Sound Power vs Sound Pressure

Published on by Al WooffittLeave a comment

Noise levels or sound levels are an important consideration in many industrial settings. Noise exposure can cause irreparable damage if the necessary safety precautions are not taken. OSHA standard 29 CFR – 1910.95 (a) addresses this very concern.

But when discussing sound levels, there are two terms that frequently come up – Sound Power, and Sound Pressure. So, what’s the difference?

Sound Power (measured in watts) refers to the rate at which sound energy (measured in decibels) is emitted, reflected, transmitted, or received over time. On the other hand, sound pressure is the local pressure change from ambient atmospheric pressure caused by a sound wave. From these definitions, we can see that sound power is what creates the sound wave, while sound pressure is the result of what we perceive after the sound wave reaches our ears.

A good way of conceptualizing this is to imagine a light bulb. Light bulbs use electricity to produce light, which means the power needed (also measured in Watts) to make the bulb shine is similar to sound power. The brightness of the light produced (measured in lumens) corresponds to sound pressure. Sound pressure is essentially what we hear or refer to as sound. This is what gets measured because it can be harmful to our hearing. If the sound pressure is too high and the ear is exposed for too long, it can lead to permanent damage, hence OSHA’s regulation mentioned above. This regulation is the result of testing performed to determine what time thresholds at which permanent damage to human hearing will occur due to exposure over a period of time. The higher the sound pressure level, the less exposure time necessary to produce irreparable damage. Within this regulation is included a time weighted chart that OSHA follow for noise exposure issues that serve as the metric by which they determine if a company is in compliance. If not, they may recommend engineering changes, work process changes or require the use of PPE (hearing protection) if the other types of controls cannot be implemented.

If you would like a way to measure noise levels in your facility, EXAIR has the perfect product – EXAIR’s Digital Sound Level Meter. We have a video blog covering its benefits and operation here.

Generally speaking, compressed air-generated noise within a facility can be rather prevalent and loud. So, if you would like to discuss how EXAIR’s quiet and efficient compressed air products can help reduce noise levels in your facility, then give us a call!

Al Wooffitt
Application Engineer

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EXAIR Leads Industry in Standards Compliance

Published on by Tyler DanielLeave a comment

EXAIR prides itself in offering products with high-performance and peak efficiency. All EXAIR products are manufactured to meet the strict requirements of a variety of different standards, ensuring that you receive a reliable, high-quality product that WILL perform to the specifications we publish.

Safety is a top priority for most companies. EXAIR’s line of Intelligent Compressed Air Products meet or exceed the strict safety standards set forth by both OSHA and the European Union. EXAIR products comply with OSHA 29 CFR 1910.242(b), the standard implemented to ensure safe operation of compressed air blowoff devices, and the EU General Product Safety Directive (2001/95/EC).

 Additionally, they comply with the noise limitation requirements set forth under 29 CFR 1910.95(a) and the EU Machinery Directive (2006/42/EC). From the Optimization product line, EXAIR’s Electronic Flow Control and the Electronic Temperature Control meet the low voltage standards of EU Low Voltage Directive (2006/95/EC). A CE label is placed on all products that comply with applicable directives.

A more recent edition to the EXAIR line of Cabinet Coolers has been our UL HazLoc and ATEX lines for maintaining safe operating temperatures for control panels in hazardous areas or ATEX Zones. In these spaces, it’s critical to have a product that’s designed for safe operation to alleviate any risks for fire or explosion due to combustible materials or vapors that may be in the atmosphere.

In the assembly of electrical products there can be hazardous materials used during production. The Restriction of Hazardous Substances, also known as RoHS or (2002/95/EC), restricts the use of materials such as: lead (Pb), mercury (Hg), cadmium (Cd), hexavalent chromium (CrVI), polybrominated biphenyls (PBB), polybrominated diphenyl ethers (PBDE), and four different phthalates. The electrical portions of EXAIR’s Static Eliminators, Electronic Flow Control, Electronic Temperature Control, Digital Flowmeter, solenoid valves, and thermostats all comply with the amendment outlined in the European Commission decision L 214/65.

