Do you meet OSHA’s guidelines for workplace hose safety?

How Hose Reels offer an effective and practical solution to minimizing potential accidents, while increasing safety and efficiency in all types of industries

Ask a Question:
What does OSHA say about workplace hose safety?

Answer:
An OSHA guideline publication states:

“Hoses, cables, and other equipment shall be kept clear of passageways, ladders and stairs.”

OSHA says reduce your slips, trips and falls.
Slips, trips and falls constitute the majority of general industry accidents, which cause 15% of all accidental deaths, and are second only to motor vehicles as a cause of fatalities. The OSHA standard for walking and working surfaces apply to all permanent places of employment, except where only domestic, mining, or agricultural work is performed. www.osha.gov

Consider adding reels to increase safety & efficiency with your electrical cords, welding cables, air hose, oil, grease, liquid/water or fuel hoses.

Ask a Question:
Why should my business use Hose Reels?

Answer:
If your business or plant has multiple air hoses, electrical cords or welding cables- then industrial air hose reels and cord and cable reels can be one of your most effective equipment additions you’ll ever make…as well as one of the safest!

How safe are your workplace walkways?

Hose reels are an important part of workplace safety. Tripping accidents- which include tripping over hose –unfortunately are a main cause listed on incident reports. Adding hose reels can provide a cost effective solution to helping reduce accidents, while increasing safety and efficiency in all types of industries.
Hose reels offer an effective and practical solution to minimizing potential accidents, while increasing safety and efficiency in all types of industries. Reels may be spring rewind, manual hand rewind, or in cases of very heavy, long hoses- motorized reels work best.

Five Reasons to use Air Hose Reels:

1. Efficiency- Hose reels make all your hose handling more efficient. - An organized, clean workplace is proven to be more efficie- Maintaining hose within easy reach saves time and money.- Reels also provide a quick and efficient way to store the hose, electrical cords or welding cables after each use…unlike an operator having to stop and coil them up manually. - Many industries strive to improve efficiencies (and safety) by implementing more efficient tools and equipment to increase productivity and reduce worker effort in doing a task. Reels are inexpensive and indeed are a "tool" that can help meet such goals.

2. Safety- Hoses, when not in actual use, left lying randomly coiled on the floor or ground, may present major tripping hazards and can result in injury.- Reels decrease you chances of injuries from tripping.- Reels prevent hose, cords and cable from cluttering walkways.- Using electrical cords or extension leads in industrial situations often presents significant safety hazards. The use of spring rewind electrical cord reels can offer significant safety benefits.- Reduce accidents and insurance expense…slips, trips and falls are the leading cause of work stoppage in industry.

3. Protects Equipment- Hoses, electrical cords, and welding cable can last five times longer when stored on a reel and help save you from replacing them as often.- Storing hoses, cords, and cables on reels prevents them from being stepped on or run over by equipment, increasing their service life.- Reels can often provide a solution for protecting electrical cables from damage when not in use, damage that could potentially cause electrocution.

4. Minimizes Leakages- Hoses on reels can reduce the threat of expensive air leakages.- Using hose reels reduces leakage and spills of expensive fluids.

5. Increase Productivity- Easily locating your air hoses when and where you need them can increase productivity. - Using hose, cord and cable reels benefits an employer by increasing the safety of the work environment and increasing efficiency.- All these factors help improve your work environment, which saves you time, equipment and money.

For more about Hose Reels visit www.hosereels.biz

What Contaminates Your Compressed Air?

Clean, dry, oil free compressed air and gas is a basic need for many industries.
One drop of unwanted oil can cause an entire automated process to malfunction.
It can cause seals in pneumatic valves and cylinders to swell, resulting in sluggish operation - or in worst cases, complete seizure of moving parts.

3 things that can contaminate your compressed air system and ruin your product or processes:

1) Solid particles come from ambient air contaminants like dust and from rusted, oxidized pipework. They will cause pneumatic equipment to malfunction, cause instrument and control failures, and contaminate end products.

2) Condensed water droplets come from the humidity in ambient air.
Water will oxidize pipework and pneumatic equipment, ruin paint finishes and end products.

3) Liquid oil and oil vapors are introduced by compressor lubricants and by hydrocarbon vapors present in ambient air. Oil-free compressed air is particularly important in food and pharmaceutical processes.

Compressed Air Filters effectively and efficiently remove solid particles, remnants of oil, water mist and other liquid from compressed air and gas which can...
-wear out pneumatic machinery
-block valves and orifices, causing high maintenance
-corrode piping systems which cause costly air leaks
-result in abrupt equipment stoppages, lost product, time and money


How to clean your Compressed Air...

Depending on the level of air purity required, different levels of filtration and types of filters are used. Filters are used in conjunction with other "filtering equipment" - such as a Water Separator or Compressed Air Dryer- to help remove harmful contaminates from your system.

General Purpose Filters - also called "particulate filters" are used to remove solid particles.
Oil and Oil Vapor Removal Filters - also called "coalescing-type filters" are used to remove oil and vapors.

A particulate filter is recommended after a desiccant-type dryer to remove desiccant fines.
A coalescing-type filter is recommended before a desiccant type dryer to prevent fouling of the desiccant bed.
Additional filtration may also be needed to meet requirements for specific end uses.
Compressed air filters downstream of the air compressor are generally required for the removal of
contaminants, such as particulates, condensate, and lubricant.

