Keep Your Pneumatics “Healthy” and “Running Like a Brand New Car”

Compressed air systems are used in facilities to operate pneumatic systems, and these systems are vital for industries.  So, it is important to keep them running.  The system can be segregated into three different sections; the supply side, the demand side, and the distribution system.  I like to represent these sections as parts of a car.  The supply side will be the engine; the distribution system will be the transmission; and, the demand side will be the tires.  I will go through each section to help give tips on how to improve the “health” of your pneumatic system.

From the supply side, it will include the air compressor, after-cooler, dryer, and receiver tank that produce and treat the compressed air.  They are generally found in a compressor room somewhere in the corner of the plant.  The air compressor, like the engine of your car, produces the pneumatic power for your plant, and needs to have maintenance to keep it working optimally.  The oil needs to be changed, the filters have to be replaced, and maintenance checks have to be performed.  I wrote a blog that covers most of these items, “Compressed Air System Maintenance”.

To connect the supply side to the demand side, a distribution system is required.  Distribution systems are pipes which carry compressed air from the air compressor to the pneumatic devices.  Just like the transmission on the car, the power is transferred from the air compressor to your pneumatic products.

Maintenance is generally overlooked in this area.  Transmissions have oil which can be detected if it is leaking, but since air is a gas, it is hard to tell if you have leaks.  Energy is lost from your pneumatic “engine” for every leak that you have.  So, it is important to find and fix them.  A study was conducted within manufacturing plants about compressed air leaks.  They found that for plants without a leak detection program, up to 30% of their compressed air is lost due to leaks.  This will be equivalent to running on only 6 cylinders in a V-8 engine.

EXAIR offers the Ultrasonic Leak Detector to find those pesky leaks.  It makes the inaudible “hiss”; audible.  It can detect leaks as far as 20 feet (6m) away with the parabola attachment, and can find the exact location of the leak to be fixed with the tube attachment.

Another area for discussion with the distribution system is contamination like rust, oil, water, and debris.  Compressed air filters should be used to clean the compressed air that supplies your pneumatic products. They can remove the debris for your pneumatic products to have a long life.  You can read about the EXAIR compressed air filters here, “Preventative Maintenance for EXAIR Filters”.

The third section is the demand side.  So, you have an engine that makes the power, the transmission to transfer that power, and the tires to use that power safely and efficiently.  Many managers miss the importance of the demand side within their pneumatic system.  If you are using blow-off devices like open pipes, coolant lines, copper tubes, or drilled pipe; it will be like running your car on flat tires.  It is very unsafe as well as reducing gas mileage.  To improve safety and efficiency, EXAIR has a line of Super Air Nozzles and Super Air Knives.  Not only will it increase your “gas mileage” to save you money, but they also will keep your operators safe.

In this analogy, you can have a high-performance engine and a durable transmission, but if your tires are bald, flat, or cracked; you cannot use your car safely and efficiently.  The same thing with your compressed air system.  You have to optimize your blow-off devices to get the most from your pneumatic system.  EXAIR is a leader in engineered blow-off devices for efficiency and safety.  So, if you want to improve the “health” of your pneumatic system, you should begin at how you are using your compressed air on the demand side.  EXAIR has Application Engineers that will be happy to help you in trying to keep your pneumatic system running like a “brand new car”.

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

 

