Six Steps to Optimization: Step 1 – Measure the Air Consumption

Six Steps to Optimizing Your Compressed Air 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. In this blog, I will cover the first step – 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 are 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.

There are many different types of flow meters. Many of them entail a breakdown of your current compressed air lines by cutting, welding, or dismantling for installation. This will add cost in downtime and maintenance staff. But, not with the EXAIR Digital Flowmeters. In this blog, I will share the features and benefits of the Digital Flowmeters including options for you to start measuring and optimizing your compressed air system in Step 1.

Digital Flowmeter

Overall, it only takes a few minutes to install and start measuring. The installation kit comes with a drill bit and a drill guide to properly locate the two holes on the pipe. The Digital Flowmeter uses a clamp to mount to the pipe and to seal the area around the probes. Once it is powered, the unit is ready to measure the air flow inside the pipe with a large LED display. The display can be customized to show flow readings in three different units; SCFM, M3/hr or M3/min; and, it can display the Daily Usage and Cumulative Usage.

To get started, the EXAIR Digital Flowmeter is a thermal dispersion device that can accurately measure compressed air flows. They use two sensing probes for comparative analysis. One probe is a temperature sensing probe, and the other is a flow-sensing probe. By comparing these, the Digital Flowmeter can measure precisely the mass air flow without needing to be recalibrated. They are a cost-effective, accurate, and simple way to measure compressed air flows.

EXAIR stocks a large volume of Digital Flowmeters to ship same day for U.S. and Canadian customers. We also offer a 30-day unconditional guarantee to try them out. We stock meters for pipe diameters from ½” NPT to 4″ NPT Schedule 40 black pipe. EXAIR can also offers flow meters up to 8″ NPT black pipe; copper pipes with diameters from 3/4″ to 4″, and aluminum pipes with diameters ranging from 40mm to 101mm. If you have another type of piping for your compressed air system, you can give us the material, O.D. or I.D., and wall thickness. We may still be able to get a Digital Flowmeter for you.

For measuring, all the units come standard with a 4 – 20mA analog output. Per your request, we can change this signal to a serial output for RS-485 or Ethernet connections. What more can we offer with the EXAIR Digital Flowmeter? Options. Options upgrade the flow meters to better suit your application. Here is a list below:

EXAIR’s Digital Flowmeter w/ USB Data Logger

USB Data Logger: This option allows for a recording of the flow information. With a software download, you can setup the USB Data Logger to record the flows from once a second (roughly 9 hours of storage) to every 12 hours. After the data points are recorded, you can then download the information into the software to review. Then the information can be uploaded into an Excel program to do further analysis.

Summing Remote: With compressed air pipes running along the ceiling and walls, reading the Digital Flowmeter may be difficult. The Summing Remote has a 50-foot (15 meter) cable to bring the LED display into viewing. The Summing Remote is powered by the Digital Flowmeter, and it can be positioned at eye level, inside managers’ rooms, or around large equipment for monitoring.

Digital Flowmeter w/ Wireless Capability, Gateway, and Drill Guide Kit

Wireless Capability: Our latest Digital Flowmeter now has wireless capabilities. They use a Zigbee® communications to pick up flow readings from other flow meters and the Gateway. The Gateway can detect over 100 Digital Flowmeters in your facility. From the Gateway, the information is transferred through a LAN. You can record and analyze the flow information from each meter on the network with our EXAIR® Logger Software. You can set limits to send warnings when your compressed air system is using too much or too little of compressed air. This technology makes it very easy for measuring your compressed air system in the entire facility without having to be there.

Hot Tap DFM

Hot Tap Digital Flowmeter: This option is a great way to install a Digital Flowmeter to the pipe without shutting down the compressed air line. We offer this option for 2″ and larger flow meters for steel and copper pipes. It gives a quick and easy way to attach if you have a 24-hour operation or a critical process that needs to continue to run.

Pressure Sensing Port

Pressure Sensing Digital Flowmeter: If you would like to know the compressed air flow and the air pressure, this option will be able to do this. They are available with the Digital Flowmeters for steel and copper pipes that are 2″ and larger, and for the aluminum piping that is 50mm and larger. This option can display pressure units in either PSI or Bar right on the same LED display that shows the flow readings.

Blocking Rings

Block-Off Rings: If you want to move your Digital Flowmeter, the Block-Off Rings will be able to cover the openings in your compressed air pipe. They seal around the drilled opening when the Digital Flowmeter is removed from the pipe. They are reusable; so, they can be removed if you want to remount the Digital Flowmeter in the same spot. If you want to use one flow meter in different locations, the Block-Off Rings allow you do this.

When you need to analyze your pneumatic components, flow is an important point in diagnosing the overall “health” of your compressed air system. The EXAIR Digital Flowmeter can give you that important data point. With optimization, you can cut your energy consumption, improve pneumatic efficiencies, and save yourself money. This blog is an overview of Step 1 of six steps. You may have more questions; and, that is great! You can find them in other EXAIR blogs, or you can contact an Application Engineer at EXAIR.

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

Compressed Air Flowmeter Overview and Options

 

EXAIR Digital Flowmeters can be an important part of your compressed air system for optimization.  Flow is a measurement that is directly related to your cost for operation; and, it can help in determining efficiency, leak rates and the overall “health” of your pneumatic system.  Th Digital Flowmeters are easy-to-read, easy-to-install, and easy-to-record devices.  You will not have to disrupt your piping system with cutting, welding, or dismantling for installation.  In this blog, I will share some product information and options that work with the EXAIR Digital Flowmeters.

