One of the fun parts of Application Engineering at EXAIR is explaining the operation of Vortex Tubes to our customers. Sometimes they’re described as a “reverse tornado” inside of a tube, spinning a pressurized airstream and converting it into a hot and cold flow. Other times we describe it through the generation of two vortices with differing diameters, and the difference in diameters results in one vortex shedding energy in the form of heat.
But, no matter the way we explain their operation, we always stress the importance of proper compressed air plumbing. If the compressed air piping/hoses/connections are not properly sized, performance problems can arise. (This is true for any compressed air driven device.)
This fundamental came to light when working with one of our customers recently. They were using a medium sized Vortex Tube to provide spot cooling in an enclosed space, but were not seeing the flow and temperature drop they knew to be possible with an EXAIR Vortex Tube. And, after looking at installation photos of the application, the root cause was quickly spotted.
I noticed what looked to be a very small hose connected to the inlet of the Vortex Tube in the image above.
After further inspection of another photo, the small diameter tube was in full view. This small hose serves as a restriction to compressed air flow, which in turn limits both flow and operating pressure of the downstream devices. What that meant for this application, was poor performance from the Vortex Tube, all stemming from this reduction in piping size.
When looking to find the root cause of a performance issue with a compressed air driven unit, things aren’t always as easy as they were with this application. A visual inspection is always a good idea, but if everything looks correct, here is a list of troubleshooting steps to consider:
- Check for quick-disconnects in the plumbing system. Quick-disconnects are great from an operator’s perspective, but they can wreak havoc on compressed air flows due to small inside diameters and air volume restriction.
- Determine the operating pressure at the device. This is imperative. In order to make proper decisions to correct the performance concern, good information is required. Knowing what is happening at the device is crucial for proper understanding. There may be 100 PSIG at the main compressed air line, but only 60 PSIG at the device due to plumbing problems. A pressure gauge at the inlet of the compressed air product can provide this information.
- Check that the compressed air system has enough volume to properly supply the device. A compressed air driven unit without the correct volume of compressed air is just as bad as having a lack of pressure.
- Check for leaks. The US Department of Energy estimates that 20-30% of compressor output in industrial facilities is lost as leaks. If your system and devices aren’t operating as they’re supposed to, check for leaks. They may be contributing to the poor performance. (Don’t know where your leaks are coming from? Use our Ultrasonic Leak Detector!)
Fortunately for this customer, after improving the size of this tubing performance was on par with our published specifications and this customer was back in operation. If you have a question about how to improve the utilization of the compressed air devices in your application, contact an EXAIR Application Engineer.