We discuss optimizing compressed air systems and starting all of them on your demand side. If you are new to the blog or to compressed air, this is an important place to start because it can put capacity back into your system and help prevent shutdowns due to excessive compressed air use. One of the keys to utilizing compressed air in applications is to ensure it is off when not needed. This is also a benefit of compressed air.
You see, you can use an electromechanical solenoid valve to rapidly turn compressed air off and on. Because it is compressed and will rapidly feed through a blowoff you can use this rapid off/on to your advantage within a facility. Rather than just having to let a blower stay on or wait for it to spool up and fill a large duct, the piping of a compressed air system can already be supplied, and the valve can be located very near to the blowoff “nozzle” which means you can get the work done with instant response time. And, any amount of gap in demand builds capacity back into your supply system.
The EXAIR Electronic Flow Control gives the ability to turn the compressed air off and on within 1/10th of a second. Don’t blink, you’ll miss it! That’s right, if you had an intermittent demand or even something that would benefit from repeated impacts of the air on the surface it can be done down to one tenth of a second with the EFC. Even if you just use this rapid off/on for blowoff on a continuous product and it works to where you don’t need the continuous you can save as much as 50% of the air going into what would otherwise be a continuous operation blowoff, assuming an on 1/10th and off 1/10th (of a second).
The other advantage to something like an Electronic Flow Control is that it simplifies the operators’s input to work correctly. There are no valves for them to physically turn on and off, no foot pedals to step on and energize the air, and no triggers to pull. While these all have their place, they lend themselves to variations in the length of time used or not used. Most processes in production environments don’t handle variables extremely well. Consistency is key and the EFC delivers on this point.
If you want to talk about how you can benefit from a rapid off/on of compressed air and put some capacity back into your system, contact an Application Engineer today.
If you’re a registered user on our website, you likely got word of this already through our August 15, 2023 Press Release. If not – or even if you did and want some more details – read on, and I’ll tell you all about it.
Like all of our previous catalogs, Catalog #35 provides specification, dimensional, and performance data on all of our stock products. Many of them include detailed descriptions of “textbook” applications for those products. You’ll also find:
Efficiency Lab (page 6): If you want a full performance report on a compressed air device you’re using right now, this is a free service we offer. Contact an Application Engineer and arrange to have it sent in. We’ll test it for compressed air consumption, force applied, and sound level, and send you a report on it. It’ll include, of course, the EXAIR engineered product(s) that we’ll recommend, along with performance data on them, as a comparison.
Our Six Steps (page 7): The first page of our Optimization section details the Six Steps To Optimizing Your Compressed Air System. It’s not necessary to follow them in order, and not all of them are applicable to every single compressed air system. But if you’re serious about reducing your compressed air costs, this is a comprehensive plan on how to do it for sure.
OSHA Maximum Allowable Noise Exposure table & typical Air Consumption values of common “homemade” blow offs (page 53): We put this here so you can turn the next few pages and see what a difference engineered products like EXAIR Super Air Nozzles can make.
Droplet Size data (page 98): Use this to determine the suitability of our Atomizing Spray Nozzles for liquid spraying applications.
Vortex Tube Specification and Performance tables (pages 201-202): If you know how much cold air flow you need, and at what temperature you need it, you can use these tables to determine which EXAIR Vortex Tube (or other Spot Cooling Product) to use.
Now, if you’ve ever had any of our previous catalogs, you might have noticed that those were already in there, and that’s all pretty great. What’s REALLY great about Catalog #35, though, is some of the new features:
Line Vac Conveyance Data (pages 176-177): While there’s WAY too many variables in bulk conveyance applications to accurately calculate conveyance rates. We’ve done some controlled, in-house testing with several different materials, several different Line Vacs, at several different lengths & heights, though, and we’re proud to publish that in the new catalog. This shouldn’t be considered a guarantee of performance, but if you’re wondering how much of a particular bulk material you can convey, this table will certainly get you in the right ballpark.
Best Practice for Using EXAIR Intelligent Compressed Air Products (pages 239-240): This information has always been in the Air Data files on our website, along with an ABUNDANCE of data that’ll help you get the most out of your compressed air system. Now, it’s at your fingers.
Of course, I’d be remiss if I wrote a whole blog on the new catalog without mentioning the new products:
Model 9207 Ultrasonic Leak Detector (pages 18-19): This serves the same function as the now-obsolete Model 9061, but with some handy upgrades like a LED display, a sleek new body, and high quality ear buds.
1/2 NPT HollowStream Cone Atomizing Nozzles (page 105): With five new distinct models at the high-flow end of our already comprehensive line of Liquid Atomizing Spray Nozzles, these provide up to 53 gallons per minute of liquid flow, and are capable of passing particulate up to 0.344″ in diameter.
Like our previous catalogs, Catalog 35 is now available for download (in product line sections due to file size) from the PDF Library at EXAIR.com. You can also request a copy to be mailed to you, or you can contact an Application Engineer to have individual product line sections (again, because of file size) email to you right away.
As always, if you’d like to talk about how to get the most out of your compressed air system, our team of Application Engineers are here Monday to Friday, 7am to 4pm Eastern, to help with that. Give me a call.
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.
Recently I blogged about a refrigerant leak in my homes HVAC system. For that, I had to use a special leak detector which sniffed out gases within the air. Compressed air systems are not as complicated and a simple Ultrasonic Leak Detector can be utilized to find leaks that may be getting you down. Those compressed air leaks can cause inaudible pressure loss within a production line. This leads to equipment faulting out, maybe even compressors over working and an increase in energy demand. So how do you fight a foe that you cannot see, feel, or hear?
Equipping yourselves with the right tools is the ideal way, converting ultrasonic emissions into an audible level by the human ear and a visual representation as well can be done easily with the new EXAIR Ultrasonic Leak Detector. This detector was demoed by Tyler Daniel in a recent video and can be shipped same day on orders received by 2 PM ET that are shipping within the US. So why exactly do you need to worry about this?
Well, leaks can actually account for up to 30% of an industrial facilities compressed air capacity. If you have a 2,000 SCFM compressed air system, That could result in 2,000 * .30 = 600 SCFM of compressed air being wasted. 600 SCFM costs the average user $72.00 USD per 8 hour shift of operation. If you operate for 3 shifts per day and average 6,000 hours of operation per year, then that equates to $54,000 USD per year in savings if you just find and fix the 30 % of airflow that is leaking out.
If you want to discuss how to use the ULD or what a good approach is to how to break down and optimize a compressed air system, that is what our entire team of Application Engineers is for. Contact an Application Engineer today!