Tag: scfm flow meter

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

Week 5 Back to Basics — Keep The Flow Steady

Published on by Brian FarnoLeave a comment

This week’s installment in the Six Steps to Compressed Air Optimization focuses on making use of intermediate storage.

The purpose of intermediate storage in a compressed air system is to eliminate spikes in demand from your compressor. A common example is a blowoff operation that only needs air for a few seconds at a time, followed by periods of inactivity. By installing a receiver tank at the point of use, you reduce the immediate strain on your compressed air system and smooth out the peaks in consumption.

For readers with an electrical background, you can think of intermediate storage as the compressed air equivalent of a capacitor—absorbing demand spikes and helping the system run more evenly.

When applied correctly, intermediate storage improves system efficiency, reduces strain during intermittent operations, and is relatively simple to install and maintain. A properly sized receiver tank can make a big difference in stabilizing your system’s performance while extending equipment life.

We’re now just one step away from completing the Six Steps to Compressed Air Optimization. In the final installment, we’ll cover how to properly control your system for maximum efficiency.

Until next time, keep optimizing.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Week 4 Back to Basics— Shut It Down When It Isn’t Needed

Published on by Brian FarnoLeave a comment

Well, trusty blog readers, we are now two-thirds of the way through the Six Steps to Optimizing Your Compressed Air System.

So far, we’ve:

The next step is simple but powerful: turn off compressed air applications when they’re not needed.

If your process doesn’t require compressed air continuously, the EXAIR Electronic Flow Control (EFC) can help. This device uses a sensor to automatically control how long your compressed air operation runs, turning it on only when needed.

A great example is from a customer who used compressed air to clean computer monitors. When the screen wasn’t in the airstream, the air was simply wasted. With the EFC, air was shut off automatically whenever it wasn’t needed—saving energy, reducing costs, and extending the life of equipment.

The objective in this step is crystal clear: when your compressed air doesn’t need to be on, turn it off and save.

For more information on the EFC—or on any part of our Six Steps to Optimizing Your Compressed Air System—feel free to contact us.

Until next week, keep optimizing.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

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

Published on by John BallLeave a comment

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.

Six Steps to Optimizing Your Compressed Air System

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 costs 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.

Overall, it only takes a few minutes to install and start measuring. The installation kit comes with a drill guide to properly locate the two holes in the pipe. Please de-energize the compressed air in that line to install.  The Digital Flowmeter uses a clamp to mount on 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 of air flow without needing to be recalibrated. They are a cost-effective, accurate, and simple way to measure compressed air flow.

EXAIR stocks a large volume of Digital Flowmeters to ship on the same day for U.S. 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 offer flow meters for 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 set up the USB Data Logger to record the flow 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 to 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.

Hot Tap DFM

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

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 to 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 efficiency, and save yourself money. This blog is an overview of Step 1 of six steps. You may have more questions about the other steps, and that is great! You can find them in other EXAIR blogs, or you can contact an Application Engineer at EXAIR.  We will be happy to help you. 

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