Listed below are types of filtration equipment available in today's market. The specifications offered are from Champion Air Compressors as a market example.

Water Separator
Installation: after an air compressors’ (or a stand-alone) aftercooler
Design: One-stage filtration with two stainless steel orifice tubes. Labyrinth style air flow path removes liquid water by forcing abrupt directional changes.
Performance*: Handles bulk liquid inlet loads to 30,000 ppm w/w and provides 10 micron solid particulate separation. Efficient to flows as low as 5% of rated flow.

Separator/Filter
Installation: after an air compressors’ (or a stand-alone) aftercooler or as a prefilter to a refrigerated dryer
Design: Two-stage filtration with first stage of two stainless steel orifice tubes which remove bulk liquids and solid particulates to 10 micron. Second stage has in-depth coalescing fiber media which captures solid particulates to 3 micron.
Performance*: Handles bulk liquid inlet loads to 25,000 ppm w/w and
provides 3 micron solid particulate filtration.

General Purpose Filter
Installation: 1 micron particulate prefilter for refrigerated dryers and high efficiency oil removal filters.
Design: Two-stage filtration with a first stage of multiple layers of fiber media which pre-filter the air. Second stage has indepth coalescing fiber media which coalesces oil aerosols and removes finer particulates to 1 micron.
Performance*: Handles bulk liquid inlet loads to 2,000 ppm w/w, provides 1 micron solid particulate filtration and oil removal to 1 ppm.

Dry Particulate Filter
Installation: Dry, solid particulate afterfilter for heatless desiccant dryers
Design: Two-stage filtration with life-prolonging outside/in air flow with first stage of alternate layers of fiber media and a media screen capturing large particulates. Second stage captures finer particulates. Not designed for any liquid loading.
Performance*: Provides 1 micron solid particulate filtration of desiccant dust.

High Efficiency Particulate Filter
Installation: Prefilter to desiccant and membrane dryers, afterfilter to refrigerated dryers and stand-alone oil removal at the point-of-use of compressed air.
Design: Two-stage filtration with a first stage of multiple layers of fiber media which prefilter the air. Second stage has in-depth coalescing fiber media which coalesces oil aerosols. Includes an outer-coated, closed cell foam sleeve.
Performance*: Handles bulk liquid water inlet loads to 1,000 ppm w/w and provides 0.008 ppm oil aerosol removal and 0.01 micron solid particulate separation.

Maximum Efficiency Oil Removal Filter
Installation: Prefilter to desiccant and membrane dryers with a Grade C prefilter, oil-free air applications.
Design: Two-stage filtration with a first stage of a coated, closed-cell foam sleeve which acts as a prefilter and flow disperser. Second stage has in-depth coalescing fiber media which coalesces fine oil aerosols. Includes an outer-coated, closed cell foam sleeve.
Performance*: Handles bulk liquid water inlet loads to 100 ppm w/w and provides 0.0008 ppm oil aerosol removal and 0.01 micron solid particulate separation.

Oil Vapor Removal Filter
Installation: Afterfilter to high efficiency liquid oil removal filters for true oil-free applications.
Design: Two-stage filtration with a generously-sized first stage of a stabilized bed of carbon particles which remove the majority of the oil vapor. Second stage has multiple layers of fiber media with bonded microfine carbon particles which remove the remaining oil vapors. Includes an outer-coated, closed cell foam sleeve which prevents fiber migration.
Performance**: No liquid should be present at filter inlet. Provides 0.003 ppm w/w oil (as a vapor) removal and 0.01 micron solid particulate separation.

* Filter efficiencies have been established in accordance with CAGI standard ADF400 and are based on 100°F (38°C) inlet temperature
** Filter efficiency has been established in accordance with CAGI standard ADF500 and is based on 100°F (38°C) inlet temperature


FILTRATION TIPS:
Filtration only to the level required by each compressed air application will minimize pressure drop and resultant energy consumption.
Elements should also be replaced as indicated by pressure differential to minimize pressure drop and energy consumption, and should be checked at least annually.
You can customize your air treatment applications by choosing the combination of dryers, filters, and separators that give you the level of clean air or gas that you need.


Who establishes quality industry standards for filters?

ISO 8573.1 was developed in 1992 by ISO (International Organization for Standardization) to help plant engineers specify desired compressed air quality globally by providing “Quality Classes” for solid particulates, humidity and oil. Quality classes provide engineers with an internationally accepted unit of measure.

A typical pharmaceutical plant, for example, would have a compressed air specification of ISO Quality Classes 1.2.1.
This is equivalent to 0.1 micron particulate filtration, -40°F (-40°C) dew point, and 0.008 ppm (0.01 mg/m3) oil filtration.
No matter what language is spoken and what unit of measure is used, using ISO 8573.1 Air Quality Classes ensures that your factory will get the compressed air quality you specified.



Access the Market Example Resouce: Champion CFF Series Compressed Air Filter Brochure.

How to tell when your compressor needs an air dryer

Ask a Question:

Can water or moisture be damaging my compressed air system?



Answer:

Absolutely! Water corrodes pipes, valves, machinery controls. None of this is good.

When controls malfunction, production can stop or product can be impaired and all this costs you time and money. Water in Aerosol or Vapor form is more difficult to remove and requires the use of a Compressed Air Dryer.



Ask a Question:

How does water or moisture get into my compressed air?



Answer:

Through your Compressor inlet.

Water vapor (humidity-moisture) enters the air system through the air compressor inlet air filter. The air compressor sucks in approximately 7 cubic feet of atmospheric air at 0 psig, and that volume of air is compressed into 1 cubic feet of air at 100 psig. The water vapor (humidity-moisture) that was in the 7 cubic feet of atmospheric air is now compressed into 1 cubic feet of compressed air.



There are 3 forms of water in compressed air:

Liquid water

Aerosol (mist)

Vapor (gas)

Any of these forms of moisture can create problems down the road in equipment or may create serious problems in your process or end product today.



Ask a Question:

How to tell if you need a Refrigerated Air Dryer?



Answer:

If you are experiencing the following problems...then you may need a Refrigerated Compressed Air Dryer:

Liquid water is in your air lines and hoses

Water vapor sprays out of your tool exhaust

Pipe lines corrode and rust

Paint Sprayer has water spots in the paint

Your Equipment Manufacturer specifies "DRY AIR"



Ask a Question:

What can help remove moisture from my Compressed Air System?



Answer:

Refrigerated Air Dryers can be one of the best solutions to removing water and moisture from youCompressed Air System.



Ask a Question:

How does a Refrigerated Air Dryer Work?



Answer:

• The refrigerated air dryer cools the incoming compressed air first in an air-to-air heat exchanger where the outgoing cool dry air pre-cools the hot incoming air and condenses some moisture out.



• Then the incoming air enters an air-to-refrigerant heat exchanger where the air is cooled to 38º F by the liquid refrigerant. This process causes the moisture to condense into liquid water and it is drained away. The out going air then enters the air-to-air heat exchanger and is warmed up to keep the outside of pipes from sweating.



• The refrigeration compressor pumps hot hi-pressure gas refrigerant (Freon) into the condenser which transfers the heat from the refrigerant gas to the ambient air as the gas condenses into a liquid.



• The liquid refrigerant (Freon) is then metered to a cold low pressure where it enters the air-to-refrigerant heat exchanger and the heat from the hot compressed air is adsorbed into the cold refrigerant (Freon). The refrigeration compressor then sucks low pressure hot gas refrigerant (Freon) into the refrigeration compressor and the cycle starts over again.



BOTTOM LINE:

If you are experiencing unwanted moisture and water in your Compressed Air System, then seriously consider the addition of a Refrigerated Air Dryer. After all - what is the best way to spend your money --on constant maintenance, failed equipment and ruined end products or by investing in a properly sized compressed air dryer?



Experience proves it! Remove Water and Moisture to improve Compressed Air Quality & Efficiency!



Increase Production - less down time due to moisture related equipment problems

Reduce loss due to inferior products ruined by moisture in lines

Bring more profit to your bottom line


Learn More about Refrigerated Air Dryers www.airdryers.biz


1-888-229-9999

Owned & Operated by

Tommy McGuire

McGuire Air Compressors, Inc.

“Real People with Real Air Compressor Experience”

P.O. Box 1100

Graham NC 27253


Learn more about Industrial Air Compressors www.industrialaircompressors.biz


For Geunine Reelcraft Hose Reels: www.hosereels.biz

Air Hose Leaks and Air Hose Saftey

Compressed Air ANSWERS & TIPS are
Important Information to pass on to those who work with
Your company’s compressed air systems & related equipment

How Air Hose Reels can save you time and money and increase satefy.
Plus - tips to prevent losing up to 30% of your compressed air because of
AIR LEAKS.


Ask a Question:
What does OSHA say about hose safety?

Answer: An OSHA guideline publication states:
“Hoses, cables, and other equipment shall be kept clear of passageways, ladders and stairs.”


OSHA says reduce your slips, trips and falls.
Slips, trips and falls constitute the majority of general industry accidents, which cause 15% of all accidental deaths, and are second only to motor vehicles as a cause of fatalities. The OSHA standard for walking and working surfaces apply to all permanent places of employment, except where only domestic, mining, or agricultural work is performed. www.osha.gov

Consider adding reels to increase safety & efficiency with your electrical cords, welding cables, air hose, oil, grease, liquid/water or fuel hoses.

Ask a Question:
Why should my plant use Air Hose Reels with our air tools?

Answer: If your business or plant has multiple air hoses running from your air compressor to a variety of air tools, then industrial air hose reels can be one of your most effective equipment additions you’ll ever make…as well as one of the safest!


Here’s 5 Reasons to use Air Hose Reels:
1. Efficiency
Hose reels make all your hose handling more efficient. An organized, clean workplace is proven to be more efficient.
2. Safety
Hose reels decrease you chances of injuries from tripping hazards. Reduce accidents and insurance expense: Slips, trips and falls are the leading cause of work stoppage in industry.
3. Protects Equipment
Hoses (and cords) last five times longer when stored on a reel. This can save you from replacing hoses as often.
4. Stops Leakages
Hoses on reels can reduce the threat of expensive air leakages.
5. Increase Productivity
Locating your air hoses when and where you need them increases productivity. All these factors help improve your work environment, which saves you time, equipment and money.

For more about Hose Reels visit www.hosereels.biz



Have you ever wondered what that hissing sound is when you walk through your plant or shop area? Most likely it’s a COMPRESSED AIR LEAK.

But what about the air leaks you can’t hear? Size cannot be judged by sound.

Do You know how much your AIR LEAKS are costing you?

A Department of Energy publications states:
“Compressed air leaks can account for 20% to 30% of compressors cfm output in small to medium size plants.”

In other words- you could be losing up to 30% of your compressed air because of AIR LEAKS! That’s your money leaking away! It is worth the effort to find and fix your air leaks.

Ask a Question:
How do you estimate the SIZE and COST of an AIR LEAK?

Answer:
Here’s how to estimate the size of air leaks:
It’s not very hard. We’ll use the “TIME METHOD” to estimate percentages of loss due to air leaks in your plant.
1.Turn OFF all air operated end-user equipment.
2.Start your air compressor and let it cycle 5 times.
3.Time the OFF-LINE/UNLOAD TIME
(not pumping time) using your watch. (Example: 5 minutes)
4.Time the ON-LINE/LOAD TIME
(pumping time) using your watch. (Example: 2 minutes)
5.Calculate total percentage of air leaks
as follows: Add the OFF / UNLOAD and the
ON / LOAD times together:
Example: T(5 minutes) + T (2 minutes)= 7 minutes
Divide ON / LOAD time T (2 minutes) by the total minutes: 2 ÷ 7 = 0.29

The result tells you 29% of your air compressor’s CFM’s are doing nothing but maintaining your AIR LEAKS.

How to figure the cost of air leaks:
Based on values from the Compressed Air & Gas Handbook, we can assume
4* CFM per air compressor horsepower. So, if you have a 100 HP compressor and the above determined 29% air leaks -use this formula:
100 HP x 4*=400 CFM x 29% (.29 air leak loss) = 116 wasted CFM.
As the chart below shows, you now know that you are
losing over $13,000 a year because of AIR LEAKS.

SIZE OF YOUR LEAK--CFM AIR LOSS--WASTED DOLLARS @YEAR
Orifice Diameter Inches
1/32 ------------------1.6 -------------- $211.70
3/32 -----------------14.5 --------------$1905.30
1/4 -----------------104.0 -------------$13665.60
1/2 -----------------415.0 -------------$54531.00

*These figures are based on values from the Compressed Air & Gas Institute Handbook. Calculations assume a conservative cost of $.25 /1000 cubic feet of compressed air, 100% coefficient of flow and working 8,760 hours/year at 100 psig.


Owned & Operated by
Tommy McGuire
McGuire Air Compressors, Inc.
“Real People with Real Air Compressor Experience”

For Champion Air Compressors...
http://www.industrialaircompressors.biz/

For Reelcraft Hose Reels for Air, Water, Oil & fluid
plus Electric Cord Reels & Welding Cable Reels...
http://www.hosereels.biz/

For Arrow Refrigerated Air Dryers...
http://www.airdryers.biz

Email us:
compressors@mcguire.biz

Call us:
1-888-229-9999

Fax us:
1-336-229-9998

Mailing address:
McGuire Air Compressors,Inc.
P.O. Box 1100
Graham NC 27253

Air Compressor Trouble Shooting Tips

Ask a Question:
What are some good trouble shooting tips to help me maintain my compressed air system?

Answer:
Here are some great Air Compressor Trouble Shooting Tips to help you or anyone providing the regular maintenance for your compressed air system.
Below are listed several very common problems, their probable cause and some usual remedies for the trouble.
Of course, there can be multiple problems and unique circumstances to every compressor issue...but these tend to solve the most common situations.

PROBLEM:
Low pressure at point of use

Probable Cause: Remedial Action
Leaks in distribution piping: Check lines, connections and valves for leaks
Clogged filter elements: Clean or replace filter elements
Fouled dryer heat exchanger: Clean heat exchangerLow pressure at compressor discharge: See below


PROBLEM:
Low pressure at compressor discharge

Probable Cause: Remedial Action
For systems with modulating load controls, improper adjustment of air capacity system:
Follow manufacturer's recommendation for adjustment of air capacity system

Worn or broken valves Improper air pressure switch setting: Check valves and repair or replace as required
Follow manufacturer's recommendations for setting air pressure switch

Improper air pressure switch setting: Follow manufacturer's recommendations for setting air pressure switch


PROBLEM:
Water in lines

Probable Cause: Remedial Action
Failed condensate traps: Clean, repair, or replace the trap
Failed or undersized compressed air dryer: Repair or replace dryer. If you do not have an Compressed Air Dryer, consider adding this equipment.


PROBLEM:
Liquid oil in air lines

Probable Cause: Remedial Action
Faulty air/oil separation: Check air/oil separation system; change separator element
Compressor oil level too high: Follow manufacturer's recommendation for proper oil level


PROBLEM:
Dirt, rust or scale in air lines

Probable Cause: Remedial Action
In the absence of liquid water, normal aging of the air lines: Install filters at point of use


PROBLEM:
Excessive service to load/hour ratio

Probable Cause: Remedial Action
System idling too much:
For multiple compressor system: consider sequencing controls to minimize compressor idle time
Adjust idle time according to manufacturer's recommendations

Improper pressure switch setting: Readjust according to manufacturer's recommendations


PROBLEM:
Elevated compressor temperature

Probable Cause: Remedial Action
Restricted air flow: Clean cooler exterior and check inlet filter mats


PROBLEM:
Restricted water flow

Remedial Action:
Check water flow, pressure, and quality; clean heat exchanger as needed


PROBLEM:
Low oil level

Remedial Action:
Check compressor oil level, add oil as required


PROBLEM:
Restricted oil flow

Remedial Action:
Remove restriction, replace parts as required


PROBLEM:
Excessive ambient temperature

Remedial Action:
Improper ventilation to compressor; check with manufacturer to determine maximum operating temperature


Owned & Operated by
Tommy McGuire
McGuire Air Compressors, Inc.
“Real People with Real Air Compressor Experience”

For Champion Air Compressors...
http://www.industrialaircompressors.biz/

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
http://www.hosereels.biz/

For Arrow Refrigerated Air Dryers
to remove moisture from your compressed air system...
http://www.airdryers.biz/

Email us: compressors@mcguire.biz
Call us:1-888-229-9999
Fax us:1-336-229-9998
Mailing address:
McGuire Air Compressors,Inc.
P.O. Box 1100
Graham NC 27253

Are you wasting compressed air?

Potentially Inappropriate Uses of Compressed Air

Compressed air is clean, readily available, and simple to use.As a result, compressed air is often chosen for applications forwhich other energy sources are more economical. Inappropriate uses of compressed air include anyapplication that can be done more effectively or more efficiently by a method other than compressed air.

Don't WASTE your Compressed Air.
Check your facility for wasteful and perhaps even un-safe uses of compressed air.

Examples of potentially inappropriate uses of compressed air include:
• Open blowing
• Sparging
• Aspirating
• Atomizing
• Padding
• Dilute-phase transport
• Dense-phase transport
• Vacuum generation
• Personnel cooling
• Open hand-held blowguns or lances
• Diaphragm pumps
• Cabinet cooling
• Vacuum venturis.

Here's an explaination of each potentially inappropriate use and a suggested alternative:


Open Blowing

Open blowing is using compressed air applied with an open, unregulated tube, hose, or pipe for one of these applications:
• Cooling
• Bearing cooling
• Drying
• Clean-up
• Draining compressed air lines
• Clearing jams on conveyors.

The alternatives to open blowing are vast.

Some are:
• Brushes
• Brooms
• Dust collection systems
• Non-air-loss auto drains
• Blowers
• Blowers with knives
• Electric fans
• Electric barrel pumps
• Mixers
• Nozzles.

Sparging

Sparging is aerating, agitating, oxygenating, orpercolating liquid with compressed air. This is a particularly inappropriate application because liquid can be wicked into a dry gas, increasing the dew point.The lower the dew point of the compressed air, the more severe the wicking effect. This can occur with oil, caustics, water rinse materials, etc.
Alternatives to sparging include low-pressure blowers and mixers.

Aspirating
Aspirating is using compressed air to induce the flow of another gas with compressed air such as flue gas.
An alternative is a low-pressure blower.

Atomizing
Atomizing is the use of compressed air to disperseor deliver a liquid to a process as an aerosol. Anexample is atomizing fuel into a boiler. Fluctuating pressure can affect combustion efficiency.
An alternative is a low-pressure blower.

Padding
Padding is using compressed air to transport liquids and light solids. Air is dispensed over the material to be moved. The expansion of the air moves the material. The material is usually only moved short distances. An example is unloading tanks or tank cars. Molecular diffusion and wicking are typical problems with padding.
An alternative is low to medium pressure blowers.

Dilute-Phase Transport
Dilute-phase transport is used in transporting solids, such as powdery material, in a diluted format with compressed air. Molecular diffusion and wicking are typical problems with dilute phase transport.
An alternative is a low- or high-pressure blower or a low pressure air compressor designed for 35 psig. The pressure required depends upon the moisture content and size of the material being transported.

Dense-Phase Transport
Dense-phase transport is used to transport solids in a batch format. This usually involves weighing a batch in a transport vessel, padding the vessel with compressed air, forcing the batch into a transport line, and moving it in an initial plug with a boost o fcompressed air at the beginning of the transport pipe.Once the material is moving in a plug, the operation may fluidize the material in a semi-dense or moderate dilute-phase using fluidizers or booster nozzles along the transport path. The material is typically transported to a holding vessel that dispenses it on an as-needed basis using pad air from the secondary transport vessel to move it to the use location. A typical application would be the dense-phase transport of carbon black.

There are typically four compressed air elements to the transport. These elements are control air for the equipment, pad air for the initial transporter, transport air to move it in the piping, and fluidizers or booster nozzles along the transport piping. Most dense-phase manufacturers specify 80 to 90 psig with one singlel ine supporting the entire process. The control air and booster nozzles typically use pressures in the 60 to70 psig range. The actual article psig required for the pad air and the transport air is typically 30 to 45 psig. Because of the lack of storage in most of these applications and the high-volume, short-cycle transport times, the original equipment manufacturers request 80 to 90 psig and use the entire supply system as the storage tank. As this usually has a negative impact onthe plant air system, separate compressors, filters, and dryers are applied to this process at the elevated pressure.

Alternatives include supporting the control air,pad air, and boosters with regulated plant air plusmetered storage, and using a two-stage, positivedisplacementblower (28 psig) or single-stage compressor(40 to 50 psig) for the transport air. Another alternativeis to use metered storage for both the pad air andtransport cycle. This necessitates providing the entirer equirement from storage and metered recovery percycle, with a metering adjustment to refill the vessel just before the next transport cycle. The storage should be sized to displace the required air first for the padand then for the transport cycles within an allowable pressure drop to terminate the transport cycle pressureat the required article pressure. This will flatten the volumetric load on the system, eliminate any impacton other users, and reduce the peak energy required to support the process.

