Tag: Swivel Fittings

Steps to Find Compressed Air Leaks in your Facility

Published on by Jordan T ShouseLeave a comment

The Second Step to optimize your compressed air system is to Find and fix leaks in your compressed air system. The reason leaks are important to find and fix is because they can account for 20-30% of a compressors total output. A compressed air leak fixing process can save 10-20% of that lost volume.

6-steps-from-catalog

Unintentional leaks will result in increased maintenance issues and can be found in any part of a compressed air system. Leaks can be found at a poorly sealed fitting, quick disconnects and even right through old or poorly maintained supply piping. Good practice will be to develop an ongoing leak detection program.

The critical steps needed for an effective leak detection program are as follows:

  1. Get a foundation (baseline) for your compressed air use so you have something to compare once you begin eliminating leaks. This will allow you to quantify the savings.
  2. Estimate how much air you are currently losing to air leaks. This can be done by using one of two methods.
    • Load/Unload systems, where T= Time fully loaded and t=Time fully unloaded:
        • Leakage percent = T x 100
          ——
          (T + t)
    • Systems with other controls where V=cubic feet, P1 and P2=PSIG, and T=minutes
        • Leakage = V x (P1-P2) x 1.25
          ————–
          T x 14.7
  3. Know your cost of compressed air so you can provide effectiveness of the leak fixing process.
  4. Find, Document and Fix the leaks. Start by fixing the worst offenders, fix the largest leaks. Document both the leaks found and the leaks fixed which can help illustrate problem areas or repeat offenders, which could indicate other problems within the system.
  5. Compare the baseline to your final results.
  6. Repeat. We know you didn’t want to hear this but it will be necessary to continue an efficient compressed air system in your plant.

EXAIR has a tool to assist you in finding these leaks throughout your facility, the Ultrasonic Leak Detector. Check one of our other Blogs here, to see how it works!

Leak Detector

 

If you’d like to discuss how to get the most out of your compressed air system – or our products – give me a call.

Jordan Shouse
Application Engineer
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Compressed Air Accessories for Clean Air, Quiet Air, and Adjustability

Published on by johnball2014Leave a comment

In this blog, I would like to turn your attention to our accessories that support our Intelligent Compressed Air® Products.  EXAIR products use compressed air to coat, conserve, cool, convey and clean.  To maximize the performance, it is important to have the controls and options to increase their “flexibility”.  EXAIR offers these items as Accessories.  Pneumatic applications come in many variations and forms, and Accessories can help you to adapt to your application and to remove any “guess work”.

Here are the different categories and explanations of each item that EXAIR recommends for our products.  With their defined functions, they can help you in different areas to enhance your pneumatic experience.

Filters/Regulators:

  • Filter Separators remove bulk liquid and contamination from the compressed air stream. EXAIR stocks a range of sizes from ¼” NPT ports to 1 ¼” NPT ports.  They use a 5-micron filter and a mechanical baffle to remove slugs of liquid from your compressed air system.  Most Filter Separators have an auto-drain to automatically remove the buildup of liquid inside the bowl.   I would consider the Filter Separator as a minimum level of protection required to protect your EXAIR products.
  • The Oil Removal Filters remove very small particles of dirt and oil from the compressed air; making it even cleaner. The 0.03-micron media of the Oil Removal Filter will “coalesce” the fine liquid particles into large droplets.  Thus, allowing gravity to remove it from the compressed air stream.  EXAIR offers different sizes ranging from ¼” NPT to 1 ½” NPT ports.  As a note, Oil Removal Filters are great for removing very fine particles, but if you have a system with lots of water, I would recommend a Filter Separator upstream of the Oil Removal Filter for optimal filtration.
  • Pressure Regulators control the amount of air pressure being supplied to your EXAIR products. This is important if you are trying to save compressed air, control the force, or convey material.  EXAIR, being a leader in compressed air savings, recommends to use the minimum amount of air pressure to do the job.  This will save compressed air and save you money.  Regulators have a characteristic called “droop”.  Droop is the amount of air pressure that it drops downstream when you start flowing compressed air.  If the regulator is not sized properly, you can “starve” your pneumatic component, causing loss of function.  EXAIR properly sizes our regulators in our kits to make sure that you won’t “starve” our product.
  • EXAIR also offers Mounting Brackets for the regulators and the filters to help support them to a wall or structure. To connect filters and regulators together without a pipe nipple, we also have Coupling Kits for sizes up to ¾” NPT.  And for combination kits which includes a filter and a regulator, we offer the Mounting Bracket and Coupling Kit together for a set.

