If you are looking for a way to save money and make your blow off applications safer, look no further than EXAIR’s Engineered Air Nozzles & Jets. By upgrading your blowoff, cooling, and drying operations to use one of our Super Air Nozzles or Jets you can save as much as 80% of your compressed air usage when compared with an inefficient solution. Plus you can remove open ended pipes and other unsafe blow offs that OSHA will fine you for.
An open copper pipe or tube, even if “flattened” as we commonly see, wastes an excessive amount of compressed air. This wasted compressed air can create problems in the facility due to unnecessarily high energy costs, maintaining system pressure that can affect other processes and excessive noise exposure for personnel. An open pipe or tube will often produce sound levels in excess of 100 dBA. At these sound levels, according to OSHA, permanent hearing damage will occur in just 2 hours of exposure.
By simply replacing the open tubes and pipe with an EXAIR Super Air Nozzle, you can quickly reduce air consumption AND reduce the sound level. Sound level isn’t the only thing an OSHA inspector is going to be concerned about regarding an open pipe blowoff, in addition OSHA 1910.242(b) states that a compressed air nozzle used for blowoff or cleaning purposes cannot be dead-ended when using with pressures in excess of 30 psig. I don’t know if you’ve ever tried to use an air gun with 30 psig fed to it, but the effectiveness of it is dramatically reduced. This is why there needs to be a device installed that’ll prevent it from being dead-ended so that you can operate at a higher pressure.
EXAIR’s Super Air Nozzles are designed for maximum performance and safety. The engineered features keep EXAIR nozzles running quietly, and cannot be dead-ended. Using an OSHA compliant compressed air nozzle for all points where a blowoff operation is being performed should be a priority. Each individual OSHA infraction will result in a fine if you’re surprised with an OSHA inspection. Inspections are typically unannounced, so it’s important to take a look around your shop and make sure you’re using approved products.
You’ll find all of the tools you need in the EXAIR catalog. Click here if you’d like a hard copy sent directly to you! Or, get in touch with us today to find out how you can get saving with an Intelligent Compressed Air Product.
A metal fabricator made stainless steel tubes with a ½” (13mm) inner diameter. Their process started by cutting the tubes into 8” (203mm) lengths. The tubes would go through a wash system, then to a honing machine. Once the inner diameter was honed to the specific diameter and concentricity, the tubes would be washed again for packaging. The honing machine used oil to accurately grind the inner diameter. Since oil and water does not mix, they had to dry the I.D. before honing. They contacted EXAIR to see if we could find a solution.
For cleaning the I.D. of parts, EXAIR manufactures three different sizes of Back Blow Air Nozzles that are designed to clean inside tubing, pipes, hoses, and channels. They can range from internal diameters from ¼” (6.3mm) up to 16” (406mm). The 360o rear airflow pattern can “wipe” the entire internal surface without contacting the surface to remove water, coolant, chips, and debris. In reviewing the inner diameter above, I was able to recommend a model 1004SS Back Blow Air Nozzle. This 316SS robust designed nozzle can fit inside and clean tubes with internal dimensions ranging from ¼” (6.3mm) to 1” (25mm); perfect for the ½” (13mm) diameter tube.
The customer indicated to me that there was a rush to start this project. EXAIR stocks thousands of cataloged items for same day shipping. He asked if EXAIR had any other components to help them to expedite their drying process. Well, of course we do! Since the tube was 8” (203mm) long, EXAIR has extension tubes that are used with our VariBlast Compact Back Blow Safety Air Gun. We have them ranging from 6” (152mm) to 72” (1829mm) in incremental lengths. For this customer, I recommended the 12” (305mm) extension to reach through the tube. And, since it was a manual operation, I also recommended the model 9040 Foot Valve.
Their operator could place the tube over the model 1004SS Back Blow Nozzle and with the Foot Valve, turn on the compressed air to dry the tubes. With the powerful air stream, the entire internal surface was dry for the honing process to follow.
If you need to clean the inside of tubes, hoses, pipes, etc., EXAIR has the perfect nozzles for you, the Back Blow Air Nozzles. EXAIR can attach these nozzles to our VariBlast Compact, Soft Grip and Heavy Duty Safety Air Guns for easy-to-use operations. For this customer above, they were able to use components to get the operation running the next day. If you need more information, you can share your application with an Application Engineer at EXAIR. We will be happy to help.
I received an email from an engineer that was looking at our Super Air Nozzles. They currently were using four blow-off lines that were made from 6mm ID copper tubes. The system was designed to blow out holes after machining. The engineer was in charge of the task of optimizing 25 machining stations similar to this one. He was familiar with EXAIR products from his previous employment, and he recognized the waste of compressed air by using open pipe. He purchased four Nano Super Air Nozzle, model 1110SS, for a trial. He was impressed with the performance, the low sound level, and the engineered design in safety. But, for upper management in his company, he had to show a cost savings in order to change all the stations in the facility. He asked me to help him in calculating the compressed air savings.
