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

 

Replacing a 1/4″ Open Copper Tube With a 2″ Flat Super Air Nozzle Leads To Quick ROI

The generation of compressed air accounts for approximately 1/3 of all energy costs in an industrial facility and up to 30% of that compressed air is wasted through inefficient operation. Open pipes or homemade blowoffs waste a ton of compressed air, resulting in high operating costs. By replacing these devices with an energy efficient, engineered solution, you can reduce this waste and dramatically cut energy costs.

For example, let’s look at the average operating costs for a single 1/4″ open copper tube. (If you don’t know you current energy costs, a reasonable average to use is $ 0.25 per every 1,000 SCF used, based on $ 0.08/kWh.

1/4″ Copper tube

A single 1/4″ open copper tube consumes 33 SCFM @ 80 PSIG and costs roughly $ 0.50 per hour to operate. (33 SCF x 60 minutes x $ 0.25 / 1,000 = $ 0.50). For an 8 hour shift, the total cost would be $ 4.00 ($ 0.50 x 8 hours = $ 4.00).

If we were to replace the 1/4″ open copper tube with our Model # 1122 2″ Flat Super Air Nozzle with 1/4″ FNPT inlet, the air consumption would be reduced to 21.8 SCFM @ 80 PSIG. This may not seem like much of an air usage reduction, but when you look at the monetary, total cost of ownership for purchasing and operating the nozzle, the savings can quickly add up.

2″ Flat Super Air Nozzle

The operating cost for a 2″ Flat Super Air Nozzle with 1/4″ FNPT inlet is $ 0.33 per hour (21.8 SCF x 60 minutes x $ 0.25 / 1,000 = $ .033) or $ 2.64 per 8 hour shift ($ 0.33 x 8 hours = $ 2.64).

We can now compare the operational cost between the 2 devices:

1/4″ open copper tube operating costs:
$ 0.50 per hour
$ 4.00 per day (8 hours)

2″ Flat Super Air Nozzle operating costs:
$ 0.33 per hour
$ 2.64 per day (8 hours)

Cost Savings:
$ 4.00 / day (open copper tube) –  $ 2.64 / day (2″ Flat Super Air Nozzle) = $ 1.36 savings per day

The Model # 1122 2″ Flat Super Air Nozzle has a list price $ 67.00 USD.

ROI or Return On Investment calculation:
$ 67.00 (Cost) / $ 1.36 (savings per day) = 49.26 days.

The 2″ Flat Super Air Nozzle would pay for itself in just over 49 days in operation. This is the savings for replacing just ONE 1/4″ open copper tube with an engineered solution! In most industrial plants, there could be several of these which presents even more opportunities to reduce the overall operational costs.

Our focus here at EXAIR is to improve the overall efficiency of industrial compressed air operating processes and point of use compressed air operated products. If you are looking to reduce compressed air usage in your facility, contact an application engineer and let us help you optimize your current system.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Super Blast Safety Air Gun Saves Air vs. an Inefficient Homemade Lance

I was recently contacted by a Chicken Farm in Canada about a blow off application for cleaning the dust and debris off the walls and ceilings in their barns. They currently use a 185 SCFM portable, engine driven compressor and a lance made from 3/4″ open copper tube. The barns are rather large, approximately 10′ high by 500′ long, and they place the compressor in the middle of the barn and have a 250′ length of hose going to the homemade blowoff. This setup worked fine for a minute or so but then the airflow would start to weaken at the point-of-use and the compressor would run continuously as it wasn’t able to maintain pressure to keep up with the demand of the copper pipe.

Picture of existing homemade air lance

After discussing the details of the application, I recommend the customer use our Model # 1214-6 Super Blast Safety Air Gun with 6′ aluminum extension. This would reduce the air demand to 91 SCFM, more suitable for use with the existing 185 SCFM compressor.

 

Super Blast Safety Air Gun Model # 1214

The design of the Super Blast Safety Air Gun features a spring loaded manual valve, providing automatic shutoff and a comfortable foam grip. The 6′ extension provides the extra reach they need to effectively treat the walls and ceilings in the barn.

The Super Blast Safety Air Guns are ideal for wide coverage, long distance applications. They use our Large Super Air Nozzles and Super Air Nozzle Clusters, providing forces levels from 3.2 lbs. up to 23 lbs, depending on which nozzle is fitted on the assembly. Air inlets range from 3/8 FNPT up to 1-1/4 FNPT and aluminum extensions are available in 36″ or 72″ lengths.

If you have any questions or need further assistance, please contact an application engineer.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN