OSHA Safety, Efficiency, and Flexibility from Engineered Compressed Air Nozzles

Throughout my years here at EXAIR as well as my years in the metal cutting industry, one of the most common quick fixes I see in production environments for compressed air blowoffs in a process is an open copper pipe that is contorted into a position, pinched at the end, and more often than not kinked from repositioning. I call this a quick fix because it does blow air, more often than not it will get production up and running, but it does not meet or exceed OSHA standards for safety and is an inefficient use of compressed air. [OSHA Standards 29 CFR 1910.242(b) and 29 CFR 1910.95(a)]

EXAIR Super Air Nozzles that are easy replacements for 1/8″ and 1/4″ Copper pipe.

The first engineered solution I could offer to prevent any costly OSHA fines and to lower the ambient noise level caused by these blowoffs is to implement an EXAIR Engineered Air Nozzle. We offer a wide variety of nozzles ranging from a 4mm thread up to a 1-1/4″ NPT thread. With this wide range comes a wide variety of forces and flows as well.

Today, I would like to focus on the common sizes of copper blowoffs which are 1/8″ and 1/4″. To simply adapt a nozzle to copper line a compression fitting can be easily sourced, often from EXAIR, and convert the copper tubing in place to an NPT threaded outlet for easy installation of an EXAIR nozzle. More often than not a compression fitting is how the copper tubing is tied into the machine’s compressed air system.

We have a total of 37 engineered air nozzles from stock that will easily fit a compression fitting which goes to a 1/8″ NPT or 1/4″ NPT thread. Several of these are also adjustable through a gap adjustment or a patented shim adjustment to vary the force and flow out of the nozzle from a forceful blast to a gentle breeze in order to me your application needs. What if you want to eliminate the copper line and compressions fittings?

EXAIR offers a replacement option for the ever-common copper tube that is more robust and does not require a tool to be properly repositioned. We currently offer twenty-four different models of our Stay Set Hoses that can be easily connected to any of the nozzles mentioned above. The lengths that are available are 6″ (152mm), 12″ (305mm), 18″ (457mm), 24″ (610mm), 30″ (762mm) and 36″ (914mm).

These lengths are available with two separate connection options. 1/4″ MNPT x 1/4″ MNPT or 1/4″ MNPT x 1/8″ FNPT. The Stay Set Hoses can easily be bent by hand into position for a precise placement of the air pattern from the engineered nozzle attached to it. This permits operators a tool free adjustment for fast and reliable location to keep production up and running. They can also be paired with Magnetic Bases.

EXAIR Magnetic Bases are available in single outlet or dual outlet configurations. Both include a 100 lb. pull magnet that will hold tight to any ferrous metal surface for secure mounting, as well as a quick 1/4 turn miniature valve on each outlet. This permits independent customization of the force our of each output for the dual outlet mag base. Each magnetic base offers a 1/4″ FNPT inlet port and outlet port. We offer these with any of combination of the Stay Set Hoses mentioned above as well as any of the Super Air Nozzles mentioned above.

Mag Bases come with one or two outlets. Stay Set Hoses come in lengths from 6″ to 36″.

The Super Air Nozzles, Stay Set Hoses, and Magnetic Bases can be easily combined before they ship to your facility to make a complete blowoff station that is easily installed and adjusted to fit any of the needs your process may have for a point of use blowoff. If you want help determining how much compressed air you would save by replacing the open pipe blowoffs with an engineered solution like a Stay Set Magnetic Base Blowoff System please contact myself or any Application Engineer here at EXAIR.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

EXAIR’s Flat Super Air Nozzles: Customize Your Blowoff Application

 

EXAIR’s Flat Super Air Nozzles provide a 1” or 2” wide airstream with hard-hitting force. All of EXAIR’s Flat Super Nozzles adhere to OSHA Standard 29 CFR 1910.242(b) for dead-end pressure, providing a safe and efficient method of delivering a strong blast of air.

The flow and force from the Flat Super Air Nozzle is adjustable by regulating the pressure supplied to it as well as by installing different thicknesses of shims. Thicker shims provide more force and flow, while a thinner shim will reduce the force and flow as well as the overall air consumption. This makes the Flat Super Air Nozzle and ideal solution for applications that may require variable force for different applications.

The nozzles are also available in your very own Blowoff System that can be customized to fit the exact application. You have the ability to put together the best combination of nozzle, Stay Set Hose, and Magnetic Base to suit your needs. Available with either a single or dual Magnetic Base and any of our Stay Set Hoses, there’s many different possibilities. To begin:

  1. Select the Air Nozzle you’ll need.

EXAMPLE: HP1125SS 2” High Power Stainless Steel Super Air Nozzle

  1. Then select the length of Stay Set Hose. They’re available in lengths ranging from 6”-36”.

EXAMPLE: An HP1125SS with a 24” Stay Set Hose would be an HP1125SS-9224.

  1. Finally, you have the option to also select a Magnetic Base if necessary. These are available with either a one outlet Magnetic Base, or Two Outlet which would include (2) separate nozzles. For a single outlet, change the second digit of the “added on” dash number to a “3”. For a two outlet, change that number to a “4”.

 EXAMPLE: An HP1125SS with 24” Stay Set Hose and Dual Magnetic Base is a Model HP1125SS-9424.

bok_1122-9412_400

This allows you to customize the solution using ANY nozzle and ANY length Stay Set Hose, creating a custom solution for your application. If you’d like to talk about any of our Super Air Nozzles and which would be best for your application, feel free to give us a call.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

 

Upgrade Blowoff Applications with Engineered Products to Increase Safety and Efficiency

At EXAIR, it’s our business to make sure that you get the most out of your compressed air system.  We’ve got a Six Step plan to help you do just that, and one of those steps is the topic of today’s blog:

We have a couple of ways to help with step #1.  You can use a Digital Flowmeter to measure your total compressed air usage, and take advantage of our Efficiency Lab service to determine the consumption of individual compressed air devices that may be running up the total.  Based on our performance tests of those devices, we can recommend suitable EXAIR Intelligent Compressed Air Products to replace them with, along with the expected reductions in air consumption & noise levels…quieter is always better too.

We’re going to skip right over Step #2…just for now…but if you can’t wait, click on the picture above for more on finding & fixing leaks.

Once you get our recommended replacements in (I mean, why wouldn’t you?), they’re going to be part of your compressed air system, so naturally, we want to make sure you get the most out of them as well.  Key considerations are suitable supply lines, and proper installation.

In the case of a Super Air Nozzle or Air Jet, these are oftentimes one and the same.  They’re all small enough, and lightweight enough, to be adequately supported by compressed air piping (assuming the piping is adequately supported,) metal tubing (via a compression fitting adapter,) or even mounting solutions like our Stay Set Hoses.

Just a few ideas for installing an EXAIR Super Air Nozzle

Sometimes, though, you need a firm, vibration-resistant mounting…that’s where we recommend our Swivel Fittings.  A hex retainer tightly locks the ball in position, but allows for easy repositioning when loosened.  They come in standard NPT sizes from 1″ NPT down to 1/8″ NPT, and we even have them for the M4, M5, and M6 metric threads for our Atto, Pico, and Nano Super Air Nozzles.

Typical threaded fittings are limited in the angles you can achieve. EXAIR Swivel Fittings provide 50° of adjustability.

Even a highly efficient blow off needs to be aimed well in order to do its job well.  If you’d like to discuss how to get the most out of your compressed air system – or our products – give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Reduce Sound Level in your Factory, Improve Worker Safety and Comfort

Checking the sound level in your processes is an important aspect of ensuring a safe working environment for your employees. Loud noises and the exposure time can lead to significant health concerns. Permanent hearing loss, increased stress levels due to the uncomfortable work environment, and potential injury due to lack of concentration or inability to hear the surroundings are all examples of some risks associated with a noisy environment.

The Occupational Safety and Health Administration, known by most simply as OSHA, introduced Standard 29 CFR 1910.95(a) as a means of protecting operators from injury associated with high noise levels. The chart below indicates maximum allowable exposure time based on different noise levels. At just 90 dBA, an operator can operate safely for 8 hours. Open end pipe blowoffs and some air guns fitted with cross drilled relief holes will often result in noise levels in excess of 100 dBA. At 110 dBA, permanent hearing loss can be experienced in just 30 minutes!

OSHA Chart

The first step to lowering your sound level is to take a baseline reading of your various processes and devices that are causing the noise. EXAIR’s Sound Level Meter, Model 9104, is an easy to use instrument that provides a digital readout of the sound level. They come with an NIST traceable calibration certificate and will allow you to determine what processes and areas are causing the most trouble.

SoundMeter_new_nist225

From there, EXAIR has a wide range of Intelligent Compressed Air Products® that are designed to reduce compressed air consumption as well as sound levels. For noisy blowoffs where you’re currently using an open-ended pipe or a loud cross-drilled nozzle, EXAIR’s Super Air Nozzles are the ideal solution. Not only will they pay for themselves over time due to compressed air savings, but your operators will thank you when they’re able to hear later on in life!!

Drilled pipe is another common culprit of high noise levels. Rather than purchasing an engineered solution, the idea is that a simple drilled pipe is just as effective right? Not at all!! Not only does a drilled pipe produce exceptionally high sound levels, but the amount of compressed air used is also very inefficient. EXAIR’s Super Air Knife is available in lengths ranging from 3”-108” and has a sound level of just 69 dBA at 80 PSIG. At this sound level, operators won’t even require hearing protection at all!

SAK vs drilled pipe
EXAIR’s Super Air Knife is the ideal solution for replacing noisy, inefficient drilled pipe

With all of these products available in stock, EXAIR has the tools you need to reduce sound level in your processes. If you’d like to talk to an Application Engineer about any applications that you feel could benefit from a sound reduction, give us a call.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

EXAIR Intelligent Compressed Air Products Are Automation’s Best Friend

For decades, children and adults (really cool ones, anyway) have enjoyed the popular board game, Mouse Trap:

The fun of the game is that it exaggerates the notion of providing an overly complicated solution to a simple problem – a notion made famous by Rube Goldberg, whose namesake machines are as thought-provoking as they are entertaining to watch.

As fun as Rube Goldberg machines are, there are actually ways to engineer something “just enough” – that’s what automation engineers strive to do every day; and EXAIR is here to help.

Probably the most popular feature, for automated applications, of engineered compressed air products is instantaneous performance.  For example:

  • When an electric motor-powered blower is used for a blow off, cooling, or drying application, there’s going to be a “ramp-up” period to reach full rated flow.  Not so with an EXAIR Intelligent Compressed Air Product, like a Super Air Wipe, Super Air Knife, Super Air Nozzle, Super Air Amplifier, etc.  They are generating their rated flow as fast as you can open the supply valve.

    EXAIR Intelligent Compressed Air Products such as (left to right) the Super Air Wipe, Super Air Knife, Super Air Nozzle, and Super Air Amplifier provide instant on/off performance, at rated levels.
  • Likewise, vacuum pumps necessarily take some time to develop their rated vacuum level.  But the venturi in an EXAIR E-Vac Vacuum Generator draws its full rated vacuum flow as soon as the compressed air is turned on.  The peak vacuum level is achieved in the amount of time it takes to pull the air out of the lines or vessel.

    These are all examples of how an E-Vac pick-and-place system is just a solenoid valve away from being an automated process.
  • All EXAIR Atomizing Spray Nozzles can be fitted with a No Drip feature, which allows instant on/off control, simply by opening/closing a valve in the compressed air supply line.  This is often done with a solenoid valve tied in to the machine controls, or with an EXAIR EFC, Electronic Flow Control (more on that in a minute.)  They can handle up to 180 cycles per minute, for quick bursts of atomized mist, on demand.  No other method of liquid flow control can match that kind of performance.

    Fine mist liquid spray, on demand, from an EXAIR No Drip Atomizing Spray Nozzle.
  • EXAIR Spot Cooling Products, Cold Guns, and Cabinet Cooler Systems all use Vortex Tube technology.  This “splits” a supply of compressed air into a hot, and cold air flow.  Unlike refrigerant, chilled water, or cryogenic gas methods, they don’t rely on conduction or convection heat transfer between materials, so cold (and hot) air is produced, at rated flow and temperature, instantly.  They, too, can be turned on & off as often as needed…there are no moving parts to wear or damage.

    The unique phenomenon of the Vortex Tube principle makes cold air instantly for as long – or short – a time as needed.

Automation projects often incorporate existing logic, controls, timers, etc. to actuate the process.  For example, if you wanted to use a Chip Vac to vacuum debris from a chop saw, you can simply wire a solenoid valve into the power switch of the saw…it’ll run while the saw runs, and stop when the saw is turned off.

EXAIR’s award winning EFC Electronic Flow is ready to go, right out of the box.

If there are no existing logic, controls, timers, etc., EXAIR has a solution for those cases too: the EFC Electronic Flow Control.  We have four models to accommodate up to 350 SCFM of compressed air flow – that’s ten feet worth of Super Air Knives.  The EFC consists of a photoelectric sensor that opens/closes a solenoid valve, based on the programming of the integral timer.  It’s a stand alone system that doesn’t require input from, nor is it affected by, any external factors.

Automation projects can get pretty intricate.  EXAIR Intelligent Compressed Air Products are aimed at keeping their involvement as simple as possible.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Video Blog: EXAIR’s Soft Grip Super Air Scraper

The video below showcases a new EXAIR product, the Soft Grip Super Air Scraper. This combines the comfort of a Soft Grip Safety Air Gun with the powerful air stream of the 2″ Flat Super Air Nozzle and adds the scraping ability of a handheld scraper all in one convenient package.

If you would like to discuss your application, please contact us.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

Compressed Air Pressure Regulators Conserve And Protect

Imagine you’re enjoying a nice shower. A cascade of warm water is soothing your body – and spirit – then, someone starts the dishwasher. Or a load of laundry. Or flushes the toilet. Suddenly, the “soothe” turns to “scald” or “freeze,” depending on whether you’ve been robbed of hot, or cold water.  So, what happened?

What happened is, all of those “loads” on your house’s water supply that can ruin your shower experience are controlled by simple on/off valves…they open to permit a certain amount of water FLOW to pass.  When the dishwasher starts, or someone decides to wash a load of whites, the HOT water from your nice warm shower is diverted, leaving a stream of cold water.  When a toilet flushes, or it’s a load of colors, the COLD water is diverted…and that’s not just unpleasant, but downright painful.  Either way, (in my house anyway,) a teenager is getting read the riot act.

The same phenomenon can apply in a compressed air system, if simple flow control valves are used to throttle the appropriate supply of air to a pneumatic device.  If someone, for example, hooks up an air gun to blow off their tools or parts, the valves on EVERYTHING else will need to be opened up some to keep those devices working the same.  In the case of an air gun like this, it usually happens too quick to make the necessary adjustments (by hand) and you’re probably left with a machine tripped off-line, or a ruined part.

Pressure Regulators can prevent this by keeping (or regulating) their downstream pressure to a set value.  If a load elsewhere in the system is activated, the Pressure Regulator opens up, automatically, to keep its output constant.  When that load is secured, the Pressure Regulator closes back down accordingly.  Either way, no single load affects the operation of any others.

That’s only half the value of the use of Pressure Regulators, though.  The other half is, well…the value.  Just looking at a typical function of many EXAIR Intelligent Compressed Air Products – blow off – they’ll all pretty much accomplish the task if you run them, unrestricted, straight off your header.  That’ll give you a good, strong blast of air flow…and it may be more than what’s required, and a waste of good air.  Pressure Regulators will prevent this by allowing you to “dial in” the supply pressure to whatever it takes to get the job done, and no more.

EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

Compressed air isn’t free.  Heck, it isn’t even cheap.  Don’t use any more than you have to, and get the most out of what you do use.  Pressure Regulators are one important step in doing this.  If you’d like to talk about optimizing your use of your compressed air system, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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