A brief video showcasing the EXAIR model 9061, Ultrasonic Leak Detector’s, performance on vacuum leaks. For more information or questions on what else the ULD can be used for, contact an Application Engineer!
In my blog last week, “A Digital Flowmeter can help to improve your monthly electric bill”, I wrote about a company that was being charged for compressed air that was being used in the facility. To give you the short version, a Digital Flowmeter determined that the power supply company was not miscalculating the amount of compressed air usage, but the facility had compressed air leaks.
Now that he found the issue, he focused on the next step; to find and fix the leaks in his compressed air system. Being that EXAIR already helped him in measuring the air flow, he wondered if we could also help him to find the leaks. And we can. I recommended the model 9061 Ultrasonic Leak Detector.
Whenever a leak occurs, it will generate an ultrasonic noise. These noises have a range of frequencies from audible to inaudible. The frequencies in the range of 20 Khz to 100 Khz are above human hearing. The Ultrasonic Leak Detector can pick up these high frequencies, and make the inaudible leaks, audible. The model 9061 has three sensitivity ranges and LED display; so, you can find very small leaks at a great distance away. This unit comes with two attachments. The parabola attachment can locate leaks up to 20 feet (6.1 meters) away. This was great for locating leaks in pipes that ran in the ceiling. Once you find an area with a leak, the tube attachment could define the exact location. When he started using it, he was amazed with the performance. The Ultrasonic Leak Detector found 44 leaks in his facility. He tagged all the locations for the maintenance crew to fix.
As an example for how much compressed air costs, a 1/16” diameter leak in a compressed air line will lose roughly 4 SCFM of air at 100 psig. An air compressor needs 1 horsepower of energy to make roughly 4 SCFM of compressed air. As you can see, it take a lot of energy to supply a small leak. If we go one step further to equate a cost to this leak, it costs roughly $0.25/1000 SCF (SCF is Standard Cubic Foot). Being that this company was operating 5 days per week at 24 hours, this one small hole in a compressed air line would cost him $43.20/month. With 44 leaks throughout his plant, you can see how this could add up to be a large amount of money at the end of each month.
The EXAIR Optimization line uses different devices to help you to get the most out of your compressed air system. With this customer, he was “throwing” money away each month. With the Ultrasonic Leak Detector, he could now put that excess money back into the company’s “pocket” for future use.
No one likes paying their bills at the end of the month. But, if you can save yourself some money, it helps to make it a little easier. For this customer, he received a monthly bill for his compressed air.
An industrial facility consisting of four separate manufacturing plants and a power company that supplied all of them with utilities, i.e. hot water, natural gas, electricity, and compressed air. The parent company decided to reorganize and sell the entities. At the end of it, the power company was controlled by a different organization than the manufacturing plants. The power plant was contracted to still supply the utilities to the individual plants, but now they would be charged individually on a monthly basis.
Being that compressed air is one of the most expensive utilities, the general manager of a solid-state electronic plant really noticed the charge on his bill. He did an estimate on the amount of air that his equipment was using, and he compared it to the charges. There was roughly a 20% difference in the figures. Because of the excessive amount of money, he contacted EXAIR to see what we could offer.
In discussing their system, the compressed air was supplied through one 6” schedule 40 black pipe. The pipe came into the facility in the ceiling and it branched off to supply the entire shop with compressed air. He was looking for something to measure the compressed air flow with the ability to measure a cumulative amount. He could use this amount to compare to his monthly usage. He was also concerned about cutting into his compressed air line as this could cause him much downtime and additional costs. He needed something easy to install, accurate, and versatile.
I suggested our 6” Digital Flowmeter with the Model 9150 Summing Remote Display. EXAIR Digital Flowmeters are designed to measure flow continuously and accurately. You do not need to weld, cut, or disassemble pipe lines to install. With a drill guide, the Digital Flowmeter can be easily mounted onto the 6” black pipe by drilling two small holes. After that, they just had to insert the Digital Flowmeter into the holes, and tighten the clamp around the pipe. The total procedure took less than 30 minutes, so downtime was minimal. The EXAIR Digital Flowmeter measures flow by comparative analysis with thermal dispersion; so, the accuracy is very high and recalibration is not required.
With the option of the Summing Remote Display, they could attach it to the Digital Flowmeter and display the flow remotely up to 50 feet away. They mounted it on the wall next to his office for the operational functions. With a simple press of a button, it can show the current flow rates, daily flow rates, and cumulative flow rates. So, during the billing cycle, he was able to get the cumulative measurement to compare the results, and reset the counter to zero for the next month.
Believe it or not, the power company was correct in their measurements. But, not to waste an entire blog, I did have him turn the compressed air supply off after business hours to watch the flow rate. He did find his 20% difference in compressed air leakage. The Digital Flowmeter was able to measure low flows to target other problem areas in your compressed air system. Now he had another chore in leak detecting and pipe fixing.
EXAIR Optimization line has different products that can help you to get the most out of your compressed air system. With the customer above, he was able to measure his compressed air flow with the Digital Flowmeter, as well as detecting other issues. I will now have to talk to him about our Ultrasonic Leak Detector.
One of the best analogies I’ve heard to explain the importance of monitoring compressed air related to banking. With any bank account there are deposits and withdrawals, and if withdrawals exceed deposits, problems ensue. So, most people/businesses/institutions have systems in place to monitor their banking accounts, ensuring that there is always enough of a balance in the account to cover expenses.
The same is true for a compressed air system. If the demand exceeds the supply, problems ensue…Lowered pressure and force from compressed air driven blow offs, irregular performance within pneumatic circuits of CNC machines, and general decline of any devices on the system all begin to occur when demand exceeds supply. So, this begs the question of how to prevent a mismatch between compressed air demand and available supply.
Enter the Digital Flowmeter. The entire purpose of the Digital Flowmeter is to provide a method to see (in real time or over a specific period of time) what the existing demand is within a compressed air system. This quantifies the “withdrawal” into an output that can be compared to what is produced by the compressor, allowing for analysis and proper balance of the system.
The application photo at the top of this blog shows the DFM being installed to do just that. This unit is being set up to use a USB Data Logger to capture compressed air flows at a customer-chosen time interval. By monitoring their compressed air flow, this customer can optimize their compressed air system (align output of the compressor with demand of the facility), determine whether there are any leaks in the system, and determine the effectiveness of the compressed air which is being used.
It is important to remember that compressed air is the most expensive utility in any industrial facility. Failing to monitor the system is akin to blindly writing checks on your bank account. Proper system performance starts with proper monitoring, which the Digital Flowmeter easily provides.
If you’re interested in learning more about monitoring your compressed air system, contact an EXAIR Application Engineer. We’ll be happy to discuss specifics and options available.
EXAIR Digital Flow Meters are used to measure compressed air use throughout a facility, and they can also provide preventive measurements for critical processes.
A customer of ours had a paint booth that was used to touch-up large metal panels. Inside that paint booth, they had two, High Volume Low Pressure (HVLP) paint spray guns. These paint guns work well as they limit the air pressure to the air cap to reduce overspray and bounce back. With the lower air pressure, the paint can have a tendency to dry and block a portion of the nozzle. This can affect the atomization and the lay down of the paint. To overcome this, operators have a tendency to increase the air pressure which can create other issues in spraying, as well as using excessive paint. They decided to install some compressed air flow meters in their compressed air lines to monitor their paint system, and with the idea to prevent quality of spray problems before they occur. They contacted EXAIR to get a better understanding on what we can offer.
