One important item discussed in Compressed Air Challenge’s Fundamentals of Compressed Air Systems seminars is leakage. The most common waste category is compressed air. When studies are done looking at leakage rates compared to the total amount of compressed air produced, on average somewhere between 20% and 30% is found at manufacturing facilities (Fig. 1). […]
Air Preparation
How can you reduce air leaks without turning a wrench?
What if you could reduce all your leaks without turning a wrench? Well, it is possible with good pressure control. And sometimes it is as easy as turning a knob. The principle is shown in the following orifice chart, Fig. 1. As the pressure to a leak reduces by 1 psi, the flow consumed by […]
Compressed air fail: Dead PFCs
One of many energy conservation measures available to industrial users is the use of pressure/flow control regulators. These are installed in systems to reduce the plant pressure while leaving the air compressors to operate within a wide pressure band, making them more efficient. A compressed air pressure/flow controller is a device used to regulate and […]
Electro-pneumatic proportional pressure regulator for high flow applications
Engineers and other manufacturing professionals looking for a single device that regulates pressure extremely accurately while handling high flows will find it in the Proportion-Air QB4 electro-pneumatic proportional pressure regulator. The QB4 pressure control valve is a complete electronic pressure regulating package consisting of a pilot unit with two solenoid valves, closed-loop electronic controls and […]
Compressed air fail: Pony compressor
A large automotive service shop had two 100-hp compressors, one being a VSD, both available to supply the compressed air they needed for painting and body assembly of large vehicles. The load was full of peaks, and the maintenance staff needed up to 400 cfm to provide flow to paint booths and breathing air hoods […]
Compressed air fail: Penny pinching
A farm implement manufacturer expanded its facility about 15 years ago, and personnel decided they wanted a premium compressed air system. They purchased three very efficient two-stage premium compressors, one being a VSD, and connected the equipment with large piping to reduce pressure loss. Filters were mist-eliminator style to reduce pressure loss. Air dryers were […]
Compressed air fail: Poor sealing methods
If you have ever done leakage detection with an ultrasonic leak detector you will get to know the common leak locations. If you have no detector, there is no excuse these days, excellent equipment is available for you to purchase at a reasonable price, go get it! A common sight — or rather sound — […]
Using pressure regulator assemblies for industrial applications
Accurate, repeatable pressure regulation for applications like testing industrial products and processes, running fountains, or controlling the temperature of saturated steam can be easily achieved with the right pressure regulator assembly. A Proportion-Air QBX proportional electro-pneumatic pressure regulator piloting a Burling Valve BD4 pressure reducing regulator is an ideal combination to meet the demands of […]
Compressed air fail: Bearing cooling
A wood products company hired a compressed air auditor to check out its system and try to discover why it now needed to run three compressors rather than the normal two units that previously satisfied the plant demand. The auditor placed instruments on their system to measure pressure, power, temperature, and flow — and quickly […]
Understanding air flow and FRLs
By Josh Cosford, Contributing Editor Pneumatic systems are widely used within industrial environments to power machinery and equipment, providing reliable and efficient performance. The Filter-Regulator-Lubricator (FRL) is vital in maintaining optimal air quality and pressure within these systems. However, when selecting an FRL, one must not overlook the significance of understanding FRL air flow characteristics, […]
