Is it the valve or is it the cylinder whichever it s costing you a lot of money
Below is a MRR and PLR article in category Reference Education -> subcategory Other.
Is It the Valve or the Cylinder? Either Way, It’s Costing You Money
Reducing air leaks in your plant can save thousands of dollars annually. Compressed air is among the most expensive forms of energy, yet it’s also versatile, fast, and powerful.
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Save Costs by Reducing Air Leaks
One of the most significant ways to cut costs in your plant is by minimizing air leaks. Compressed air is expensive, so every bit wasted is money lost.
Detecting Air Leaks
During quieter times, walk around your machinery. Listen for the distinctive hissing of air escaping from the exhaust ports of your air valves. This sound represents dollars being lost as compressed air leaks into the atmosphere.
To help identify leaks, consider using ultrasonic compressed air leak detectors. If your plant doesn’t have a designated quiet period, investing in one of these devices can lead to significant energy savings.
Understanding Air Valve and Cylinder Function
Typically, an air valve connects to an air cylinder, often a double-acting one with two air lines. As the air valve shifts, it alternates air flow to the cylinder, pushing air out through one line or the other. When one line is supplying air to the cylinder, the other allows exhaust.
While machinery operates, air will continuously exhaust from the valve ports. However, when equipment is idle, any air escaping through valve ports indicates a problem, resulting in profit loss.
Common Problem Areas
Inside a cylinder, a piston separates the two ends. A seal around the piston prevents air from bypassing. Over time, this seal can wear, allowing air to bypass and escape, wasting energy.
Similarly, air valves contain seals that prevent air from moving from the supply side to the exhaust side. When these wear out, compressed air leaks, costing you money.
Identifying the Source of the Leak
To determine where the leak is, inspect the cylinder. If the rod is extended, air enters from the rear port. If retracted, air enters from the rod end.
Try this test:
1. Crimp the charged air line supplying the cylinder. Most air lines are flexible, making this task simple.
2. Listen at the valve. If the hissing stops, the cylinder’s seal is the issue.
3. If air continues to escape from the exhaust port, the valve's internal seal is likely the culprit.
Act Quickly
Whether the problem lies with the valve or the cylinder, address it promptly. Wasting compressed air is wasting money.
Reducing air leaks not only decreases operational costs but also improves efficiency. Keep your plant running smoothly and economically by addressing leaks swiftly.
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