EXAIR is also committed to providing products that are conflict mineral free. In support of Section 1502 of the Dodd-Frank Wall Street Reform and Consumer Protection Act, EXAIR complies with the conflict minerals rule to curb illicit trade of tin, tantalum, tungsten and gold in the DRC region. Using the CMRT 4.20 template, we’re able to document our supply chain to ensure our materials are not being sourced from places that could finance conflict in the DRC and surrounding countries.

According to regulation (EC) No 1907/2006 Title I, Article 3, paragraph 3, the European Union enacted legislation requiring substances and chemicals imported into the EU to be registered to ensure a high level of protection for human health and the environment. Per Title II, Article 7, paragraph 1, articles must be registered when a substance is intended to be released during normal conditions of use that would exceed 1 metric ton per producer per year. Since EXAIR products do not contain substances that are intentionally released, registration is not required.

If you’re looking to maintain compliance in your industry, EXAIR products have you covered. If you have any questions about these standards of compliance feel free to reach out to us. Our team of Application Engineers have years of experience in industry and are waiting to take your call.

Tyler Daniel

Application Engineer

E-mail: TylerDaniel@EXAIR.com

X: @EXAIR_TD

Starting a Leak Prevention Program: Maximize Efficiency and Savings

Published on by Jordan T ShouseLeave a comment

Compressed air systems are the unsung heroes powering countless processes across all industries. However, they come with a hidden cost: leaks. Even the most well-maintained systems experience some level of leakage, often wasting 20-30% of a compressor’s output, according to the Compressed Air Challenge. This inefficiency translates directly into higher energy bills, increased compressor wear, and unnecessary maintenance expenses. The good news? You can take control of these losses by implementing a Leak Prevention Program. Let’s dive into how to establish such a program and why it’s a game-changer for your bottom line.

Compressed air isn’t cheap—it’s often one of the most significant energy expenses in a facility. When leaks go unchecked, you’re not just losing air; you’re losing money. A single leak can cost thousands of dollars annually, depending on its size and your energy rates. For example, at $0.07 per kWh, a leak as small as 1/8 inch can waste over $2,933 worth of compressed air per year. Multiply that by dozens of leaks across a system, and the financial impact becomes staggering. Beyond the dollars, leaks force compressors to run longer and harder, shortening their lifespan and driving up maintenance costs. A Leak Prevention Program isn’t just a nice-to-have—it’s a strategic necessity for operational efficiency and sustainability.

EXAIR provides resources and tools to help you design and execute an effective Leak Prevention Program. Here’s a step-by-step approach to getting started:

  1. Establish a Baseline – Before you can measure improvement, you need to know where you stand. Document your current compressed air usage by tracking compressor run times, energy consumption, and system pressure. This baseline serves as your reference point to quantify savings once leaks are addressed. To measure the total volume of air, you can implement the EXAIR Digital flow meter.
  2. Identify Leaks – Here’s where EXAIR’s Ultrasonic Leak Detector (Model 9207) shines. Leaks produce high-frequency turbulence—ultrasonic “white noise” that’s inaudible to the human ear but easily detectable with the right technology. This handheld, high-quality detector converts these ultrasonic signatures into audible sounds through headphones and displays intensity on an LED screen, allowing you to pinpoint leaks up to 20 feet away. Whether it’s a faulty fitting, a worn valve, or a cracked pipe, the detector’s precision ensures you won’t miss a thing—even in noisy industrial environments.
  3. Document and Prioritize – Once leaks are identified, record their location, size, and estimated cost. There are two main approaches: the Seek-and-Repair method, where leaks are fixed immediately, or the Leak Tag method, where leaks are tagged and logged for scheduled repairs. For larger facilities, a master leak list can streamline tracking and ensure accountability. Prioritize repairs based on leak size and accessibility—tackling the biggest offenders first maximizes early savings.
  4. Repair and Verify Fix the leaks using appropriate methods—tightening connections, replacing seals, or upgrading components. After repairs, use the Ultrasonic Leak Detector again to confirm the fixes hold. This verification step ensures your efforts translate into real results.
  5. Track Savings and Optimize Compare your post-repair compressed air usage to your baseline. The reduction in energy costs, compressor runtime, and maintenance needs will reveal the program’s ROI, then you can turn your leak prevention program into a continuous improvement process.