In discussing their system, I learned they had an enclosed semi-downdraft spray booth. They had two runs of ½” NPT Schedule 40 compressed air lines that came from the mainline above. Both compressed air lines were positioned outside the booth in the left and right back corner. (Each HVLP spray gun had its own compressed air supply). The compressed air pipes ran down along the wall with standoffs in the back area. From there, it elbowed into a filtration system then into the spray booth. The customer mentioned that he did not have much room between the wall and the spray booth. The booth had windows located in the door about 20 feet away. As for their HVLP spray guns, they were set up to operate at 15 SCFM and 30 PSIG. Depending on how often the spray guns were used during the operation, the paint had a tendency to dry and start to cause blockage. Before the operator knew it, the paint gun started to become inconsistent, causing blemishes. They would then have to rework the panel which was costly, affecting profitability.
The EXAIR Digital Flowmeters are designed to measure flow continuously and accurately. You do not need to weld, cut, or disassemble pipe lines to install. With a drill guide, the Digital Flowmeter can be easily mounted onto the pipe. They did not need to unscrew filters, piping, etc. to install these in the back corners of the spray booth. They just had to drill two small holes, insert the two probes into the holes, and tighten the clamp. I recommended the model 9090 1/2″ Digital Flow meter. It has a flow range from 0 to 90 SCFM which was perfect to monitor the HVLP spray guns. The Digital Flowmeter measures flow by comparative analysis with thermal dispersion; so, the accuracy is very high and recalibration is not required.
Since the Digital Flowmeter was located in the back corner, we needed to get a display over to the viewing window for the operators. As an option, EXAIR offers a Summing Remote Display, model 9150. This display has large LED numbers that can remotely displaying the flow from the Digital Flowmeter up to 50 feet away. They installed the Summing Remote Display and mounted it outside the viewing windows of the spray booth. The operator could now monitor the flow of the compressed air in real time with just a glance. Now, when they were spraying paint, they could tell when the flow was starting to decrease. They could stop and make the necessary changes to the nozzles, reducing the need to rework product.
Being able to measure the unknowns in your compressed air system as a prevention tool, it becomes much easier to evaluate, correct, and discover issues that may occur before they get out of hand. The EXAIR Digital Flowmeters can give you the real-time flow measurements of your compressed air system to help identify problems.
In The Sweet Taste of Floss Part 1, I explained the benefits of using our Atomizing Nozzles to apply a liquid flavoring onto floss sticks. With that same customer, we had another opportunity to save them on compressed air and on liquid flavoring.
As described in their setup, they had a mini conveyor that would carry a 24” rod that was filled with many floss sticks. This operation was manual. It would take the operators roughly 45 seconds to load the floss sticks. The conveyor would move the rod through the spraying compartment in about 15 seconds. The customer was worried about the continuous spraying and wondered if we could help in this operation.
They had a good concern because with a constant spraying, they could have an issue with fogging the work area and wasting the liquid cherry flavoring. My suggestion was to use the EXAIR model 9055 Electronic Flow Control (or EFC). The EFC is a user-friendly controller that combines a photoelectric sensor with a timer. It has eight different programmable on/off modes to minimize compressed air usage and in this case, liquid spray. For this type of operation, the EFC worked great. They did not need to manually turn on and off the system, or purchase a PLC that would require programming. The EFC is in a compact package that is easy to mount and setup.
In evaluating their application, the Signal “OFF” Delay would be correct setting to run in this operation. (The EFC comes factory set in this mode). The sensor will detect the part and open the solenoid immediately. Once the part clears the sensor, then it will keep the solenoid open for the set amount of time. For this project, they set the timer for 15 seconds. They mounted the photoelectric sensor at the beginning of the entrance to the spraying compartment. Once the sensor detected the rod that was filled with floss sticks, it would turn on the compressed air to the Atomizing Nozzles. After the timing sequence hits 15 seconds, the EFC would turn off the solenoid which would stop the spraying. It would rerun this sequence every time a rod would pass by the sensor. This optimized their operation; especially when they had any issues with loading the rod with floss sticks. It reduced their liquid and compressed air usage by 75%, and it kept the work area free of fog.
If you need an easy way to save on compressed air usage or in this case fluid, the EFC could be the device for you. It can save you much money in your operational costs, and during these economic times, we know that every bit counts. If you are still a little “foggy” on the EFC, you can contact an Application Engineer at EXAIR for help.