EXAIR Air Guns Increase Safety And Reduce Air Use

Many times we receive calls from customers that fall right in line with our focus here at EXAIR  – providing Intelligent Compressed Air Products that improve overall safety for operators and plant personnel in industrial operations as well as reduce compressed air usage, ultimately lowering energy costs. Such was the case last week when I received an inquiry from a customer who was looking for a handheld device that could easily attach to their existing air hose to replace the loud and inefficient homemade air nozzles they are currently using to blow off steel chips and coolant from their saws and drills. Their current set up includes a combination of smashed air guns, similar to the one shown below, some small open tubes and cheap plastic nozzles. The blowoffs were working but their operators were starting to complain about excessive noise during operation and notice the compressor in the area was running continuously during the cleaning cycle. Their first proposed solution was to lower the supply pressure which did lower the sound level and air usage somewhat, but now the exiting airflow wasn’t powerful enough to clear the debris. After doing an internet search they decided to reach out to EXAIR for assistance.

crushed-gun
Crushed guns create high pitch wind shear and provide no relief path for the air to exit safely

All of the Safety Air Guns we offer utilize our Air Nozzles which are engineered to meet or exceed OSHA Standard CFR 29 – 1910.95(a) for allowable noise exposure levels. As the Standard reads, when employees are subjected to sounds in excess of 90 dBA, some type of engineered controls should be used to lower the sound to a permissible level. Prolonged exposure to excessive noise can result in serious health issues, like tinnitus or a constant ringing of the ears, as well as stress and reduced productivity. In addition, our engineered Air Nozzles cannot be dead ended, meeting OSHA Standard 1910.242(b). With the design of our Air Nozzles, there is always a safe path for the air to exit so the outlet pressure will not reach 30 PSIG if the nozzle exhaust were to be blocked or pressed against the skin.  Due to this design, our units are safe to operate at higher pressure, resulting in a high velocity, forceful airflow.

1210
Model 1210 – Soft Grip Safety Air Gun

For this application, I recommended the customer use our Model # 1210 Soft Grip Safety Air Gun. This particular unit incorporates our Model # 1100 Super Air Nozzle which produces a low sound level of 74 dBA, well within the OSHA guidelines, and consumes only 14 SCFM @ 80 PSIG while having the necessary power to solve their application.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Intelligent Compressed Air Products: Pulling In Free Air

Home of Intelligent Compressed Air Products
EXAIR is the home of Intelligent Compressed Air Products.

What is an Intelligent Compressed Air product? What makes it intelligent? Compressed air is typically a manufacturing facility’s most expensive utility. A standard cost is $0.25 per 1,000 Standard Cubic Feet (SCF) produced. Any pipe, manifold, or fitting can be modified to blow compressed air, but these homemade blow offs will be very noisy, waste a tremendous amount of compressed air and create an OSHA violation. In contrast EXAIR’s intelligent compressed air are engineered solution are quiet, use a minimal amount of compressed air and comply with OSHA safety standards.

Let’s take EXAIR Model 1100 Super Air Nozzle as an example. Connecting it to a 1/4 NPT fitting, will produce 13 ounces of force on a target when mounted twelve inches away, and use 14 SCFM of compressed air. To produce so much force using that little air, the Super Air Nozzle must be precisely designed and manufactured to maximize the entrainment of ambient air.

With the air nozzle we use compressed air to induce a primary air flow. This primary air flow is a high velocity jet of air that create low pressure area around the primary airflow entraining the ambient or free air. These air streams combine past the tip of the nozzle creating a powerful blast of air. The Super Air Nozzle can entrain air up to a ratio of 25 parts of ambient air moved for every 1 part of compressed air.  All of our Super Air Nozzle create this level of air entrainment.

AirflowAnimation
EXAIR Super Air Nozzle entrains ambient air up to a 25:1 ratio

In addition to entraining a significant amount of air, the Super Air Nozzle also reduces the noise level. Most homemade nozzles are not well constructed so, the hole(s) that allow the air to escape may have sharp jagged edge which will induce noise or turbulence. Even commercial nozzles with cross drill holes create a tremendous amount of wind shear which leads to an ear splitting compressed air squeal. The smooth design of the Super Air Nozzle creates a laminar flow of air that reduces the noise of the nozzle to 74 dBA. For reference a 1/4″ open tube can easily create noise levels over 100 dBA. Using a compressed air nozzle, can greatly reduce the amount of noise in and around your shop.

Finally, EXAIR Super Air Nozzle complies with OSHA standard 29 CFR 1910.242, which requires that all nozzles that use compressed air over 30 PSIG must provide a point of relief in case the nozzle is dead ended. EXAIR Super Air Nozzle uses multiple orifices that are recessed, so that the air always has a path of escape. Many homemade nozzles do not have any provision to protect from dead ending, which means they do not comply with the OSHA standard.

EXAIR Super Air Nozzles are an important upgrade from a homemade nozzle and many times an upgrade for a commercial nozzle, because they entrain ambient air, reduce noise level, and comply with OSHA regulation.

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com