Have you heard the story of the Gimli Glider? An Air Canada flight ran out of fuel on July 23, 1983, at an altitude of 41,000 feet, midway through the flight. The cause? It was a mix up of pounds and kilograms when calculating the weight of fuel to load for the flight. (Give it […]
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Compressed air fail: Cycling dryer savings
Your equipment controls can sometimes tell you some good stories if you observe carefully. And sometimes tell of problems. Consider two thermal mass cycling air dryers installed in a foundry. Thermal mass cycling dryers are designed to reduce the energy consumption of the internal cooling system by turning off and on (cycling) the refrigerant compressor […]
Compressed air fail: Blowing reduction
It is very common in an industrial facility to have compressed air blowing applications installed at various locations to provide cleaning of sensing eyes and scanners. But it is important to keep in mind that this blowing demand can add up quickly — especially if there are many of these applications installed within the plant. […]
Why is condensate disposal important in compressed air systems?
A wood products company had a two-compressor system installed on a mezzanine. Under the compressors and dryers were the piping and storage receivers. Each tank and each compressor had timer drains installed to expel the condensate that forms when the compressed air cools in the compressor aftercooler, piping, and storage vessels. The outlets of these […]
Compressed air fail: Flowmeter position
A local food company was resizing its compressed air system while renewing its plant operations. To get the sizing correct, the plant maintenance foreman purchased a flow meter to measure the output of the compressors. The meter was installed with a data logger to capture the flow profile of the plant. The readings showed that […]
Watch out for dangerous blow wands
Despite years of warnings — and the development of OSHA standards — there are still many dangerous compressed air blow wands in service at facilities throughout the world. Countless injuries and even deaths could have been prevented if safer devices were used or the blowing eliminated altogether. Fig. 1 shows a wand used to clean […]
Using CAGI data sheets for refrigerated air dryers
If you are shopping for a refrigerated air dryer, it is a good idea to consult the Compressed Air & Gas Institute (CAGI) published data from the manufacturer before you buy. If you buy a non-cycling air dryer, the unit will consume about the same power no matter what — even if the associated air […]
A new era of human-robot collaboration: the first pneumatic cobot
What if there was a robot that was easy to operate, did not require a safety fence and was also attractively priced? That would introduce a whole new era in human-robot collaboration. This new era is now dawning – with the world’s first pneumatic robot from Festo, which was announced by Festo at Hannover Fair […]
A leak detection fail!
A recent question received by email: I need some help from you regarding air leak calculation. We just purchased a new air leak detector that calculates leakage flow. We have high air leakage in our LPG bottling plant and our leak detector showed a flow of 9130.2 L/S. If we convert this to CFM then it will total […]
Why should you look for hidden leaks in your compressed air system?
Air leaks can form in many places in a compressed air system. Some are obvious, but others are well hidden from detection. In Fig. 1, we can see a compressor air cooler that has been subject to frequent high-pressure cleaning using compressed air blow wands. And due to the stresses involved with the cleaning, it […]