The EXAIR Ultrasonic Leak Detector is an important building block for this program. Its ability to detect leaks quickly and accurately sets it apart from rudimentary methods like listening for hisses (which only catches the worst offenders) or using soapy water (impractical for large systems). The detector’s portability and ease of use mean your team can cover an entire facility efficiently, even during normal operations. Its directional sensitivity zeros in on leak sources, minimizing guesswork and downtime. With minimal training, your staff can become proficient, making it a practical investment for any operation.

Compressed air leaks will rob your system of its capacity, compressor life, and electrical cost.  It is important to have a leak preventative program to check for leaks periodically as they can happen at any time.  The EXAIR Ultrasonic Leak Detector and the Digital Flowmeters will help you accomplish this and optimize your compressed air system.  Once you find and fix all your leaks, you can then focus on improving the efficiency of your blow-off devices with EXAIR products like Super Air Knives, Super Air Nozzles, and Super Air Amplifiers, and save yourself even more money.  This blog is an overview of Step 2 of the Six Steps to Optimization. You may have more questions; and, that is great! You can find them in other EXAIR blogs, or you can contact an Application Engineer at EXAIR.

Jordan Shouse
Application Engineer

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Air Leak Photo Courtesy of the Compressed air Challenge

NEMA Ratings Explained

Published on by jasonkirbyLeave a comment

NEMA ratings serve as important standards that delineate the specific environments suitable for electrical enclosures. Established by the National Electrical Manufacturers Association, this rating system indicates the capacity of a fixed enclosure to endure various environmental conditions. Below are some of the reasons why NEMA ratings are used for rating enclosures.

Environmental Protection– NEMA ratings serve as a benchmark for the level of protection that electrical enclosures offer against various environmental elements, including dust, moisture, chemicals, and corrosion.

Safety – Ensuring the safety of personnel and preventing accidents related to enclosures is of the utmost importance. By choosing the correct NEMA-rated enclosure, the risks associated with electric shock and exposure to hazardous materials can be significantly reduced or entirely avoided.

Equipment Performance– To ensure optimal performance of electrical equipment, it is essential to adhere to specific environmental requirements tailored to the equipment’s needs. The ratings associated with the equipment will guide you in selecting appropriate enclosures that offer adequate protection against temperature extremes, humidity, and excessive vibration.

Compliance and Regulations– NEMA ratings are established by regulatory bodies and industry standards to ensure that electrical installations adhere to essential requirements. Adhering to these ratings minimizes the risk of non-compliance and the potential legal ramifications that may arise from it.

Equipment Durability and Reliability– Electrical enclosures designed with the appropriate NEMA ratings provide enhanced durability and reliability by safeguarding internal components from environmental influences. This protection not only prolongs the equipment’s lifespan but also minimizes maintenance requirements and boosts overall system performance.

NEMA 12 Cabinet Cooler Systems are oil-tight, dust-tight, and rated for indoor duty. They can also be installed on the wall of an enclosure (instead of the top) with a Side Mount Kit.

EXAIR Cabinet Cooler NEMA Ratings:

NEMA 12 enclosures are designed primarily for indoor use in industrial, manufacturing, and machining environments. These robust metal enclosures provide effective protection against dust, dirt, and non-corrosive liquids, including oils and lubricants.

NEMA 4 rating signifies that an electrical enclosure is designed to withstand exposure to wind-driven dust and rain, splashing water, and water from hoses, while also resisting damage from ice accumulation. This rating makes the enclosure suitable for both indoor and outdoor applications, ensuring robust protection against various environmental conditions.

NEMA 4X rating indicates that an electrical enclosure is suitable for both indoor and outdoor applications, providing protection against wind-driven dust, rain, splashes, and hose-directed water, as well as resistance to corrosion. The inclusion of the “X” signifies enhanced corrosion protection, making these enclosures ideal for challenging environments such as marine locations and chemical processing facilities.

If you have questions about NEMA Ratings, or anything regarding EXAIR and our products, please do not hesitate to reach out.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk