Tag: dead end

How One Customer Improved Safety and Reduced Noise with a Simple Retrofit

Published on by Brian FarnoLeave a comment

I recently had the opportunity to help a customer facing some serious concerns about their compressed air usage. They had just completed a safety audit conducted by a third-party firm, and one of the main issues identified was the use of handheld blow guns throughout their production floor.

“Thumb guns” are especially popular for blowoff because of their compact size, ergonomic design. and low price.

Even though the tools in question were commercially available and marketed as having “safety tips,” the auditors recorded noise levels exceeding 90 dBA—well above the acceptable threshold. The audit team explained that to maintain a safe work environment, noise levels needed to stay below 84 dBA, and the simplest way to get there was to address the blow guns being used.

That’s when the customer turned to us for help.

We discussed the application in detail, and it quickly became clear that EXAIR’s Model 1100 Super Air Nozzle would be a great fit. Not only does it significantly reduce noise levels—down to 74 dBA—but it also meets OSHA’s 30 PSI dead-end pressure requirement, ensuring operator safety in the event of a blocked nozzle.

This customer wasn’t focused on maximizing air output or performance—they simply wanted to make their environment safer for their team. What made this installation even better was the unexpected benefit: while addressing the safety concerns, it also reduced compressed air consumption. A win-win.

It’s always rewarding when we can help customers meet compliance goals and improve safety, but it’s even better when we can go beyond their expectations and help them uncover savings they weren’t even looking for.

Free testing. Verifiable data. EXAIR Efficiency Lab.

If you’re dealing with high noise levels or safety compliance issues around your compressed air applications, don’t hesitate to reach out. Our team is ready to help you find a solution that protects our people, meets regulations, and improves overall efficiency through the EXAIR Efficiency Lab.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Industrial Safety: Compressed Air

Published on by John BallLeave a comment

At EXAIR, we have a statement that says, “Safety is everyone’s responsibility.”  EXAIR builds its name around manufacturing safe and protective compressed air products.  In the United States, we have an organization called the Occupational Safety and Health Administration (OSHA) that enforces governmental directives for safe and healthy working environments.  They do training, outreach programs, and educational assistance for manufacturing plants to reduce injuries and fatalities.  They can also enforce these directives with heavy fines for violations.  With compressed air systems, the two most common violations are 29CFR 1910.242(b) for dead-end pressure/chip shielding and 29CFR 1910.95(a) for maximum allowable noise exposure.

Unsafe Nozzle

Here is an example of a nozzle that is dangerous.  As you can see, there is only one path where the air can pass through.  Other similar types of blow-off devices that would fall into this same group would include copper tubes, flexible lines, and open pipes.  They are dangerous as compressed air cannot escape if it is blocked by your body or skin.  If operated above 30 PSIG (2 bar), these nozzles could penetrate the skin and create an air embolism within the body, which can cause bodily harm or death.  This is a hazard that can be avoided by using EXAIR Super Air Nozzles and Safety Air Guns.  The nozzles are designed with fins, which allow the air to escape and cannot be blocked by your skin.  So, you can use the EXAIR Super Air Nozzles safely above 30 PSIG (2 bar) and remain OSHA compliant.

Unsafe Air Gun

To counteract the dead-end pressure violation, some nozzle manufacturers create a hole through the side of the nozzle (reference photo above).  This will allow the compressed air to escape, but now the issue is noise levels.  With an “open” hole in the nozzle, the compressed air is very turbulent and very loud.  The National Institute for Occupational Safety and Health (NIOSH) states that 70% to 80% of all hearing loss within a manufacturing plant is caused by compressed air.  OSHA created a chart to show the maximum allowable noise exposure.  This chart shows the exposure time and noise limits before hearing protection is required.  The EXAIR Super Air Nozzles, Super Air Knives, and Super Air Amplifiers are designed to have laminar flow, which makes them very quiet.  As an example, the model 1210 Soft Grip Safety Air Gun has a sound level of only 74 dBA, well under the noise exposure limit for 8 hours.

One of the last things that companies think about when purchasing compressed air products is safety.  Loud noises and dead-end pressure can be missed or forgotten.  To avoid any future fines or having to purchase additional personal protective equipment (PPE), it will be much safer to purchase EXAIR products.  If you would like to improve the safety of your facility and reduce energy costs, an Application Engineer at EXAIR can review your current blow-off devices.  Remember, safety is everyone’s responsibility. 

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Photo: Industrial Security Signal by DavidRockDesign.  Pixabay license

About OSHA 29 CFR 1910.242(b) for Compressed Air Safety

Published on by Brian FarnoLeave a comment

In February of 1972 OSHA released a standard to improve worker safety when operating handheld compressed air devices being used for cleaning purposes. This directive focuses around human skins permeability. That is, if you were to take an open ended pipe that had compressed air being discharged over 30 psig it can actually push through the skin and create an air embolism.

OSHA’s Directive 29 CFR 1910.242(b)

Air Embolisms are extremely painful, and in extreme cases, can be deadly. The risk associated with an air embolism can be mitigated by following the OSHA directive and reducing the downstream pressure of an air nozzle or nozzle pressure below 30 psi for all static conditions. Dead ending is when the passageway for the air becomes blocked and turns a dynamic flow of air into a static flow. This is in the event the pipe, nozzle, lance, etc. becomes blocked by a human’s body. This is a directive that all Intelligent Compressed Air® products from EXAIR focus on meeting or exceeding.

Our Air Nozzles and Jets video shows a great depiction of how this can be achieved with our engineered design of nozzles. The recessed holes and the fact that there are multiple passages for the air to exit are easy to see on the nozzle. Products like the Super Air Knife may not be so easy to see but the way the air knife cap overlaps prevents the Super Air Knife from being dead ended in the event an operator comes into contact with the discharge air.

Even though this directive was created in 1972 it continues to be at the forefront of industrial environments. I have even been to a custom artwork facility that was effected by this standard because they would use a handheld blowgun to remove dust and debris before matting and framing artwork with glass. They also removed dirt and dust from the frames before paint. This wasn’t your typical manufacturing environment yet they were still held to the same standards and were made safe by implementing engineered solutions such as our Super Air Nozzle.

If you would like to discuss how we can help increase your operator safety and ensure you meet or exceed OSHA 29 CFR 1910.242(b), please contact an Application Engineer today.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

1 – OSHA Instruction STD 01-13-001 – Retrieved from: https://www.osha.gov/enforcement/directives/std-01-13-001

EXAIR Safety Air Gun Promotion

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From August 1st to September 30th, 2018, EXAIR will be giving away a 1” Flat Super Air Nozzle with the purchase of any promotional VariBlast, Soft Grip, or Heavy Duty Safety Air Gun.  EXAIR is stressing the importance of safety in the workplace with the EXAIR Safety Air Guns as well as the versatility of the different types of EXAIR Super Air Nozzles.

SAGpromoAD_500xsq

This promotional item, the model 1126 1″ Flat Super Air Nozzle, has a patented shim to blow a 1” wide stream of air to clean surfaces quickly and efficiently and is a $45.00 USD value. For more details on the Promotion, click on the photo/link above. For more information about the Flat Super Air Nozzles, click HERE.

Inexpensive air guns can be purchased just about anywhere- online, via catalogs, and through industrial supply companies. Typical quality is less than ideal – broken triggers, leaky valves – a short lifespan in an industrial setting are merely a few of the issues observed.  Most are loud and inefficient – they just blow large amounts of compressed air, and at noise levels that violate OSHA requirements.  Some may even generate dangerous dead end pressure situations that that can result in serious or fatal injuries if blocked.

EXAIR’s Safety Air Guns have been engineered and designed to eliminate these issues. They are durable for use in industrial situations and comfortable to use for extended periods of time.  With an EXAIR engineered air nozzle, each model provides top performance by entraining large volumes of surrounding air into the air-stream. Operation is assured to be safe along with low compressed air consumption and noise levels.  Due to the design, the airflow that exits the nozzle cannot be blocked, as required by OSHA Standard 29 CPR 1910.242(b).

Safety Air Guns
The EXAIR VariBlast, Soft Grip and Heavy Duty Safety Air Guns

The VariBlast style of safety air gun offers variable force based on the range of trigger pull. Force can be varies, form a light breeze, to full force maximum output. This cast aluminum air gun can be fitted with any of the EXAIR 1/8 NPT engineered air nozzles.

The Soft Grip style of safety air gun  has a durable cats aluminum body suited for rugged, industrial use. The ergonomic design has a soft vinyl cover, a large trigger for easy operation, and a hanger hook for easy storage.

The Heavy Duty style of safety air gun is powerful with a durable aluminum cast body and ergonomic composite rubber grip, best suited for rugged industrial environments. Hours of fatigue free operation are possible.

With all of the Safety Air Guns styles, Chip Shields and Extension Pipes are available, from 6″ to 72″ in length.

1210-6cs
Soft Grip Safety Air Gun, with Chip Shield and 12″ Extension

With many nozzle options, from a whisper quiet 58 dBA and 2.5 SCFM of flow up to 60 SCFM and 87 dBA (still below the OSHA 8 hour noise level threshold) there is a model that will fit practically any application. Application Engineers are available by phone, email, and chat to review your specific blow off needs, and help to select the best possible solution available.

We invite to you to try out an EXAIR Safety Air Gun, and get the free 1″ Wide Flat Super Air Nozzle as a bonus.

To discuss your application and how an EXAIR Intelligent Compressed Air Product can improve your process, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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