Photo: Ford Mustang Roadster by openclipart-VectorsPixabay License

Understanding Noise: Sound Power Vs. Sound Pressure

Sound Power and Sound Pressure have been covered a few other times here on the EXAIR Blog. Once here by Brian who made the visual correlation in regards to a speaker and a musical instrument. And here by Russ who breaks down how you calculate sound power level with the below equation!
Sound Power Equation
too lou Sound Power Level Equation
All machines generate sound when they are in operation. The propagated sound waves cause small changes in the ambient air pressure while traveling. A sound source produces sound power and this generates a sound pressure fluctuation in the air. Sound power is the cause of this, whereas sound pressure is the effect. To put it more simply, what we hear is sound pressure, but this sound pressure is caused by the sound power of the emitting sound source. To make a comparison, imagine for example a simple light bulb. The bulb’s power wattage (in W) represents the sound power, whereas the bulb’s light intensity represents the sound pressure.
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Light Bulb
Sound power does not generally depend on the environment. On the contrary, the sound pressure depends on the distance from the source and also on the acoustic environment where the sound wave is produced. In the case of indoor installations for example, sound pressure depends on the size of the room and on the sound absorption capacity of the surfaces. For instance, say the room walls don’t absorb all the sound but reflect parts of it, then the sound pressure will increase due to the so called reverberation effect. (reverberation time is broadly defined as the time it takes for the sound pressure to reduce by 60 dB after the sound emitting source has been shut off). OSHA puts the following limits on personnel exposure to certain noise levels:
Working in areas that exceed these levels will require hearing protection.
EXAIR’s line of Intelligent Compressed Air Products are engineered, designed, and manufactured with efficiency, safety, and noise reduction in mind.  If you’d like to talk about how we can help protect you and your folks’ hearing, call us. Jordan Shouse Application Engineer Send me an email Find us on the Web  Like us on Facebook Twitter: @EXAIR_JS Light Bulb image courtesy of  josh LightWork  Creative Commons License

Benefits and Options for Safety Air Guns

EXAIR Safety Air Guns are available, from stock, with Chip Shields.

Throughout industrial environments, there are often manual cleaning or blow-off applications that are performed with compressed air. These operations vary in frequency, intensity, and how critical to the operation they may be.

When it comes to OSHA standards and comfort of operators, many of the solutions found in manufacturing do not meet the standards and are dangerous to operators.

This is where EXAIR steps in and focuses on the end application while coupling a high performing engineered solution with an ergonomic and safe handheld safety air gun. In other words, EXAIR safety air guns are safe, easy to use, and typically reduce compressed air consumption. Currently, we offer four types of handheld safety air guns.

The VariBlast Compact Safety Air Gun:

This is my personal favorite in our current lineup of safety air guns.  The compact size fits comfortably in the hands of operators. The multi-finger trigger with patented VariBlast function is easily controlled for extended periods of time. The VariBlast Compact Safety Air Gun also has two compressed air inlets. This gives the ability to plumb compressed air into the bottom 1/4″ FNPT port or the top 1/4″ FNPT which a safe way to run air hoses for virtually any work station. The 1/8″ NPT outlet permits enough airflow to operate up to our High Power 1″ Flat Super Air Nozzle all the way down to our Atto Super Air Nozzle.  The patented design also delivers variable flow from any of the nozzles attached to operate anywhere from a gentle breeze up to a forceful blast.

The VariBlast Compact Safety Air Gun can also be coupled with an extension up to 72″ lengths as well as the Chip Shield to meet or exceed OSHA standards for compressed air cleaning.

The Soft Grip Safety Air Gun:

This safety air gun is the next step up in size and options as far as force and flow of compressed air go. The four-finger trigger and integrated hook design make this safety air gun ideal for industrial environments where a little more force is needed from the air to blowoff products.  The Soft Grip Safety Air Gun offers a 1/4″ NPT female thread inlet on the bottom and is available with up to an 1106 1/2″ Large Super Air Nozzle on the discharge.  This will deliver up to 60 SCFM of compressed air and provide 3.3 lbs of force from 12″ away.  The Soft Grip Safety Air Guns are also available with up to a 72″ extension and a chip shield.

Heavy Duty Safety Air Guns

Heavy Duty Safety Air Gun with extension.
eg. 1350-72

The Heavy Duty Safety Air Gun is even more robust than the Soft Grip Safety Air Gun and showcases a 3/8″ NPT female inlet to provide enough airflow to operate up to our model 1106 Large Super Air Nozzle as well to provide 60 SCFM  of airflow and provide 3.3 lbs of force.  Extensions are available in lengths up to 72″ with the addition of the chip shield.

 

Super Blast Safety Air Guns

Super Blast Safety Air Gun makes short work of large area cleanup.

The final Safety Air Gun offered is the Super Blast Safety Air Guns which are offered in four different NPT sizes. Ranging from 3/8″ NPT up to 1-1/4″ NPT and flows and forces from 56 SCFM providing 3.2 lbs of force up to 400 SCFM giving off 23 lbs of force.  These are available with an optional 3′ or 6′ extension to provide a robust blast for the heaviest cleaning or blowoff operation.

