EXAIR not only has products that will reduce your air consumption, cost and noise levels but also has the tools to help you calculate the annual savings and Return on Investment (ROI). Sometimes you have the materials in house to make your own pneumatic tools so you get that piece of pipe in the maintenance crib, drill several holes and connect your compressed air. It works, your team is proud of the solution and everyone moves on to the next fire, right?
Several projects later you notice that your compressed air usage seems very high so a team is assembled and challenged with a cost savings program geared towards compressed air savings. EXAIR is the company that can help. We have Intelligent Compressed Air Products, Free Expert Technical Help and savings calculators that can be used to show the savings in your reports and presentations. EXAIR’s cost savings calculator will simplify the savings for each process you study and help your efforts in purchase justifications.
We have several examples of helping our customers save money such as this blog by one of our talented Application Engineers. You will realize more than cost savings as you should also see significant sound reductions and safety improvements as all of our products meet or exceed OSHA standard 29 CFR 1910.95 (a) which outlines allowable noise exposure for personnel and OSHA standard 29 CFR1910.242 (b) Dead End Pressure requirements.
When you begin compressed air cost savings program and have questions as to where to start, how to calculate and how to prepare your justifications please give EXAIR a call and talk with one of our many talented Application Engineers. EXAIR’s Intelligent Compressed Air products and Application Engineers will support all your efforts to decrease compressed air usage, reduce sound levels and increase the safety of your environment.
When discussing ROI, return on investment, for an industrial compressed air system it is necessary to understand what it costs to produce compressed air. Generally we calculate that it costs .25 cents to produce 1,000 SCF (Standard Cubic Feet) of compressed air here in the Midwest of the United States. For our example let’s consider a typical 250 HP industrial compressor running 24 hours per day/5 days per week for 52 weeks. This compressor can generate 374,400,000 SCF per year, using the industry standard utility cost for the Midwest of .25 cents per 1,000 SCF it will cost $93,600 to produce that volume of compressed air.
To avoid wasting money on compressed air generation it is extremely important to eliminate unintended or wasteful compressed air use in your plant. The two main offenders are leaks and open tube blow-offs. While soapy water is a good method for discovering leaks, EXAIR offers the Ultrasonic Leak Detector. This handy device allows leaks to be detected at distances of up to 20′ away! Also consider how safe and convenient it is to find leaks in overhead pipes while standing on the ground instead of on a ladder. Using a tool like this to do an entire system leak audit can easily result in many small leaks being identified and when fixed result in a large savings.
Now let’s look at what an open pipe or tube may consume. A single 1/4″ OD copper tube can use 33 SCFM @ 80 PSIG inlet pressure. Using the manifold pictured above as our example with 13 open tubes, each tube can consume 33 SCFM @ 80 PSI inlet pressure. With 13 open tubes running 24 hours a day, 5 days a week, 52 weeks per year equates to a total consumption of 160,617,600 SCF annually. If we installed the EXAIR model 1100 Super Air Nozzle using a simple compression fitting we would reduce the air consumption dramatically. The EXAIR 1100 Super Air Nozzle consumes 14 SCFM @ 80 PSIG inlet pressure, running 24 hours a day, 5 days a week, 52 weeks per year equates to a total consumption of 68,140,800 SCF annually. That change will save you 92,476,800 SCF annually which is equal to $23,119.20 and 24.7% of air compressor capacity! These calculations are all based on continuous running applications, if intermittent operation is possible consider the EXAIR Electronic Flow Control for even greater savings. The EXAIR Electronic Flow Control combines a photoelectric sensor with timing control that limits compressed air use by turning it off when no part is present
Open pipe blow offs also violate OSHA standard 29 CFR 1910.242(b) requirement for using compressed air for cleaning when pressurized above 30 PSIG. Not to mention they generally are louder than 90 dBA, which is the maximum allowable noise exposure without hearing protection under OSHA standard 29 CFR – 1910.95 (a). The EXAIR engineered Super Air Nozzle is a great way to avoid a OSHA fine.