The EXAIR Digital Flowmeter is a thermal dispersion device that can accurately measure compressed air flows.  They use two sensing probes for comparative analysis.  One probe is a temperature sensing probe, and the other is a flow-sensing probe. By comparing these, the Digital Flowmeter can measure accurately even in low flow regions.  Also, they do not need to be re calibrated.  They are CE and RoHS certified., and they do not have any moving part to wear.  The EXAIR Digital Flowmeters are a cost-effective, simple way to measure compressed air flows.

To get started, I will go over the design of the Digital Flowmeter.  The two sensing probes as discussed above will have to be installed in the air stream.  This is done with the Drill Guide Kit.  This kit includes a guide to properly locate the two holes in the pipe and a drill bit for the correct clearance.  The Digital Flowmeter uses a clamp design to mount onto the pipe and to seal the area around the probes.  Once it is powered, the unit is ready to measure the air flow inside the pipe with a large LED display.  The display can be customized to show flow readings in three different units; SCFM, M3/hr or M3/min.  It can also display Daily Usage and Cumulative Usage. Overall, it only takes a few minutes to install and start using.

EXAIR stocks a large volume of Digital Flowmeters to ship same day.  We also offer a 30-day unconditional guarantee for domestic and Canadian customers to try them out.  The ranges that we stock are for pipe diameters from ½” NPT to 4” NPT Schedule 40 black pipe.  For non-stocked items, EXAIR can go as large as 8” NPT Schedule 40 black pipe.  We can also get Digital Flowmeters to use with copper pipes from 3/4” to 4” sizes, and to use with aluminum pipes with the O.D. ranging from 40mm to 101mm.  If you use other types of piping for your compressed air system, you can give us the material, outside diameter/inside diameter, and the wall thickness.  We may still be able to get a Digital Flowmeter for you to use.

What sets our Digital Flowmeters apart from other types are the features and benefits.  All of the units come standard with a 4 – 20mA analog output.  We can also offer this signal as a serial output per your request for RS-485 or Ethernet connections.  The maximum pressure for the units is 200 PSIG (13.8 Bar), but we have a high pressure option to go as high as 600 PSIG (41 Bar).  If your Digital Flowmeter needs better protection for splash resistance, we can also offer units with a NEMA 4 (IP66) rating.

What more can we offer with the EXAIR Digital Flowmeter?  Options.  Options upgrade the flow meters to better suit your application.  Here is a list below.

USB Data Logger: This option allows for a record of the flow information.  With a software download, you can setup the USB Data Logger to record the flows from once a second (roughly 9 hours of storage) to every 12 hours.  Once the unit has been configured, you just plug in the unit into the Digital Flowmeter and let it record the data points.  You can then upload the information into the software program to review.  It also has the ability to transfer the information into an Excel program to do further analysis.

Summing Remote:  With compressed air piping running along the ceiling and walls, it may be difficult to see the Digital Flowmeter.  The Summing Remote has a 50-foot (15 meter) cable to bring the flow measurements from the Digital Flowmeter for viewing.  The Summing Remote is powered by the Digital Flowmeter, and it can also show the daily and cumulative readings.  They can be positioned at eye level near stations, inside managers’ rooms, or around large equipment for monitoring.

Hot Tap:  This option is for Digital Flowmeters that are 2” and larger for steel and copper pipes.  It gives a quick and easy way to attach the Digital Flowmeter to the pipe without shutting down the compressed air line.  If you have a 24-hour operation or a critical process that needs to run, this option would be a great way to install the EXAIR Digital Flowmeter without disturbing the system.

Pressure Sensing:  If you would like to know the compressed air flow and the air pressure on the same unit, this option is able to do this.  They are available with the Digital Flowmeters for steel and copper pipes that are 2” and larger, and for the aluminum piping that are 50mm and larger.  This option can display the pressure units in either PSI or Bar right on the LED display.

Block-Off Rings:  If you want to relocate your Digital Flowmeter, the Block-Off Rings will be able to cover the openings.  They seal around the area when the Digital Flowmeter is removed from the pipe.  They are reusable; so, they can be removed if you want to remount the Digital Flowmeter in the same spot.  Or if you want to use one flow meter in different locations, the Block-Off Rings allow you do this.

Wireless Capability:  Our latest Digital Flowmeter now has wireless capabilities.  They use a Zigbee® communications to pick up flow readings from different flow meters without running communication wires.  The Gateway is a system that can detect over 100 Digital Flowmeters located throughout your facility.  From the Gateway, the information is transferred through a LAN to your computer.  You can record and analyze the flow information from each meter on the network with our EXAIR® Logger Software.  You can set limits to send warning when your compressed air system is using too much or too little of compressed air.  This technology makes it very easy for measuring your compressed air system in different areas without having to be there.

When you need to analyze your pneumatic components, flow is an important point in diagnosing the overall “health” of your compressed air system.  The EXAIR Digital Flowmeter can give you that important data point.  With this overview, you may have additional questions and that is great.  An Application Engineer at EXAIR is here to help.  We can support you in determining the product and options that will work best for you.

John Ball
Application Engineer
Email: johnball@exair.com

Twitter: @EXAIR_jb