Tag: pressure sensing

Using EXAIR Digital Flow Meters

Published on by jasonkirbyLeave a comment

One of the primary contributors to issues with compressed air systems is inefficiency stemming from waste. Common culprits include open pipe blow-offs, air leaks, and malfunctioning nozzles, all of which can hinder the performance of an air compressor, making it difficult to maintain optimal pressure levels. The implementation of Digital Flowmeters offers a solution by enabling precise monitoring of this waste. By temporarily shutting down the compressed air system and isolating specific sections, operators can identify leaks; any flow detected during this isolation indicates the presence of air leaks, which can account for a staggering loss of up to one-third of the system’s compressed air capacity. Additionally, replacing open pipe blow-offs and defective or inferior nozzles with engineered products from EXAIR can significantly mitigate waste. The use of Digital Flowmeters not only provides a clear visual representation of reduced compressed air consumption but also facilitates straightforward calculations of cost savings and return on investment, making it an invaluable tool for enhancing system efficiency.

In facilities that operate around the clock in three shifts, continuous monitoring of the compressed air system is crucial to ensure optimal performance. The implementation of Digital Flowmeters, which offer features such as USB Dataloggers or serial communication, facilitates this monitoring process. For instance, I recently collaborated with a company that experienced frequent machine shutdowns attributed to a low-pressure switch, particularly during the third shift, occurring approximately once a week. To address this issue, they installed a Digital Flowmeter equipped with a USB Datalogger, which enabled them to track the specific day and time of the incidents. Through this data, they discovered that the third shift custodian was regularly emptying the water from the reservoir tank of the compressed air system, inadvertently causing the pressure drop that led to the shutdowns. Without the insights gained from the Digital Flowmeter, identifying the root cause of the problem would have been significantly more challenging.

EXAIR’s Digital Flowmeter w/ USB Data Logger

EXAIR offers a comprehensive range of Digital Flowmeters designed for various piping systems, including sizes from ½” to 4” for Schedule 40 black pipe, with the capability to accommodate up to 8” in this category. Additionally, we provide options for ¾” to 4” in copper piping and from 25mm to 101mm in aluminum tubing. For unique requirements, EXAIR is equipped to calibrate flowmeters to meet specific sizes and types. Our product line also includes Pressure Sensing Digital Flowmeters, which allow for simultaneous measurement of pressure and flow, as well as Hot-Tap Digital Flowmeters that can be installed on pressurized pipes without interrupting the flow. To enhance user experience, we offer a Summing Remote Display, enabling visualization of flow data in more accessible locations. For effective monitoring, our Digital Flowmeters come with a USB Datalogger that captures data for graphing purposes, alongside a 4-20 mA output for seamless data acquisition, with an optional serial output available for further integration.

If you have any questions about Digital Flowmeters, or anything regarding EXAIR and our products, please do not hesitate to reach out. We would love to hear from you!

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

Digital Flowmeters: A Benefit for Compressed Air Systems.

Published on by John BallLeave a comment

The compressed air system is the “heart” of most industrial plants.  And just like your heart, monitoring this system is very important.  It is expensive to make compressed air, and if you do not have any controls, you could waste money and give a poor performance to your pneumatic system.  EXAIR has a range of Digital Flowmeters that can help provide information about your system.   

First, let’s look at how the Digital Flowmeter can help to solve problems, monitor anomalies, and determine preventative measures. 

Solving problems: One of the biggest reasons for compressed air problems is waste.  With open pipe blow-offs, air leaks, and broken nozzles, the air compressor cannot keep up.  With the Digital Flowmeters, they can monitor that waste.  For leaks, you can turn the compressed air system off and isolate sections.  If you see a flow measurement during this time, then there are air leaks.  Air leaks are known to waste up to one-third of your compressed air capacity.  Another technique for finding waste is to replace open pipe blow offs, broken or substandard nozzles with EXAIR engineered products.  Digital Flowmeters provide a visual flow measurement of the reduction in compressed air usage, and it is an easy way to calculate cost savings and pay back.

Monitor Anomalies: With facilities that operate three shifts, it is important to monitor the compressed air system for 24 hours.  The Digital Flowmeters have options like a USB Datalogger or serial communication to monitor.  I recently worked with a company that had system shutdowns on their machines due to a low-pressure switch.  This event would happen about once a week on the third shift.   They determined the reason for the shutdown was by installing a Digital Flowmeter with a USB Datalogger.  They were able to determine the day and time when the problem occurred.  What they found was the third shift custodian would empty the water from the reservoir tank in their compressed air system.  They would not have been able to pinpoint their problem otherwise. 

Preventive Measures: A blow molding facility used the Digital Flowmeters to monitor the amount of air required to run each size of plastic bottle.  If the amount of air flow was too high or too low, he knew that there was either a set-up issue or the machine needed to be reconditioned.  With pneumatic equipment like valves and cylinders, the seals wear overtime.  Using Digital Flowmeters, he could create a Preventive Maintenance schedule to repair the machine instead of waiting for a failure to occur and stop its operation. 