Vacuum Generation
The term vacuum generation describes applications where compressed air is used in conjunction with aventuri, eductor, or ejector to generate a negative pressuremass flow. Typical applications are hold-downs or 55-gallon, drum-mounted, compressed air vacuum cleaners. This is by far the most inefficient applicationin industry with less than 4 percent total efficiency, although for very intermittent use (less than 30 percentload factor), compressed air can be a reasonably efficient solution.
An alternative is a vacuum pump. If a compressed-air-generated vacuum is required, install a solenoid valve on the compressed air supply line to shut this application off when it is not needed. Vacuum generators are used throughout industry.

Some applications for vacuum generators include:
• Shop vacuums
• Drum pumps
• Palletizers
• Depalletizers
• Box makers
• Packaging equipment
• Automatic die-cutting equipment.

Vacuum generators are selected for safety, ease of installation, physical size of the generator, the fact that no electricity is required at the point-of-use, and low first cost. Vacuum generators are usually less economical to operate than central vacuum systems.

As a rule, in a base load situation, if the vacuum generator is operating less than 30 percent of the time,it will be more economical to operate than a central vacuum system. Otherwise, vacuum generators are, in general, less effective at pulling a vacuum and cost as much as five times more to operate than a dedicated vacuum pump. Using vacuum generators for shop vacuums and drum pumps, which are typically peak load applications, could cause another compressor to turn on and stay on until it times out. Having to operate a second compressor because of the added demand associated with a vacuum generator eliminates any apparent savings associated with a vacuum generator, even if it operates only once a day for a short period of time.

A dedicated vacuum pump, or the use of central vacuum system will provide more suction force at a fraction of the cost of vacuum produced by compressed air. In this case, it is significantly more cost effective to provide a system that is designed into the machine from the beginning than to retrofit a piece of equipment.This can be accomplished by being proactive at the time the machine specifications are prepared and the purchase orders issued. Vacuum generators must be applied properly and only after taking life cyclecosts into consideration.

Vacuum venturis are a common form for vacuum generation with compressed air systems. In a venturi system, compressed air is forced through a conical nozzle. Its velocity increases and a decrease in pressure occurs. This principle, discovered by 18th century physicist G. B. Venturi, can be used to generate vacuum without a single moving part.

Multi-stage venturi devices provide a more efficient ratio of vacuum flow to compressed airconsumed than single-stage venturi devices. Where vacuum requirements vary significantly, or are cyclical with a duty cycle of less than 30 percent, multi-stage,venturi-type vacuum generators with pressure regulators and automatic shut-off controls on the compressed air supply may be more efficient than continuously operating mechanical-vacuum pump systems. These devices also can be equipped with a vacuum switch that signals a solenoid valve to shut off the air supply when a set vacuum level is attained, thus reducing air consumption in non-porous applications. They may also be suitable where it is impractical to have a central vacuum system, particularly where the uses may not be confined to one area.

Personnel Cooling
Personnel cooling is when operators direct compressed air onto themselves for ventilation. This is dangerous because it can shoot particulates into the skin. A 1/4-inch tube blowing air on an operator can consume 15 to 25 brake horsepower (bhp) of compressed air.
An alternative is fractional horsepower fans of 1/4 bhp or less.

Open Hand-Held Blowguns or Lances
Unregulated hand-held blowing is not only a violation of most health and safety codes, but is also very dangerous. Hand-held blowguns that conform to all occupational health and safety standards should be used.

There are different styles of blowguns that candeliver various airflows, velocities, and concentrations.The proper gun must be selected for each application. Pipes installed in the end of hose and unregulated non-approved guns must not be used. Blowguns must have no more than 30 psig discharge nozzle pressure.The nozzle should be constructed to relieve back pressure if the nozzle is plugged or blocked. The blowgun must also have a spring-operated throttle mechanism so it shuts off automatically if it is dropped.

Diaphragm Pumps
A common error is to not size diaphragm pumpsf or the maximum viscosity, highest pressure, and highest volume required. The result is poor performance and an increased supply pressure requirement.
Diaphragm pumps are commonly found installed without regulators and speed control valves. Those diaphragm pumps that are installed with regulators are found with the regulators adjusted higher than necessary. This is often because of undersized regulators and supply piping or hose. The higher-than-necessary setting of the regulator increases the demand on the compressed air system and increases operating costs.With a higher pressure setting, the amount of compressed air admitted into the diaphragm chamber is increased above that which is actually required tomove the product. The amount of product actually transferred remains the same, but the amount of air used increases with the increased pressure.

The regulator should be adjusted to equal the maximum head that the pump is required to provide.A flow control valve installed up stream of the regulato rwill accomplish the required speed control. Operating the diaphragm pump without speed control increases the rate of compressed air consumption by increasing the strokes per minute of the diaphragm pump. The speed control should be adjusted to pump product in the maximum allowable time. As a general rule, the regulator and flow control valve are not included with the standard pump package. Also, when the pump has no liquid or slurry to pump, it will rapid cycle, wearing out the diaphragm and wasting air. The pump controls must be configured to turn the pump off when there is nothing to pump.

Cabinet Cooling
Cabinet cooling should not be confused with panel purging. The following are typical applications where cabinet cooling is found.
• Programmable controllers
• Line control cabinets
• Motor control centers
• Relay panels
• Numerical control systems
• Modular control centers
• Computer cabinets.