No matter the application, or amount of debris, EXAIR Safety Air Guns have an option that will fit the need while providing a safe and efficient solution. If you would like to discuss these further, please contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Compressed Air and Pneumatic Systems

Compressed Air Pipe

Compressed air is used to operate pneumatic systems in a facility, and it can be segregated into three main sections; the supply side, the demand side, and the distribution system.  The supply side is the air compressor, after-cooler, dryer, and receiver tank that produce and treat the compressed air.  They are generally found in a compressor room.  The demand side is a collection of devices that will use the compressed air to do “work”.  These pneumatic components are generally scattered throughout the facility.  To connect the supply side to the demand side, a distribution system is required.  Distribution systems are pipes or tubes which carry compressed air from the air compressor to the pneumatic devices.  The three sections have to work together to make an effective and efficient system.

Compressed air is a clean utility that is used in many different ways, and it is much safer than electrical or hydraulic systems.  But most people think that compressed air is free, and it is most certainly not.  Because of the cost, compressed air is considered to be a fourth utility in manufacturing plants.  For an electrical motor to reduce a volume of air by compressing it, it takes roughly 1 horsepower (746 watts) to compress 4 cubic feet (113L) of air every minute to 125 PSI (8.5 bar).  With almost every manufacturing plant in the world utilizing air compressors larger than 1 horsepower, the amount of energy needed is extraordinary.

Let’s determine the energy cost to operate an air compressor by Equation 1:

Equation 1:

Cost = hp * 0.746 * hours * rate / (motor efficiency)

where:

Cost – US$

hp – horsepower of motor

0.746 – conversion KW/hp

hours – running time

rate – cost for electricity, US$/KWh

motor efficiency – average for an electric motor is 95%.

As an example, a manufacturing plant operates a 100 HP air compressor in their facility.  The cycle time for the air compressor is roughly 60%.  To calculate the hours of running time per year, I used 250 days/year at 16 hours/day.  So operating hours equal 250 * 16 * 0.60 = 2,400 hours per year.  The electrical rate for this facility is $0.10/KWh. With these factors, the annual cost to run the air compressor can be calculated by Equation 1:

Cost = 100hp * 0.746 KW/hp * 2,400hr * $0.10/KWh / 0.95 = $18,846 per year in electrical costs.

Filters and Regulator

If we look at the point-of-use or demand side, the compressed air is generally conditioned to be used to run and control the pneumatic system.  The basic units include filters, regulators, and lubricators.  The filters are used to remove any oil, water, vapor, and pipe scale to keep your pneumatic system clean.  They fall into different types and categories depending on the cleanliness level required.

Filter Separators are more of a coarse filtration which will capture liquid water, oil, and particulate.  The Oil Removal Filters are more of a fine filtration which can capture particles down to 0.03 micron.  They are also designed to “coalesce” the small liquid particles into larger droplets for gravity removal.  One other group is for removing oil vapor and smell.  This type of filter uses activated charcoal to adsorb the vapor for food and pharmaceutical industries.  Filters should be placed upstream of regulators.

Pressure Regulators change the pressure downstream for safety and control.  Pneumatic devices need both flow and pressure to work correctly.  The lubricator, which is placed after the Regulator, helps to add clean oil in a compressed air line.  Air tools, cylinders, and valves use the oil to keep seals from wearing with dynamic functions.  Once the compressed air is “ready” for use, then it is ready to do many applications.

For EXAIR, we manufacture products that use the compressed air safely, efficiently, and effectively.  EXAIR likes to use the 5-C’s; Coat, Clean, Cool, Convey and Conserve.  We have products that can do each part with 16 different product lines.  EXAIR has been manufacturing Intelligent Compressed Air Products since 1983.  Compressed air is an expensive system to operate pneumatic systems; but, with EXAIR products, you can save yourself much money.  If you need alternative ways to decrease electrical cost, improve safety, and increase productivity when using compressed air, an Application Engineer at EXAIR will be happy to help you.

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