A great product that will help you keep your fingers on the pulse of compressed air consumption and demand is by incorporating the EXAIR Digital Flow Meter. This handy item mounts directly to the pipe. The digital display shows the amount of compressed air being used in any leg of your distribution system. The Digital Flow Meter is offered in sizes for 1/2″ – 4″ Schedule 40 Iron Pipe and 3/4″ – 4″ Copper Pipe. It also is available with the Summing Remote Display that is prewired with a 50′ cable, it is powered by the Digital Flow Meter and with a push of the button will display either the current compressed air consumption, consumption for the previous 24 hours or the total cumulative usage.
The Digital Flowmeters are also available with wireless capability using the ZigBee mesh network protocol, data can be passed from meter to meter to extend the distance over which the wireless system can operate. Each meter has a range of up to 100′ (30 meters). Or you can opt for the USB Data Logger option. The USB Data Logger can store approximately 9 hours of readings if set to sample once every second or up to 2 years if sampled every 12 hours.
If you would like to talk about any of the quiet EXAIR Intelligent Compressed Air® products or our line of Optimization Products, feel free to contact me or any EXAIR Application Engineer.
Russ Bowman, CCASS
Application Engineer EXAIR Corporation Visit us on the Web Follow me on Twitter Like us on Facebook
EXAIRs’ easy to use Digital Sound Level Meter Model 9104 is ideal for identifying and measuring sound levels in manufacturing environments. The source of loud noises can be quickly identified which can then translate to taking some corrective action to lower the noise. Your current compressed air processes could be easily quieted by replacing your current end use product (nozzle, open pipe, open fitting, homemade air device) with an EXAIR engineered compressed air product. All of our blowoff products meet and/or exceed the OSHA Standard 29CFR-1910.95(a) noise exposure standard.
OSHA standards set the minimum level that employers must follow and maintain to ensure safety and hazard free environments. The EXAIR Model 9104 Digital Sound Level Meter will help efforts in reducing the risk of exposure to high noise levels and reducing the risk of hearing loss. The sound Meter will measure the decibel of sound and show the reading on a large LCD display. This unit is battery operated and comes with a certification of accuracy and calibration traceable to NIST (National Institute of Standards and Technology).
If you have questions about the Digital Sound Level Meter, or would like to talk about any of the quiet EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
I recently took my daughter to a basketball game to watch Xavier University’s Lady Musketeers play. Due to Covid the arena felt empty and we could hear the players on the court and also the the coaches from the opposite side. If this was a regular season game we could barely hear ourselves let alone the teams and coaches. The obvious reason why there was not much noise is that there wasn’t much of a crowd and the crowd makes a lot of sound. So, what is sound?
Sound can be defined as “vibrations that travel through the air or another medium and can be heard when they reach a person’s or animal’s ear”. Sounds hit our ears at different pressure levels depending on its strength (“loudness” or volume) and is measured in decibels (dB).
When sound travels and comes into contact with a surface, a portion will be absorbed and another portion will be reflected. Manufacturing environments obviously can be the source of a lot of sound and personnel near the sources should be protected as much as possible. One extremely effective way to do this is to substitute a loud noise source with a quieter one or remove the source all together. PPE can be effective but is much less reliable due to people forgetting to use PPE, using PPE improperly or even deciding for themselves they do not need it.
To substitute or eliminate means something like the strategic placement of air compressor which is not near personnel or recognizing the type of product you choose to use is vital to sound management and the health and safety of people working near the point of use. Many EXAIR products can help you reduce the sound level of your current point-of-use compressed air by replacing commercial air nozzles, open pipes and homemade blowoff solutions with our Engineered Air Nozzles, Safety Air Guns, Air Amplifiers, or Super Air Knives. These products are all designed to minimize compressed air noise and can contribute to lowering the overall noise exposure of your personnel. The additional benefit is that you customers will also typically see a reduction in air consumption which saves money on generating compressed air.
EXAIR’s Digital Sound Level Meter is a tool used to identify and quantify the particular noise levels within an area. The source of loud noises can be quickly identified and isolated so corrective measures can be implemented.
Compressed air noise levels often exceed OSHA (Occupational Safety and Health Administration) noise level exposure requirements. EXAIR pneumatic products meet or exceed the OSHA Standard 29 CFR-1910.95(a) and can be used to reduce sound levels in your compressed air environment.
EXAIR has has many engineered compressed air products that can help reduce your sound levels. Our Application Engineers are ready and eager to help assist your sound level decrease projects. Please contact us at www.EXAIR.com so we can be a vital part of your successful sound reduction program.