EXAIR’s Digital Flowmeter w/ USB Data Logger

EXAIR stocks Digital Flowmeters from ½” to 4” for Schedule 40 black pipe.  We can get them up to 8” Schedule 40 black pipe.  We also have them for ¾” to 4” in copper pipe and from 25mm to 101mm in aluminum tubing.  If you have a special size or type, EXAIR can calibrate them for these sizes.  We can supply an option to measure pressure and flow with our Pressure Sensing Digital Flowmeters, and we can offer a Hot-Tap Digital Flowmeter to mount onto a pressurized pipe.  For an additional item, we do have a Summing Remote Display to visualize the flow in more convenient areas.  For monitoring, the Digital Flowmeter has a USB Datalogger which stores the information for graphing.  It also has a 4 – 20 mA output for data acquisition, and an optional serial output. 

Getting more information can help paint a broader picture of the health of your compressed air system.  The Digital Flowmeter can give you some key information.  Instead of a mystery black box in the backroom, the Digital Flowmeter can measure, monitor, and store the flow information which can be vital.  If you wish to discuss more, an Application Engineer at EXAIR will be happy to assist you.  Optimizing your compressed air system will help eliminate it from having a “coronary”.   

John Ball
Application Engineer
Email: johnball@exair.com

Twitter: @EXAIR_jb

Picture: Electrocardiogram by Clker-Free-Vector-Images.  Pixabay content license.

Pressure Sensing Flow Meters

Published on by Jordan T ShouseLeave a comment

If you are looking to add some control to your compressed air system, one of the first things you need to do is understand the baseline for where your system is. This includes, of course, the volume of compressed air you are providing, but also the pressure at which your system is seeing as well. This is especially important when you have an application that is very pressure dependent like a CNC mill tool changer.

The Pressure Sensing Digital Flowmeters are available from 2″ Sched. 40 Iron Pipe up to 8″ Sched. 40 Iron Pipe.  As well as 2″ to 4″ copper pipes.  These will be read out and with additional data logger as well, so you can track the pressure over the course of every shift, and even days.

Generating a pressure and consumption profile of a system can help to pinpoint energy wasters such as timer-based drains that are dumping every hour versus level-based drains that only open when needed. A scenario similar to this was the cause of an entire production line being shut down nearly every day of the week for a local facility until they installed flowmeters and were able to narrow the demand location down to a filter baghouse with a faulty control for the cleaning cycle.

If you’re serious about getting the most out of your compressed air use, the very first step in EXAIR’s Six Steps To Optimizing Your Compressed Air System is literally a great place to start.

Six Steps to Optimizing Your Compressed Air System

Here are some blogs on the other steps!

Step #1- Step 1 – Measure your Air

Step #2- Step 2 – Finding and fixing leaks

Step #3- Step 3 – Use Efficient and Quiet Engineered Products

Step #4- Step 4 – Turn the air off while its not in use

Step #5- Step 5 – Install Secondary Receiver Tanks

Step #6 – Step 6 – Control the air pressure

If you would like to discuss the best digital flowmeter for your system and to better understand the benefits of pressure sensing, please contact us. To find out more, give me a call.

Jordan Shouse
Application Engineer

Send me an email
Find us on the Web 
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Twitter: @EXAIR_JS

Tool Changer Photo courtesy of Luke Gilliam via creative commons

Pressure Monitoring Not Just For Air Systems

Published on by Brian FarnoLeave a comment

This past weekend we celebrated Labor Day. My family and I had the pleasure of going to a friend’s property and parking an RV to “glamp” for the weekend. The trip is only about 3-1/2 hours from our homes and when traveling in the RV it is a slow and steady wins the race kind of trip. One of the first things I do when we are prepping for the trip is to check tire pressure. Then, the last thing I do before we leave is check tire pressures.

While at their property we did the same on all of their vehicles, two side-by-side UTVs, and their boat trailer. When looking at each of these, almost all of them were low. Now, these items all sit more than they are used and only see movement maybe once a month. The weather here in the area, including Kentucky has been getting cooler in the evenings which causes the air in tires to start to take up less space and so the pressure drops. Well, after checking and filling, we went out and everything was great, until it wasn’t. When we loaded up the boat we noticed one of the tires was nearly on the rim of the trailer. With no tools on hand and a short drive, we elected to make the drive and inspect when we got back to home ground rather than in a public parking lot where someone had already offered to help if need be. Once we arrived, we inspected the tire and found no obvious signs for it to be so low on pressure. We filled it up again and let it sit for the night. After breakfast the next day we found the tire was still holding air so we assumed that when we checked the pressure initially it was at a good pressure and by doing so something must have stuck in the valve causing it to have a slow leak. Once that was seated and good, the tire held air, and we were good to roll for another day.

This made me realize how important pressure monitoring is on tires for certain vehicles and led me to install a continuous pressure monitoring system on the RV that we took. Being able to monitor tire temperature and pressure is critical and catching low pressure before it causes other issues can help reduce damage or catastrophic failure significantly. This also all made me connect my thoughts to the EXAIR Digital Flowmeters which are available with pressure sensing capabilities. These can easily be installed into a system and then be used to monitor your industrial system and potentially see issues before catastrophic failures or downtimes due to a loss of compressed air.

If you want to discuss what a Pressure Sensing Digital Flowmeter can do in your facility or even if you want to troubleshoot why you are seeing a drop in performance and how to even go about troubleshooting your entire air system, don’t hesitate to contact an Application Engineer.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF