How Can You Benefit from EXAIR’s Efficiency Lab?

How many times have you purchased a new product and worried if it was the right choice? Well EXAIR can provide that confidence using our calibrated testing equipment to compare your current product to an EXAIR product, in our Efficiency Lab. Whenever I needed a new process or product I would spend countless hours researching how will this benefit me, my employer or my customer? Research is not only time consuming but also very costly.

EXAIR believes in their product so much that we offer an Efficiency Lab where we will test your production product and help show that our products will not only work for you, but also show that they can save money, as well as make your work environment a safer place.

EXAIR has provided performance values (force, noise, air consumption, ROI) for many of our products. We make purchasing from EXAIR fun because you know in advance that our products will meet or exceed your expectations. Further backing up our commitment with the Efficiency Lab we offer an 30 Day Unconditional Guarantee. EXAIR believes in our products and want to make your purchase a risk free process.

We can test the performance of your current product to EXAIRs Intelligent Compressed Air products for air consumption, force, noise levels… and provide a comprehensive report of our analysis, including simple ROI.  

What does our Efficiency Lab cost? EXAIR believes in our products so much, that this is a free service to our customers. Simply call and talk to one of our Application Engineers at 800.903.9247 or you can send an email to lab@exair.com or visit www.exair.com and talk on our live help. If you feel we can help with a comparison them simply send your product(s) freight prepaid to EXAIR Corporation attention to our Efficiency Lab. All trials will be on a confidential basis unless you provide permission to share.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK

EXAIR Digital Flowmeters With Wireless Capability

“You can’t manage what you don’t measure” is a well-known axiom in engineering & process improvement circles.  We talk to callers every day who are keen on conserving compressed air use in their facilities by making a few tweaks, considering a complete overhaul, or more often, some point in between.  Bottom line (literally) is, compressed air isn’t cheap, so small gains in efficiency can add up.  And large gains can be complete game-changers…following our Six Steps To Optimizing Your Compressed Air System has resulted in users being able to shut down 50 and 100 HP air compressors, saving thousands of dollar A MONTH in operating costs.

Step #1 is measurement, and that’s where the EXAIR Digital Flowmeter comes in.  They’re easy to install, highly accurate, extremely reliable, and available for just about any size pipe used for compressed air distribution.  They can output a 4-20mA signal straight from their PCB board, or serial comms (RS485) through an optional control board.  USB Data Loggers and Summing Remote Displays have proven to be value-added accessories for data management as well.

Summing Remote Display (left) for remote indication and totalizing data. USB Data Logger takes data from the Digital Flowmeter to your computer and outputs to its own software (shown above) or Microsoft Excel.

If you want to go wireless, we can do that too: using ZigBee mesh network protocol, a radio module is installed in the Digital Flowmeter with wireless gateway to transmit data to an Ethernet connected gateway.  The transmitting range is 100 ft (30 meters,) and the data can be passed from one radio module to another, allowing for multiple Digital Flowmeter installations to extend the distance over which they can communicate with the computer you’re using for central monitoring.  Advantages include:

  • Wireless monitoring of EXAIR Digital Flowmeters throughout your plant.
  • Prevents unwanted joining upon the network.
  • Monitoring software is included at no extra charge.
  • Measures & transmits both current air usage, and cumulative air usage data.
  • 128 bit encryption for wireless transmissions.
  • Comes configured & programmed, out of the box, available for installation on 1/2″ to 4″ SCH40 iron pipe, or 3/4″ to 4″ Type L copper pipe.

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

If you’d like to find out more about how easy it is to measure, manage, and optimize your compressed air usage, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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How to Calculate the Cost of Leaks

Leaks are a hidden nuisance in a compressed air system that can cause thousands of dollars in electricity per year. These leaks on average can account for up to 30% of the operation cost of a compressed air system. A leak will usually occur at connection joints, unions, valves, and fittings. This not only is a huge waste of energy but it can also cause a system to lose pressure along with lowering the life span of the compressor since it will have to run more often to make up for the loss of air from the leak.

There are two common ways to calculate how much compressed air a system is losing due to leaks. The first way is to turn off all of the point of use compressed air devices; once this has been complete turn on the air compressor and record the average time that it takes the compressor to cycle on and off. With the average cycle time you can calculate out the total percentage of leakage using the following formula.

The second method is to calculate out the percentage lost using a pressure gauge downstream from a receiver tank. This method requires one to know the total volume in the system to accurately estimate the leakage from the system. Once the compressor turns on wait until the system reaches the normal operating pressure for the process and record how long it takes to drop to a lower operating pressure of your choosing. Once this has been completed you can use the following formula to calculate out the total percentage of leakage.

The total percentage of the compressor that is lost should be under 10% if the system is properly maintained.

Once the total percentage of leakage has been calculated you can start to look at the cost of a single leak assuming that the leak is equivalent to a 1/16” diameter hole. This means that at 80 psig the leak is going to expel 3.8 SCFM. The average industrial air compressor can produce 4 SCFM using 1 horsepower of energy. Adding in the average energy cost of $0.25 per 1000 SCF generated one can calculate out the price per hour the leak is costing using the following calculation.

If you base the cost per year for a typical 8000 hr. of operating time per year you are looking at $480 per year for one 1/16” hole leak. As you can see the more leaks in the system the more costly it gets. If you know how much SCFM your system is consuming in leaks then that value can be plugged into the equitation instead of the assumed 3.8 SCFM.

If you’d like to discuss how EXAIR products can help identify and locate costly leaks in your compressed air system, please contact one of our application engineers at 800-903-9247.

Cody Biehle
Application Engineer
EXAIR Corporation
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Finding & Fixing Leaks: The Benefits of Creating a Leak Detection Program

Leaks in a compressed air system can be a substantial source of wasted energy. A facility that hasn’t maintained their compressed air system will likely have a leak rate around 20-30% of the total air production.  But with a leak detection plan you can reduce air leaks to less than 10% of the compressor output.

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Along with the energy waste, leaks will contribute to higher operating cost.  Leaks cause a drop in system pressure, which can make air tools operate poorly, harming production cost and time. In addition, by forcing the equipment to cycle more often, leaks shorten the life of almost all system equipment, including the compressor. Increased running time can also lead to added maintenance and increased downtime. Finally, leaks can lead to adding unnecessary compressor volume.

Since air leaks are almost impossible to see, other methods must be used to locate them. The best way to detect leaks is to use an ultrasonic acoustic detector, Like EXAIR Ultrasonic Leak Detector (ULD). This unit can recognize the high frequency hissing sounds associated with air leaks. A person using the ULD only needs to point it in the direction of the suspected leak. When a leak is present, an audible tone can be heard with the use of the head phones, and the LED display will light.  Testing various unions, pipes, valves and fittings of a complete system can be done quickly and effectively at distances up to 20’ away!

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The advantages of ultrasonic leak detection include flexibility, speed, ease of use, the ability to test the system while machines are running, and the ability to find a wide variety of leaks. They involve very little training, operators often become competent after 10 minutes of training.

Due to the nature of ultrasound, it is directional in transmission. For this reason, the signal is loudest at its source. By scanning around a test area, it is possible to very quickly target in on a leak site and pin point its exact location. For this reason, ultrasonic leak detection is not only fast, it is also very accurate.

An active leak prevention program will embrace the following components: identification, tracking, repair, verification, and employee participation. All facilities with a compressed air system should establish an aggressive leak reduction program. A team involving managerial representatives from production should be formed to carry out this program.

A leak prevention program should be part of an overall program intended to improve the performance of compressed air systems. Once the leaks are found and repaired, the system should be started from the beginning until all leaks are addressed.

A good compressed air system leak repair program is very important in maintaining the efficiency, reliability, stability and cost effectiveness of any compressed air system.

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“First a Plant Engineer or Maintenance Supervisor must realize that leak repair is a journey, not a destination. An ongoing compressed air leak monitoring and repair program should be in place in any plant that has a compressed air system.” Explains Paul Shaw, a General Manager for Scales Industrial Technologies’ Air Compressor Division, and an Advanced CAC Instructor, “Leak identification and remediation with a high quality repair can lead to substantial energy savings that typically has a very rapid payback, usually a year or less. In the hundreds of leak audits and repairs that we have done we’ve found that the quality of the repair is critical to ensuring the customer receive the most value for his investment and that the leak remains repaired for as long as possible. From there, constantly monitoring for compressed air leaks and repairing them as they occur can help the plant continue to reap the energy benefits.”

Above is an excerpt from “Best Practices for Compressed Air Systems”, Appendix 4.E.1.

To discuss your application and how an EXAIR Intelligent Compressed Air Product can help your process, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer

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