Silencing Mufflers:

  • Reclassifying Mufflers are designed to have two functions. They can reduce noise levels by 35 dB and remove oil mist from the exhaust air.  Cylinders and valves that exhaust pressurized air may have oil in the line to keep the seals from sticking.  When exhausted, it can create a fine mist which is dangerous for operators.  The Reclassifying Mufflers can reduce the loud noise as well as collect any contamination from the exhaust air.
  • Sintered Bronze Mufflers are simple in design, cost effective, and easy to install. They have a minimal back pressure to not restrict operations of the pneumatic device.  They come in sizes from #10-32 thread to 1-1/2 NPT.  For a quick and simple way to reduce noise, the Sintered Bronze Mufflers are in stock for fast delivery.
  • Straight-Through Mufflers offer a way to reduce noise levels without worrying about clogging. They have an aluminum shell lined with sound absorbing foam, and they can reduce the noise level by 20 dB.  EXAIR offers them with two ports from ¼” NPT to ¾” NPT.  This can allow you to connect other items like blowing hose kits while reducing noise.
  • Heavy Duty Mufflers have an outer aluminum shell with an internal stainless steel screen that can protect the components from environmental contamination, and can also keep contaminant like rust from being ejected at high speed into the work area. They have a typical noise reduction of 14 dB.

Pneumatic Valves:

  • Manual Valves allow for operators to turn on and off their system by hand. The full-flow ball valves range from ¼” NPT to 1 1/4” NPT in size and will not restrict flow.  EXAIR also offers a manual foot pedal valve for hands-free operations.  This ¼” NPT Foot Valve has a 3-way operation and works great if the operator has to use both hands in their process.
  • Solenoid Valves are a way to turn on and off the supply of compressed air electrically for automated systems. We offer solenoids in three different voltages; 110Vac, 240Vac, and 24Vdc.  EXAIR has a large range of flows with ports ranging from ¼” NPT to 1” NPT.  All models are UL listed and are CE and RoHS compliant.

Hardware:

  • Swivel Fittings are a great way to securely install and aim EXAIR nozzles. They are dynamic as they can be adjusted and set to a flow direction with 50-degrees of movement.  They are made from 303SS or 316SS for corrosion resistance with ports ranging from 4mm to 1” NPT.
  • Compressed Air Fittings are a nice arrangement to connect different compressed air items together. We offer a range of hex and close nipples, couplings, reducers, tees, elbows, crosses and bulk head fittings.  If you need a quick way to connect directly to your pneumatic system, we may have it on the shelf.
  • Magnetic Bases are designed for a solid mount to steel surfaces and for easy portability of your blow-off system to different locations. It has a 100 lb. (45.5Kg) pulling force to keep the blowing device attached firmly until you want to move it.  They can be mounted in a vertical or horizontal position.  EXAIR offers a single outlet Magnetic Base (for one blow-off device); a dual outlet Magnetic Base (for multiple blowing products); and a single outlet Swivel Magnetic Base (to offer more flexibility to orientation).  The bases come with a ¼ turn shut-off valve to easily turn on and off the compressed air to the EXAIR products.
  • Receiver Tanks are used to store compressed air. They can be used at the air compressor or as secondary reservoirs for intermittent demand.  They help your compressed air system with pressure variations and high demand loads.  EXAIR offers a model 9500-60 Receiver Tank that has a capacity of 60 gallons, is rated to 200 psig, and meets ASME pressure vessel code.

 

Hoses:

  • Conveying Hoses are used with our Air Operated Conveyors or Line Vacs. The hoses are made from a durable PVC semi-flexible hose with six different diameters from ¾” I.D. up to 3” I.D.  The conveyance hoses can slip easily to the ends of the Line Vacs or to tubes for an easy transition.  EXAIR can cut-to-length Conveying Hoses up to 50 feet (15m); in increments of 10 feet (3m).
  • Coiled Hoses get compressed air from the piping system to the EXAIR product. They are made of a durable abrasion-resistant nylon material that is 12 feet long (3.6 meters).  They have swivel fittings at the end to allow for easy uncoiling, and a spring strain relief to keep the hose from kinking.  The coiled design makes it easy to reach around the work area and retract back to the substation.  This will help to keep the hose off the ground where potential dangers could occur.  We offer 3 different connection sizes; 1/8” NPT, ¼” NPT, and 3/8” NPT.
  • Compressed Air Hoses is another way to supply EXAIR products. They are useful if you need to reach from overhead sources or around equipment.   They are made from a reinforced synthetic rubber in 3/8” I.D. and 1/2” I.D. diameters.  We can make specific lengths up to 50 feet (15m).  They are rated for 250 PSIG (17 bar) air pressure, and the hose material works well for long-lasting protection against ozone, weathering and temperatures up to 158oF (70oC).  They come standard with two male ends in ¼” NPT or ½” NPT.

    Flexible and durable, EXAIR Stay Set Hoses come in lengths from 6″ to 36″.
  • Stay Set Hoses give you that possibility of manually adjusting or re-adjusting Super Air Nozzles. The hose has a “memory” function; so, it will not creep or droop until you physically move it.  They work well to direct air flows in unique ways at specific target areas.  They can be used with Super Air Nozzles, Safety Air Guns and Blow-off Kits.  The Stay Set Hoses come in lengths from 6” (15cm) to 36” (91cm), and they are offered with ¼” NPT male on both ends or with a 1/8” NPT female and a ¼” NPT male connections.  These hoses are rated for 250 PSIG (17 bar) and are made from reinforced synthetic rubber.

Temperature Accessories:

  • The ETC, or Electronic Temperature Control, is a digital temperature controller with a LED screen for precision monitoring and adjusting temperatures in a Cabinet Cooler System. The controller has easy-to-use buttons to raise or lower the desired internal cabinet temperature.  Once set, the ETC will hold the temperature to +/- 1 oF (+/- 0.5 oC).  The LED displays the internal temperature for continuous monitoring.  The ETC comes complete with the controller and a solenoid valve in two different voltages, 120Vac and 240Vac.
  • The thermostat is a way to control a solenoid valve electrically to turn on/off a Cabinet Cooler System at a set temperature. It is preset at 95°F (35°C), but it can be adjusted to other desired temperatures.  It has an accuracy to hold the set temperature within +/- 2 °F (1 °C).  It can handle voltages from 24V to 240V, AC (50/60 Hz) or DC.  They are UL Recognized and CSA certified.

In todays fast-paced world, there is a need to get your devices operating as quickly as possible.  With EXAIR Accessories, they can help you to do that.  Not only will you have confidence, as you are using the items from the manufacturer, but it will minimize downtime, setup, and malfunctions that can occur if using other types of accessories.  If you would like to discuss the proper options with your EXAIR products, an Application Engineer will be happy to help you.

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

Upgrade Blowoff Applications with Engineered Products to Increase Safety and Efficiency

Published on by Russ BowmanLeave a comment

At EXAIR, it’s our business to make sure that you get the most out of your compressed air system.  We’ve got a Six Step plan to help you do just that, and one of those steps is the topic of today’s blog:

We have a couple of ways to help with step #1.  You can use a Digital Flowmeter to measure your total compressed air usage, and take advantage of our Efficiency Lab service to determine the consumption of individual compressed air devices that may be running up the total.  Based on our performance tests of those devices, we can recommend suitable EXAIR Intelligent Compressed Air Products to replace them with, along with the expected reductions in air consumption & noise levels…quieter is always better too.

We’re going to skip right over Step #2…just for now…but if you can’t wait, click on the picture above for more on finding & fixing leaks.

Once you get our recommended replacements in (I mean, why wouldn’t you?), they’re going to be part of your compressed air system, so naturally, we want to make sure you get the most out of them as well.  Key considerations are suitable supply lines, and proper installation.

In the case of a Super Air Nozzle or Air Jet, these are oftentimes one and the same.  They’re all small enough, and lightweight enough, to be adequately supported by compressed air piping (assuming the piping is adequately supported,) metal tubing (via a compression fitting adapter,) or even mounting solutions like our Stay Set Hoses.

Just a few ideas for installing an EXAIR Super Air Nozzle

Sometimes, though, you need a firm, vibration-resistant mounting…that’s where we recommend our Swivel Fittings.  A hex retainer tightly locks the ball in position, but allows for easy repositioning when loosened.  They come in standard NPT sizes from 1″ NPT down to 1/8″ NPT, and we even have them for the M4, M5, and M6 metric threads for our Atto, Pico, and Nano Super Air Nozzles.

Typical threaded fittings are limited in the angles you can achieve. EXAIR Swivel Fittings provide 50° of adjustability.

Even a highly efficient blow off needs to be aimed well in order to do its job well.  If you’d like to discuss how to get the most out of your compressed air system – or our products – give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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The Case For EXAIR Swivel Fittings

Published on by Russ BowmanLeave a comment

One of the more common questions we get here in the Application Engineering department at EXAIR is…

“What’s the best angle to position a Super Air Nozzle?”

The simple (and perhaps a little snarky, but I swear that’s not intended) answer is…

“The angle it takes to get the results you need.”

But wait, there’s more…we’re not going to leave anybody hanging like that. Many blow off applications are going to be best served by a “sweep” of air, at a low angle. That will be ideal for removing a light layer of dust from a relatively flat and smooth surface. A bit larger angle, relative to the surface, may be necessary if you need some impingement force to dislodge sticky, clumpy, or mildly adhesive debris.  Rarely will you want to blow directly, at a perpendicular angle, to a material’s surface.  An exception to this might be if you’re trying to remove excess moisture from a porous and thin material, like a web fiber.

Regardless of what angle you need to aim your Super Air Nozzle, there are several ways to do it.  You can use a compression fitting them onto bendable copper tubing…just don’t bend it too much or too often.  We’ve got Stay Set Hoses that allow for quick & easy repositioning…they come in lengths from 6″ to 36″, and are in stock.

EXAIR Stay Set Hoses and Swivel Fittings are ideal for installation and positioning of your Super Air Nozzle.

If you want to hold it in place firmly and securely, you’re looking for a Swivel Fitting.  They’re available for almost all of our Super Air Nozzles, from the Atto to the 1″ NPT Model 1114 High Force Super Air Nozzle.  They offer 50° of total movement, and are made of Stainless Steel for durability in most any environment.

EXAIR Swivel Fittings have male NPT threads on one end, and female NPT on the other.  The smaller Swivels, for the Atto, Pico, and Nano Super Air Nozzles, have M4x0.5mm, M5x0.5mm, and M6x0.75mm female threads, respectively, in the ball of the swivel itself for direct threading of these small Super Air Nozzles.

EXAIR’s Swivel Fitting Family

Swivel Fittings can also be used with a host of other EXAIR products.  In addition to the Super Air Nozzles, for example, they’ve historically been very popular with our Air Amplifiers.  Here’s a short informational video showing just how versatile they are:

EXAIR Intelligent Compressed Air Products are made to be easy to install & operate.  This is our intent from Research & Development, to Shipping & Receiving.  If you have questions, give me a call.  I want you to get the most out of our products!

Russ Bowman
Application Engineer
EXAIR Corporation
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