He gave me some additional details about their application. He was using the compressed air about 30% of the time throughout an 8 hour day at a pressure of 80 PISG. He wanted to present the savings per day, week, and year as well as the payback period in his evaluation. I have performed many of these calculations for other customers and was happy to help. It is sometimes easier to speak in terms of savings, as everyone can relate to money, especially management.
Flow: 1110SS Nano Super Air Nozzle – 8.3 SCFM at 80 PSIG
The Calculator tells us you will see a ROI (Return on investment) is less than 5 days! And will save you $3,033.00 over a full year on compressed air generation cost alone!
Don’t be fooled by the initial cost of a tube, pipe, drilled holes, or a substandard nozzle. You can see by the facts above, if you use any additional compressed air in your blow-off application, it will cost you a lot of money in the long run. If you need any help in calculating how much money EXAIR products can save you, you can use our Air Savings Calculator from our website, or you contact an Application Engineer at EXAIR. We will be happy to help you.
Whenever there is a discussion about fluid dynamics, Bernoulli’s equation generally comes up. This equation is unique as it relates flow energy with kinetic energy and potential energy. The formula was mainly linked to non-compressible fluids, but under certain conditions, it can be significant for gas flows as well. My colleague, Tyler Daniel, wrote a blog about the life of Daniel Bernoulli (you can read it HERE). I would like to discuss how he developed the Bernoulli’s equation and how EXAIR uses it to maximize efficiency within your compressed air system.
In 1723, at the age of 23, Daniel moved to Venice, Italy to learn medicine. But, in his heart, he was devoted to mathematics. He started to do some experiments with fluid mechanics where he would measure water flow out of a tank. In his trials, he noticed that when the height of the water in the tank was higher, the water would flow out faster. This relationship between pressure as compared to flow and velocity came to be known as Bernoulli’s principle. “In fluid dynamics, Bernoulli’s principle states that an increase in the speed of fluid occurs simultaneously with a decrease in static pressure or a decrease in the fluids potential energy”1. Thus, the beginning of Bernoulli’s equation.
Bernoulli realized that the sum of kinetic energy, potential energy, and flow energy is a constant during steady flow. He wrote the equation like this:
Not to get too technical, but you can see the relationship between the velocity squared and the pressure from the equation above. Being that this relationship is a constant along the streamline; when the velocity increases; the pressure has to come down. An example of this is an airplane wing. When the air velocity increases over the top of the wing, the pressure becomes less. Thus, lift is created and the airplane flies.
With equations, there may be limitations. For Bernoulli’s equation, we have to keep in mind that it was initially developed for liquids. And in fluid dynamics, gas like air is also considered to be a fluid. So, if compressed air is within these guidelines, we can relate to the Bernoulli’s principle.
Steady Flow: Since the values are measured along a streamline, we have to make sure that the flow is steady. Reynold’s number is a value to decide laminar and turbulent flow. Laminar flows give smooth velocity lines to make measurements.
Negligible viscous effects: As fluid moves through tubes and pipes, the walls will have friction or a resistance to flow. The surface finish has to be smooth enough; so that, the viscous effects is very small.
No Shafts or blades: Things like fan blades, pumps, and turbines will add energy to the fluid. This will cause turbulent flows and disruptions along the velocity streamline. In order to measure energy points for Bernoulli’s equation, it has to be distant from the machine.
Compressible Flows: With non-compressible fluids, the density is constant. With compressed air, the density changes with pressure and temperature. But, as long as the velocity is below Mach 0.3, the density difference is relatively low and can be used.
Heat Transfer: The ideal gas law shows that temperature will affect the gas density. Since the temperature is measured in absolute conditions, a significant temperature change in heat or cold will be needed to affect the density.
Flow along a streamline: Things like rotational flows or vortices as seen inside Vortex Tubes create an issue in finding an area of measurement within a particle stream of fluid.
Since we know the criteria to apply Bernoulli’s equation with compressed air, let’s look at an EXAIR Super Air Knife. Blowing compressed air to cool, clean, and dry, EXAIR can do it very efficiently as we use the Bernoulli’s principle to entrain the surrounding air. Following the guidelines above, the Super Air Knife has laminar flow, no viscous effects, no blades or shafts, velocities below Mach 0.3, and linear flow streams. Remember from the equation above, as the velocity increases, the pressure has to decrease. Since high-velocity air exits the opening of a Super Air Knife, a low-pressure area will be created at the exit. We engineer the Super Air Knife to maximize this phenomenon to give an amplification ratio of 40:1. So, for every 1 part of compressed air, the Super Air Knife will bring into the air streamline 40 parts of ambient “free” air. This makes the Super Air Knife one of the most efficient blowing devices on the market. What does that mean for you? It will save you much money by using less compressed air in your pneumatic application.
We use this same principle for other products like the Air Amplifiers, Air Nozzles, and Gen4 Static Eliminators. Daniel Bernoulli was able to find a relationship between velocities and pressures, and EXAIR was able to utilize this to create efficient, safe, and effective compressed air products. To find out how you can use this advantage to save compressed air in your processes, you can contact an Application Engineer at EXAIR. We will be happy to help you.