When first cost is the driving factor, open tubes, air bars (copper tube with holes drilled long the lengthof the tube) and vortex tube coolers are often used to cool cabinets. When life-cycle costs are taken into consideration, these choices prove to be expensive. It is not uncommon to find an open tube or air bar consuming 7-1/2 horsepower (hp) of compressed air to cool a cabinet. Vortex tube coolers can be an improvement over open tubes and air bars because they areoften cycled with a thermostat control, which reduces air consumption. However, air to air, air to water and refrigerated cabinet coolers are available that only use1/3 hp to accomplish the same task.

Other Potentially Inappropriate Uses
Other improper uses of compressed air are unregulated end uses and those that supply air to abandoned equipment, both of which are described below.

Unregulated End Uses
A pressure regulator is used to limit maximum end use pressure and is placed in the distribution system just prior to the end use. If an end use operates without a regulator, it uses full system pressure. This results in increased system air demand and energy use, since the end use is using air at this higher pressure. High pressure levels can also increase equipment wear, resulting in higher maintenance costs and shorter end use equipment life.

Abandoned Equipment
Many plants undergo numerous equipment configuration changes over time. In some cases, plant equipment is no longer used. Air flow to this unused equipment should be stopped, preferably as far back inthe distribution system as possible without affecting operating equipment.

Using Compressed Air
As a general rule, compressed air should only be used if safety enhancements, significant productivity gains, or labor reductions will result. If compressed air is used for an application, the amount of air used should be the minimum necessary - quantity and pressure and should be used for the shortest possible duration.

Compressed air use should also be constantly monitored and re-evaluated.

www.IndustrialAirCompressors.biz
Owned and Operated by
Tommy McGuireMcGuire Air Compressors, Inc.
“Real People with Real Air Compressor Experience”
Email: compressors@mcguire.biz
1-888-229-9999

How to Minimize Pressure Drops in your Compressed Air System

Ask a Question:
What causes pressure drop in my compressed air system?

Answer:
Any type of obstruction, restriction, or roughness in the system will cause resistance to air flow and cause pressure drop.

In the distribution system, the highest pressure drops usually are found at the points-of-use, including undersized or leaking hoses, tubes, disconnects, filters, regulators and lubricators (FRLs).

On the supply side of the system, air/lubricant separators, aftercoolers, moisture separators, dryers and filters can be the main items causing significant pressure drops. The maximum pressure drop from the supply side to the points-of-use will occur when the compressed air flow rate and temperature are highest.

Your Compressed Air System components should be selected based upon these conditions and the manufacturer of each component should be requested to supply pressure drop information under these conditions. When selecting filters, remember that they will get dirty. Dirt loading characteristics are also important selection criteria.

Large end users who purchase substantial quantities of components should work with their suppliers to ensure that products meet the desired specifications for differential pressure and other characteristics.

The distribution piping system often is diagnosed as having excess pressure drop because a point-of-use pressure regulator cannot sustain the required downstream pressure. If such a regulator is set at 85 psig and the regulator and/or the upstream filter has a pressure drop of 20 psi, the system upstream of the filter and regulator would have to maintain at least 105 psig. The 20 psi pressure drop may be blamed on the system piping rather than on the components at fault. The correct diagnosis requires pressure measurements at different points in the system to identify the component(s) causing the excess pressure drop. In this case, the filter element should be replaced or the filter regulator size needs to be increased, not the piping.

How to Minimize Pressure Drop
Minimizing pressure drop requires a “systems approach” in design and maintenance of the system. Air treatment components, such as aftercoolers, moisture separators, dryers, and filters, should be selected with the lowest possible pressure drop at specified maximum operating conditions. When installed, the recommended maintenance procedures should be followed and documented.

Additional ways to minimize pressure drop are as follows:
• Properly design the distribution system.
• Operate and maintain air filtering and drying equipment to reduce the effects of moisture, such as pipe corrosion.
• Select aftercoolers, separators, dryers and filters having the lowest possible pressure drop for the rated conditions.
• Reduce the distance the air travels through the distribution system.
• Specify pressure regulators, lubricators, hoses, and connections having the best performance characteristics at the lowest pressure differential. These components must be sized based upon the actual rate of flow and not the average rate of flow.

*SOURCE: Improving Compressed Air System Performance: A Sourcebook for Industry is a cooperative effort of the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) Best Practices and the Compressed Air Challenge®.

www.IndustrialAirCompressors.biz
Owned and Operated byTommy McGuire
McGuire Air Compressors, Inc.
“Real People with Real Air Compressor Experience”
Email: compressors@mcguire.biz
1-888-229-9999

NEED HOSE REELS?
For Hose Reels for water, air, grease, fuels & other fluids or electrical cord reels and welding cable reels...visit www.hosereels.biz

NEED TO REMOVE MOISTURE FROM YOUR COMPRESSED AIR SYSTEM?
Refrigerated Arrow Air Dryers can remove harmful moisture from your compressed air system.
For competitive prices and fast dependable delivery visit www.airdryers.biz

Tips to Prevent Pressure Drops in your Compressed Air System

Ask a Question:
What causes pressure drop in my compressed air system?

Answer:
Any type of obstruction, restriction, or roughness in the system will cause resistance to air flow and cause pressure drop.


In the distribution system, the highest pressure drops usually are found at the points-of-use, including undersized or leaking hoses, tubes, disconnects, filters, regulators and lubricators (FRLs).


On the supply side of the system, air/lubricant separators, aftercoolers, moisture separators, dryers and filters can be the main items causing significant pressure drops. The maximum pressure drop from the supply side to the points-of-use will occur when the compressed air flow rate and temperature are highest. Your Compressed Air System components should be selected based upon these conditions and the manufacturer of each component should be requested to supply pressure drop information under these conditions. When selecting filters, remember that they will get dirty. Dirt loading characteristics are also important selection criteria. Large end users who purchase substantial quantities of components should work with their suppliers to ensure that products meet the desired specifications for differential pressure and other characteristics.


The distribution piping system often is diagnosed as having excess pressure drop because a point-of-use pressure regulator cannot sustain the required downstream pressure. If such a regulator is set at 85 psig and the regulator and/or the upstream filter has a pressure drop of 20 psi, the system upstream of the filter and regulator would have to maintain at least 105 psig. The 20 psi pressure drop may be blamed on the system piping rather than on the components at fault. The correct diagnosis requires pressure measurements at different points in the system to identify the component(s) causing the excess pressure drop. In this case, the filter element should be replaced or the filter regulator size needs to be increased, not the piping.

How to Minimize Pressure Drop

Minimizing pressure drop requires a “systems approach” in design and maintenance of the system. Air treatment components, such as aftercoolers, moisture separators, dryers, and filters, should be selected with the lowest possible pressure drop at specified maximum operating conditions. When installed, the recommended maintenance procedures should be followed and documented.

Additional ways to minimize pressure drop are as follows:
• Properly design the distribution system.
• Operate and maintain air filtering and drying equipment to reduce the effects of moisture, such as pipe corrosion.
• Select aftercoolers, separators, dryers and filters having the lowest possible pressure drop for the rated conditions.
• Reduce the distance the air travels through the distribution system.
• Specify pressure regulators, lubricators, hoses, and connections having the best performance characteristics at the lowest pressure differential. These components must be sized based upon the actual rate of flow and not the average rate of flow.


*SOURCE: Improving Compressed Air System Performance: A Sourcebook for Industry is a cooperative effort of the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) Best Practices and the Compressed Air Challenge®.

How to determine your compressed air needs

Types of Compressed Air Quality Levels:

Plant Air
Air tools, general plant air

Instrument Air
Laboratories, paint spraying, powder coating, climate control

Process Air
Food and pharmaceutical process air, electronics

Breathing Air
Hospital air systems, diving tank refill stations, respirators for cleaning and/or grit blasting



Ask a Question:
How can I determine what my compressed air needs really are?

Answer:
Compressed air needs are defined by the air quality, quantity, and level of pressure required by the end uses in your plant. Analyzing your needs carefully will ensure that your compressed air system is properly configured.

Air Quality
Compressed air quality ranges from plant air to breathing air.
Industrial applications typically use one of the first three air quality levels. (listed to the left)

Quality is determined by the dryness and contaminant level required by the end uses, and is accomplished with filtering and drying equipment. The higher the quality, the more the air costs to produce. Higher quality air usually requires additional equipment such as compressed air dryers or filters that remove moisture, contaminates and oils.

One of the main factors in determining air quality is whether or not lubricant-free air (oil-free air) is required. Lubricant free air can be produced with either lubricant-free compressors, or with lubricant-injected compressors that have additional separation and filtration equipment.

Before your select a lubricant-free or lubricant-injected compressor, carefully consider the specific end use for the lubricant free air, including the risk and cost associated with product contamination.

Air Quantity—Capacity
Required compressed air system capacity can be determined by summing the requirements of the tools and process operations
(taking into account load factors) at your site.

NOTE: The total air requirement is not the sum of the maximum requirements for each tool and process, but the sum of the average air consumption of each.

High short-term demands should be met by air stored in an air receiver. Systems may need more than one air receiver. Strategically locating your air receivers near sources of high demand can be effective.

It often makes sense to use multiple, smaller compressors with sequencing controls to allow for efficient operation at times when demand is less than peak.

Load Profile
Another key to properly designing and operating a compressed air system is analyzing a plant’s compressed air requirements over time, or load profile.

The variation of demand for air over time is a major consideration in system design. Plants with wide variations in air demand need a system that operates efficiently under part-load. Multiple compressors with sequencing controls may provide more economical
operation in such a case. Plants with a flatter load profile can use simpler control strategies.


Artificial Demand
Artificial demand is defined as the excess volume of air that is required by unregulated end uses (ie: leaks, open blowing) as a result of supplying higher pressure than necessary for applications. Pressure/flow controllers can help to minimize artificial demand.


Pressure
Different tools and process operations require different pressures. Pneumatic tool manufacturers rate tools for specific pressures. Each process operation pressure requirements should be specified by the engineer(s) overseeing that process.

As you can see – a wide variety of elements affect your Compressed Air needs:
-Air Quality
-Air Quantity
-Air demands and specifications involving your tools, equipment and processes

When you consider all these areas, seek the help and information you need from proper sources, then you can achieve the efficient compressed air system you need.

*SOURCE: Improving Compressed Air System Performance: A Sourcebook for Industry is a cooperative effort of the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) Best Practices and the Compressed Air Challenge®.


www.IndustrialAirCompressors.biz

Email: compressors@mcguire.biz
Owned and Operated by
McGuire Air Compressors, Inc.
“Real People with Real Air Compressor Experience”
1-888-229-9999