAIR accessories are properly fitted and located in the most efficient locations. Your compressor is capable of producing compressed air but your accessories will allow it to function the way it is meant to function. Using accessories and using them in the right manner is the intelligent choice, it will minimize your maintenance while increasing your energy efficiency for the life of your compressor. Let’s review a few of the most important compressed air accessories you should consider.

Filter Separators: Filters remove and separate water, dirt and scale from your compressed air system to keep your air clean and output pure. Clean air keeps your air products and machines more efficient and reduce the frequency of maintenance. Filter Separators will accumulate particulate matter naturally so they will need cleaned and/or replaced filter elements regularly depending on your operating environment. EXAIR provides Filter Separators and recommend they be installed prior to an Oil Removal Filter, pressure regulator or valve.

Filter Separators

Oil Removal Filters: Many air compressors use oil to lubricate therefore the risk of oil in your air lines is imminent. Although oil may not affect the compressed air system itself it can become a problem with products which do not require oil and have small air gaps. It can also be problematic if oil is blowing on to packaging or the final product. Keep this in mind and remember that oil should be removed from compressed air lines in certain instances. EXAIR’s oil removal filters will remove oil and solid particulate found in many compressed air systems.

Pressure Regulators: Regulators adjust the air pressure being supplied by your air compressor to the level that you require at the point of use. For instance your compressor generates 150 PSI but your compressed air product only requires 80 PSIG, the regulator can adjust the pressure to the desired setting and also relieve undue pressure on fittings, hoses and tools. Reducing pressure at the end-use product will also reduce the air consumption. Almost every compressed air application will use tools with varying pressure ratings making EXAIR Pressure Regulators a must-have accessory.

Hoses & Fittings: Hoses and fittings wear with time. Common issues are kinking, bending, leaks and contaminants, they should be checked often and replaced when required. Another common problem with hoses is that they are either too long and not as efficient or too short which can cause your employees reduced productivity. EXAIR offers STAY SET Hoses, Conveying Hose, Coiled Hoses and Compressed Air Hoses of different sizes and lengths. Our selection of compressed air fittings insures you can get all you need from one location.

Receiver Tanks: The use of receiver tanks can improve your overall system efficiency. Storage receivers can be placed near equipment that consume short duration of high flows of compressed air that might cause localized low pressure. EXAIR’s 60 Gallon Receiver Tank placed near the point of use can smooth out the high flows so as not to cause the start of an extra air compressor or cause localized low pressure.

If you would like more information regarding how proper use of EXAIR’s accessories can make your compressed air consumption more intelligent please contact me or any of our qualified Applications Engineers to discuss your applications.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK

 

Piping and Instrumentation diagrams (P&ID)

When it comes to drawings and diagrams to map out a process system, the piping and instrumentation diagrams (P&ID) are a great way to situate and find components.  They use different symbols to represent the type of products, the layout in the system, installation, and process flow.  These standard symbols are created by ANSI or ISO.  They are used in electrical, hydraulic, and pneumatic processes.  Since EXAIR has been manufacturing Intelligent Compressed Air Products since 1983, I will cover some pneumatic symbols and the process flow in this blog.

A colleague, Russ Bowman, wrote an article about “Knowing Your Symbols Is Key To Understanding Your Drawings”.  As a reference, air compressors are the start of your pneumatic system, and there are different types as represented by the symbols below.

The one on the left can be used for any air compressor. The others denote specific types of air compressor (from left:) Centrifugal, Diaphragm, Piston, Rotary, and Screw.

Air compressors are considered the fourth utility in industries because they use so much electricity; and they are inefficient.  So, you need to use the compressed air as efficiently as possible.  As a typical pneumatic system, the air compressors, receiver tanks and compressed air dryers would be on the supply side.  The distribution system, or piping, connects the supply side to the demand side.  This symbol is represented by a simple line.  The demand side will have many different types of pneumatic devices.  Since there are so many, ANSI or ISO has created some common types of equipment.  But if there isn’t a symbol created to represent that part, the idea is to draw a basic shape and mark it.

From top left, and then down: Automatic Drain Filter Separator, Pressure Regulator, and Super Air Knife

As an example, if I were to do a P&ID diagram of the EXAIR Super Air Knife Kit; it would look like the above diagram.  The kit will include the Super Air Knife with an Automatic Drain Filter Separator and a Pressure Regulator.  The Filter Separator is a diamond shape and since it has an Automatic Drain, a triangle is placed at the bottom.  Filter Separators are used to clean the compressed air and keep the Super Air Knife clean.  The Automatic Drain will discard water and oil from the filter bowl when it accumulates over a float.  The next item is the pressure regulator which is represented by a rectangle with an adjustment knob to “dial in” the desired blowing force.  And at the end, we drew a rectangle, which does represent a Super Air Knife, as marked.

Using the P&ID diagram for the process flow is also important.  You noticed that the Filter Separator will come before the Pressure Regulator.  This is significant when installing this system.  Remember the statement above about “using your compressed air as efficiently as possible”?  Inefficiencies come from two basic areas; pressure drop and overusing your compressed air.  Pressure drop is based on velocity.  The lower the velocity, the lower the pressure drop.  If the Filter Separator is placed after the Pressure Regulator, the lower pressure will increase the velocity.  Since air expands at lower pressure, the volume of air will increase.  And since the area of the compressed air pipe is the same, the velocity will have to increase.   For the second part with overusing compressed air, the Pressure Regulator will help.  You want to use the lowest amount of air pressure as possible for the Super Air Knife to “do the job”.  The lower air pressure will use less compressed air in your operation.

EXAIR products are engineered to be safe, efficient, and effective in your compressed air system.  If you need help to place them in your P&ID diagrams, an Application Engineer can help you.  It is important to have the pneumatic devices in the proper place, and if you want to efficiently use your compressed air, you can use EXAIR products for your blow-off devices.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb