"Newsletter Articles" Archive

By William J. Ulrich Adapted from Machine Design magazine

Like gas, electricity, and water, compressed air is a common utility in most industrial and process plants. Typically, pneumatics consumes 10 to 15% of a plant’s electrical energy, according to most experts. The big difference is that while the other utilities are purchased, compressed air must be generated in-house. This puts the burden on the user to ensure that the compressed air quality is suitable for plant operations.

Compressors produce high pressure air that is hot, wet, and dirty. In this state, it cannot be used. Just as untreated water is not potable and unregulated natural gas is a safety hazard, compressed air must be properly treated to make it fit for pneumatic equipment and processes.

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Troubleshooting refrigerated dryers
Think of your air compressor as a “rain-maker.” At 100 psig, a compressor takes eight volumes of air and compresses them into one. At 80 degree F inlet air temperature and 80% relative humidity, a 100 HP compressor will take in 100 gallons of water vapor per day.

The compressor’s aftercooler can remove 60-70% of the moisture, but beyond that the compressed air coming out of the machine is saturated and it goes into your air system as condensed water vapor. As the air cools from the hot discharge of the compressor, the ability of the air to hold water is reduced by 50% for every 20 degrre F degree drop in temperature. The air moves downstream and as it cools, the water continues to drop out. This can add up to a lot of water.

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Here is a thermal image before / after shot of K21 and K23 starter contactors. Please note… amp draw was fine. Thermal Image uncovered a problem with L2 at 158F and 175F. Further inspection of the contactors showed contacts inside the starter were severely burnt. Thanks to the thermal camera this problem was taken care of before a more serious issue took place (Fire, burnt up wiring, burnt up unit due to contactors welding closed… preventing shutdown of unit, etc.). A big difference in temps with new contactors!

If you need help getting to the true root cause of your compressed air equipment failures please call 866-468-9814.

Lompoc, Calif.—It’s not where anyone would expect to find a research lab—a small hillside ranch and vineyard at the end of a half-paved road in the northern, rural part of California’s Santa Barbara County. Even if you get through the front gate, it’s easy to drive right past where all the mad science is going on. After all, it’s just a pole barn, and, from the outside, it looks overstuffed with enough hay to feed the ranch’s five horses for a year. But behind that hay is where Derek McLeish, with occasional help from his three brothers, has built and continues to develop the world’s fastest car powered by compressed air.

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MotorAuthority.com

While major auto manufacturers race to bring new electric and hybrid cars to market, other companies are looking at alternatives to electricity – including using air to power cars. The idea of an air-powered car is nothing new, and companies have been touting the technology for the past few years but for now not much has emerged in the way of a production model, largely due to flaws with the design of the vehicles.

To read the entire article click here.

Here is a thermal image before / after shot of K21 and K23 starter contactors. Please note… amp draw was fine. Thermal Image uncovered a problem with L2 at 158F and 175F. Further inspection of the contactors showed contacts inside the starter were severely burnt. Thanks to the thermal camera this problem was taken care of before a more serious issue took place (Fire, burnt up wiring, burnt up unit due to contactors welding closed… preventing shutdown of unit, etc.). A big difference in temps with new contactors!

If you need help getting to the true root cause of your compressed air equipment failures please call 866-468-9814.

Air End rebuilding, when done before a catastrophic failure, can be an economical way to extend the life of your oil flooded rotary compressor. The 3 key questions always asked when it comes to air end “expected” life and rebuilding are:

1. “When do I know that my air end needs to be rebuilt?”
2. “How do I prevent a catastrophic failure?”
3. “How much does an air end rebuild cost?” Read More…

My Efficient Plant

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. Read More…

By Compressed Air Best Practices

A four thousand, five hundred and fifty pound (4550 lbs.) race car is running at 170 mph and facing wind resistance of 150 mph. The car then enters a curve creating a three-degree “yaw” (the change in angle from the direction the car is headed and the airstream). The car struggles to maintain speed as the yaw changes and the dynamic downforce load on the car changes. Suddenly, the driver-less car comes to a stop on the stainless-steel track. The rolling-road track is supported by a cushion of compressed air.

To read the entire article click here.