Save Your Compressed Air Today with These Simple Methods

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.

open tubes
Thirteen Open Tube Blow-Offs

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
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6 Steps to Air Savings: Step 1 – Measure!

Six Steps to Optimizing Your Compressed Air System

If you’re a follower of the EXAIR Blog, you’re probably well aware that compressed air is the most expensive utility in an industrial environment. The average cost to generate 1000 Standard Cubic Feet of compressed air is $0.25. If you’re familiar with how much air you use on a daily basis, you’ll understand just how quickly that adds up. To make matters worse, many compressed air systems waste significant amounts of compressed air just through leaks. According to the Compressed Air Challenge, a typical plant that has not been well maintained will likely have a leak rate of approximately 20%!! Good luck explaining to your finance department that you’re carelessly wasting 20% of the most expensive utility. Step 1 of the 6 steps to optimizing your compressed air system is to measure the air consumption to find sources that consume a lot of air.

In order to have an understanding of your compressed air usage across various processes and in your entire facility, you have to measure. Without a measurement of usage, there’s no way to determine your actual costs or evaluate opportunities for savings. To do so, EXAIR offers a range of Digital Flowmeters in sizes from as small as ½” Schedule 40 iron pipe and up to 4” Schedule 40 pipe from stock. Larger sizes and pipes calibrated for use on copper or metric pipe are also available.

The Digital Flowmeter provides a digital readout of the exact amount of compressed air being used. Many companies will install the DFM on each major leg of their air distribution system to allow for constant monitoring and provide a benchmark of compressed air usage.

Each meter has a built in LED display that provides the volume of air moving through the pipe in SCFM, m3/hr, or m3/min. Two small probes are inserted into holes in the pipe (drill guide kit w/ drill bit included) to detect the airflow. The unit seals to the pipe once the clamps are tightened. (If the DFM ever needs to be removed, EXAIR also offers blocking rings to seal off the holes) No cutting, welding, adjustments or calibrations are ever required.

In addition to the standard Digital Flowmeter itself, it’s also offered with wireless capability to transmit the data back to your PC, or via USB Data Logger. Both of these options will allow you to track usage over time and upload that data into an Excel spreadsheet.

EXAIR’s Digital Flowmeter w/ USB Data Logger

If you’re “flying blind” when it comes to understanding your costs of compressed air in your facility, this is the first step. Contact an EXAIR Application Engineer today to get started. We’ll be happy to help you identify areas where you could take advantage of simple savings.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Find Compressed Air Leaks with an Ultrasonic Leak Detector

The Ultrasonic Leak Detector (ULD) is a hand-held, high quality instrument that can locate costly leaks in a compressed air system. The definition of Ultrasonic as defined by Merriam-Webster is: “having a frequency above the human ear’s audibility limit of about 20,000 hertz —used of waves and vibrations.” The human hearing range depends on pitch and sound. Sound is a measure of how low or high the volume of loudness in terms of decibels (dBA) and “Pitch” is measured in Hertz (Hz).The overall spectra of the emitted ultrasonic sound is “white noise”, white noise is the broad band emission of sound.

Humans can detect sounds in a frequency range from about 20 Hz to 20 kHz. (Human infants can actually hear frequencies slightly higher than 20 kHz, but lose some high-frequency sensitivity as they mature; the upper limit in average adults is often closer to 15–17 kHz.)

The Model 9061 ULD is designed to locate the source of ultrasonic sound emissions and is used to find compressed air leaks. These ultrasonic sound emissions are converted by the ULD to a range that can be heard by humans. All this being said, the EXAIR ULD makes finding your air leaks fast and efficient.

The Model 9061 comes complete with with a hard shell plastic case, headphones, parabola, tubular adapter, tubular extension and a 9 volt battery. The ULD can be adjusted to filter out background noise typically heard in manufacturing environments by using the X1, X10 and X100 sensitivity settings. The “on/off” thumb wheel can be used for sensitivity adjustment within each of theses settings. The parabola or tubular extension can be attached to the ULD masking out background noise and finding the ultrasonic sounds being generated from the leaks.

Compressed air is an expensive cost center so using the ULD to detect and fix air leaks can not only be fun but also show a payback on investment with just one leak detection. The illustration below demonstrates just how a payback occurs.

EXAIR has many tools and accessories for your intelligent air needs and want to hear from you as we have Application engineers ready to assist your projects and compressed air challenges.

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

Turn It Off: Saving Compressed Air The Easy Way

A major benefit to utilizing compressed air is the speed at which it can be shut off and re-energized for use – in fact, this can be done instantaneously. Shutting down the supply of compressed air to an application while it is not needed can drastically reduce the compressed air consumption of the process. This is an easy remedy that can produce significant savings.

Think about a place where you have a compressed air blow off with spaces between the parts or dwell times in conveyor travel. What about break times, do operators continue to keep the air on when they leave for a break or even worse, for the day?

Step number four in EXAIR’s Six Steps to Optimization is:

A simple manual ball valve and a responsible operator can provide savings at every opportunity to shut down the airflow. But an automated solution is a no-brainer and can provide significant savings.

Quarter Turn Ball Valves are low-maintenance and easy to install/use.

For a more automated approach, you can add a solenoid valve that would tie into your existing PLC or e-stop circuit, into your compressed air supply lines to aid in turning the compressed air on and off.

For an automated on/off solution can be found by using the EXAIR EFC (Electronic Flow Control). The EFC is made to accept 110V or 220V AC, and convert it to 24V DC to operate a sensor, timer, and solenoid valve. Its multiple operating modes allow you delay on, delay-off, and delay on/off among others. The operating mode can then be set to the specific time necessary for a successful application.

The spaces between parts can be turned into money saved. Every time you reach the end of a batch run, the EFC can turn the air off. You can also add solenoid valves and run them from your machine controls. If the machine is off, or the conveyor has stopped – close the solenoid valve and save the air. The modes are all defined in the video below.

So, take a look, or even better a listen, around the plant and see what you can find that could benefit from turning the air off; even if it is just for a moment it will help put money back into your bottom line.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF