Calibration – Keep Your Meters True

EXAIR offers meters to measure the level of physical parameters such as sound and static. Each meter has sensitive electrical circuitry and a periodic calibration is recommended to ensure the meter readings are tried and true.

The model 9104 Digital Sound Level Meter is an easy to use instrument that measures and monitors the sound level pressure in a wide variety of industrial environments. The source of loud noises can be quickly identified so that corrective measures can be taken to keep sound levels at or below OSHA maximum allowable exposure limits.

The sound meter comes from the factory with an NIST (National Institute of Standards and Technology) certificate of accuracy and calibration.  As a good practice, EXAIR recommends a yearly calibration of the instrument, and we offer a service that calibrates the unit to the same NIST standards and provide a written report of the calibration.

The model 7905 Static Meter allows easy one-hand static measurements.  It is useful in both locating sources of high static charge and checking the reduction of static after treatment with an EXAIR Static Elimination product.  The unit is sensitive and responsive, and indicates the the surface polarity of objects up to +/- 20 kV when measured from 1″ away.

It is also recommended that the Static Meter be calibrated on a yearly basis.  EXAIR offers (3) levels of calibration service.  The first two provide calibration in accordance with MIL Standards using accepted procedures and standards traceable to NIST.  The third calibration service conforms to the same Mil Standard, as well as ISO/IEC standards.

Annual calibration service of your EXAIR Digital Sound and Static Meter, along with proper care and storage, will keep your meter performing tried and true for many years, providing accurate and useful measurements.

To initiate a calibration service, give us a call and an Application Engineer will issue an Returned Good number, and provide instructions on how to ship the meter to EXAIR.

If you have questions regarding calibration services for your meters or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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EXAIR Safety Air Gun Promotion

From August 1st to September 30th, 2017, EXAIR will be giving away a 1” Flat Super Air Nozzle with a purchase of a Precision, Soft Grip, or Heavy Duty Safety Air Gun.  We are promoting the importance of safety in the workplace with the EXAIR Safety Air Guns as well as the versatility of the different types of EXAIR nozzles.  This promotional item, model 1126 nozzle, has a patented shim to blows a 1” wide stream of air to clean surfaces quickly and efficiently; a $43.00 complimentary gift (click on the link below).

Promotional Nozzle with EXAIR Super Air Guns

Compressed air guns are one of the most commonly used pneumatic products in a manufacturing plant.  They are used at workstations to blow off debris and to clean parts and tools.  Because of the large quantities that are used in a plant; they are the most targeted by OSHA (Occupational Safety and Health Administration).  Majority of the common brands of air guns fail to comply with two common violations, rule 29CFR 1910.95(a) for loudness and rule 29CFR 1910.242(b) for dead-end pressure.  The reason is due to the nozzles that comes with the compressed air guns.  Fines can get very expensive, and you can alleviate these penalties by purchasing an EXAIR Safety Air Gun.  We are all responsible for safety; management, HSE department (Health and Safety Engineer), supervisors, and even the operators.  Your compressed air guns should be assessed in your facility to evaluate your safe work environment.

1310 Heavy Duty Safety Air Gun

With EXAIR Safety Air Guns, we supply an efficient, effective, and most important, safe air nozzle with all of our air guns.  They are CE Compliant and exceed the OSHA sound level and dead-end pressure requirements.  With substandard air guns, the operators would have to listen to loud noises all day and have to wear hearing protection.  As for the dead-end pressure; the EXAIR nozzles are engineered to not allow the operator to completely close the end against the hand or skin.  This is very important because if the pressure exceeds 30 PSIG, air can penetrate the skin and cause an air embolism.  Some manufacturers place a restriction inside the air gun to comply with this standard, sacrificing the effectiveness of the blowing force.  With our design, the compressed air is not able to be blocked; allowing the air to escape to atmosphere.  Even with the compressed air system set to 100 PSIG, the pressure against the skin will not exceed 30 PSIG.  Safety is a major concern for all of our customers and a priority for EXAIR in manufacturing our products.

1210-6-CS Soft Grip Safety Air Gun

As I mentioned above, the nozzles are one of the most significant parts in making a compressed air gun safe and OSHA compliant.  In combining our engineered nozzles with a quality air gun, this makes the EXAIR Safety Air Guns one of the best products on the market.  We currently have three different styles; the Precision, Soft Grip, and Heavy Duty.  These Safety Air Guns are ergonomically designed to fit comfortable in your hand; and they come with quality trigger mechanisms and a durable valve assembly.  The Precision Safety Air Gun is great for tight spaces and clearing out small holes.  The Soft Grip Safety Air Gun provides extra comfort for long extended uses, and the Heavy Duty Safety Air Gun is a rugged, heavy duty industrial air gun.  In combination with the EXAIR nozzles, the Safety Air Guns can offer another important attribute; we can save you money!!!  Compressed air is very expensive to make, and with our Safety Air Guns, we use less compressed air but still create a strong blowing force.  We do this by entraining the free ambient air into the air stream.  If you increase the mass of air to the target, it will give you a hard hitting force to remove debris from surfaces or to clean tools and holes.  The amplification ratio can be as much as 25 to 1.  That means that for every 1 part of compressed air, the EXAIR Nozzles will entrain 25 parts of ambient air.  So, the payback period for using an EXAIR Nozzle can be within weeks by the savings in the electrical cost.  With the EXAIR products, we were able to partner with Energy Star and power facilities.  For the amount of energy savings, some power companies offer rebates for using EXAIR products.   We can offer our services to see if your local power company is participating in these rebates.

1408SS-CS Precision Safety Air Gun

A substandard blow-off gun is unsafe, loud, waste compressed air, and increase production times.  EXAIR Safety Air Guns can help improve these situations in all these areas.  They are OSHA compliant, very safe and very quiet.  They use less compressed air which saves you money.  And with a variety of different nozzles, they can better fit your application to decrease down time.  EXAIR offers a 30 day unconditional guarantee on our cataloged items to try.  You can see for yourself on how effective these compressed air guns can be.  If you need help to match the best Safety Air Gun to your application, you can contact an Application Engineer.  And during the next two months, take advantage of the free 1” Flat Super Air Nozzle  offer.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Super Air Knife Math – When 72 + 72 = 75

The Super Air Knife is the latest generation of EXAIR engineered air knife that dramatically reduces compressed air usage and noise when compared to other blowoffs.

Super Air Knife Data

From the chart above, the Super Air Knife when supplied with 100 PSIG of compressed air has a sound level of just 72 dBA (A-weighted decibel scale) when measured from 3′ away.  72 dBA is a moderate sound level, and some common comparisons are ‘normal speaking voice’ at 70 dBA and ‘living room music’ at 76 dBA.

For many processes, such as a bottling line drying operation, a pair of the air knives delivers the best performance. When asked, “what is the sound level for (2) of the knives,” a little Acoustic Engineering is in order. Because the decibel scale is logarithmic, the result is not as simple as adding 72 + 72 = 144.  144 dBA is in the range of a jet aircraft take off! Thankfully, both the actual sound level and the numerical value are determined another way.  I’ll spare you a lot of the math but the equation is as below.

Capture

… where SL1, SL2, SL3 are the sound levels in dBA of the each sound makers, for as many that are being combined.

In the case of (2) Super Air Knives operated 100 PSIG, the combined sound works out to be a quiet 75.0 dBA — a powerful, efficient and quiet product ideal for many applications and process within the manufacturing environment.

Super Air Knife
Super Air Knife

As a helpful rule of thumb- combining any (2) items will yield an increase of 3 dBA, combining (3) results in a rise of 4.8 dBA, and combining (4) results in a 6 dBA rise over just (1) of the items.

The Super Air Knives have been successfully used in a wide range of applications, including part drying, sheet and conveyor cleaning, web cooling, scrap removal, pre-paint dust blowoff, and many, many more.

To discuss your application and how an EXAIR Intelligent Compressed Air Product can make your process better and quieter, 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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Excessive Noise Levels Cost You Health and Money

OSHA and the CDC make these statements about noise exposure. Did you know almost 30 million American workers are exposed to dangerous noise levels almost daily, with over 72% of those reported incidents happening in manufacturing environments? Noise induced hearing loss is the second most self-reported occupational injury and since 2004, over 125,00 workers have experienced some level of permanent hearing loss. Excessive noise levels can also reduce productivity, contribute to increased stress levels, communication errors and an irreversible condition called tinnitus or a constant ringing in the ears. In fact, disability claims associated to occupational hearing loss has risen to over $ 242 million per year.

30mill
Noise Induced Hearing Loss Is One Of The Most Common Occupational Diseases.

In effort to reduce worker exposure and increase safety, OSHA introduced Standard 29 CFR 1910.95(a). As the standard reads, employees that are subjected to sounds levels in excess of 90 dBA, some type of engineered controls should be implemented by either using some form of PPE – Personal Protective Equipment, i.e. – earplugs, earmuffs, etc. or replacing the loud device altogether with an engineered solution that is designed to reduce the sound level. When a company is found to be in violation of the Standard, OSHA hands down costly fines, in some cases nearing almost $5,000. While providing PPE may seem like the inexpensive, “quick” fix, it actually could lead to more overall cost in the form of fines or claims, as now it is the responsibility of the operator to utilize the equipment provided. The better choice of the 2 options mentioned above, would be to replace with an engineered solution that is designed to lower the sound level.

OSHA Noise Level
Noise Level Chart per OSHA Standard 29 CFR 1910.95(a)

Take for example, a section of pipe with drilled holes across the length to cover wide area applications or an open end pipe or tube for more focused blowoff, both of which typically produce sound levels in excess of 100 dBA which would limit work exposure to only a couple hours per the above chart.

EXAIR’s Intelligent Compressed Air Products are designed to meet or exceed this standard. Our products entrain large volumes of surrounding air across the profile of the device which helps to reduce wind shear, ultimately lowering the sound level. When considering replacing drilled pipe, take a look at our Super Air Knife. The Super Air Knife produces a much lower sound level at only 69 dBA which is well under the allowable exposure times set forth by OSHA. Depending on the pipe or tube size, these can quickly and easily be replaced with one of our Super Air Nozzles by just adding a fitting to the existing line. For instance, our Model # 1100 Super Air Nozzle, with a sound level of 74 dBA, again falls well within the OSHA Standard.

sound-level-comparison
Sound Level Comparison

In addition, we offer our Digital Sound Level Meter to measure sound levels ranging from 35 to 130 dBA. The unit features a backlit LCD display, fast and slow response times, Max hold and includes NIST (National Institute of Standards and Technology) certification.

SoundMeter_new_nist225
Model 9104 Digital Sound Level Meter

For assistance in gaining OSHA compliance relating to your compressed air needs, please give us a call.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

 

 

EXAIR’s High Velocity and Adjustable Air Jets – Now Available in Stainless Steel

Newly released, the EXAIR High Velocity Air Jet and Adjustable Air Jet are now available in Type 303 Stainless Steel, providing greater durability, corrosion resistance and a higher maximum temperature rating of 400 °F.  Type 303 stainless steel has good resistance to mildly corrosive atmospheres along with good oxidation resistance at elevated temperatures, making the stainless steel Air Jet a great choice for blowoff or part drying in your harsh environment. Both types of Air Jets are also available in brass, for applications at 275°F and below, and when corrosion resistance is not as critical.

6013ss
Model 6013SS – High Velocity Air Jet

Air Jets utilize the Coanda Effect – wall attachment of a high velocity fluid – to produce air motion in their surroundings. As illustrated above, a small amount of compressed air to the inlet (large black arrow) is throttled through an internal ring nozzle above sonic velocity.  A vacuum is produced, resulting in large volumes of surrounding, or “free” air, being pulled in through the jet (blue arrows.)

air jet How Air Jets Work

Both the outlet and inlet can be ducted for remote positioning applications.

If the end is blocked, flow simply reverses at well below OSHA dead end pressure requirements, ensuring safe operation.

The High Velocity Air Jet comes standard with an .015″ shim, and a Shim Set is offered that includes .006″ and  .009″ shims to provide additional adjustability and control.  The Adjustable Air Jet has a variable gap design, and can be adjusted and locked to meet the required airflow and thrust parameters.

When you are needing a simple solution to reduce excessive air consumption and noise levels on compressed air blowoff operations, EXAIR has a large line of Air Nozzles and Jets to solve your problems. You can contact an Application Engineer to discuss which Air Jet or Nozzle to best fit your application.

Brian Bergmann
Application Engineer

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Compressed Air Gun’s Many Forms Solve Many Problems

Have you just glanced around your manufacturing plant? You usually always see either the “curly” yellow hose or a red rubber hose with an air gun attached to it.  They hang at work stations, machines, packaging areas, and even in obscure places.  The reason that I bring this up is for safety reasons.

Recently we had a medium-sized manufacturing plant that was audited by OSHA. One of the first violations that OSHA found was with their compressed air guns with the typical brass pipe with the hole going through the side (one of the most typical types of nozzle).  It violated code 29 CFR 1910.65(a) for maximum allowable noise exposure.  The company had to make a choice to either purchase hearing protection for the operators or to find an alternative product.  They contacted us because we could reduce their noise level.  I suggested a Super Air Nozzle, model 1100 for their application.  When they attached our Super Air Nozzle into their air gun, they quickly heard the difference with the low noise.  With the added benefits of quality, high force, and meeting all the safety requirements, they decided to purchase the nozzles with our Safety Air Guns.  They ordered 90 pieces of our Soft Grip Safety Air Gun with Chip Shield, model 1210-CS.  This took care of the OSHA violation, and the operators were very happy with the product.

Model 1210-CS
Model 1210-CS

Another company was using compressed air with a ¼ turn valve attached to a 36” (91 cm) copper tubing. They used this device to reach into areas to blow off chips.  The Safety Compliance Officer was familiar with OSHA 29CFR 1910.242(b).  The regulation references chip shields and using pressures below 30 psig (2 bar).  Compressed air can enter the blood stream through the skin with pressures above 30 psig (2 bar) in a dead-end occurrence.  To keep his workers safe, he mandated a maximum supply line pressure of 30 psig (2 bar) throughout the plant.  This increased the cleanup time for an operation as the force was reduced greatly.  The Safety Compliance Officer contacted us about our Safety Air Guns.  I explained that with our nozzles, they are engineered to operate at higher supply line pressures and still be below the dead-end pressure requirement of 30 psig (2 bar).  With our design, it keeps the surface of your skin from blocking the air openings, like you can do with a copper tubing.  They ordered 25 pieces of our Heavy Duty Safety Air Gun with a 36” (91 cm) extension and Chip Shield, model 1310-36-CS.  The operators were happy with the durability of the gun and with the ability to increase the air pressure for faster cleaning.  The Safety Compliance Officer was happy to meet the OSHA standard and to keep his workers safe.

Model 1310-36-CS
Model 1310-36-CS

EXAIR offers a variety of different types of nozzles and Safety Air Guns to fit the requirements of your applications. All of our nozzles are safe, quiet, and powerful.  We offer them in different materials from aluminum/zinc, stainless steel, and PEEK.  They are designed to entrain ambient air to save compressed air and money.  As a note, an air gun is only as good as the nozzle it is using.  Many air guns come with a very inexpensive brand of nozzle.  They are typically very loud and very inefficient.  I always like to use the analogy of a paint sprayer.  No matter how good the spray gun is, if you have a poor nozzle, you will end up with many flaws in your paint.  The same can be said with compressed air guns.

To keep your company compliant and safe, you can always contact an Application Engineers to help pick the correct product for you.

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

A Sound Reckoning Of The Super Air Knife

In May of 1976, The Who performed a concert in London that Guiness’ Book of World Records used to certify them as the World’s Loudest Band. A sound level of 126 decibels was recorded and documented at a distance of 32 feet from the stage. That’s right at the boundary of the threshold of pain.  Which I’m sure is what they were going for.

There are a variety of charts available that relate common noises to the decibel levels they could be expected to produce. For instance, a DC-9’s engines produce a sound level of about 120 decibels at takeoff or landing. Now, imagine if such a plane were to land at the aforementioned concert: would the sound level, at a given distance, be equal to those two decibel levels added together?

The answer, of course, is no, because we’re talking about sound pressure level. It’s not EXACTLY the same as fluid pressure, but a decent analogy is that, if you have an air compressor supplying your system with 100psig compressed air, turning on your other, identical air compressor won’t result in 200psig in your system.

I mention this for a couple of reasons. One; I’m a BIG fan of The Who, and I heard one of my favorite songs of theirs on the radio this morning: “You Better You Bet,” from their Face Dances album, which came out in 1981 and hence would not have been played at the 1976 Loudest Band concert, but I digress.

The other reason is because of a conversation I had with a caller about the sound levels produced by our Super Air Knives. The published sound pressure level is 69 dBA. “dB” is short for decibels; “A” means the unit is weighted to express the relative loudness of sounds as perceived by the human ear. Anyway, the caller was interested in knowing how much louder our longer Super Air Knives were than their shorter counterparts. The answer is, of course, they’re not louder…for the same reason that your second air compressor doesn’t double the air pressure in your system, which is the same reason that the fictional jet landing at the rock concert wouldn’t double the sound level.

Now, a couple of things to consider: the sound pressure levels that we publish were measured at a distance of 3 feet to the side of the Super Air Knife. Sound levels at a closer distance, and/or in front of or behind the Air Knife, will be different. Also, the Super Air Knife was blowing into free air. If the air flow is impinging on a surface, there will be a sound level associated with that as well. If it’s in excess of the 69 dBA that the Super Air Knife is producing, then that’s what your ears are going to be subject to.

All things considered, though, the Super Air Knife is INCREDIBLY quiet, considering the amount of air flow it’s producing. The science behind this has to do with what makes them so efficient with their use of compressed air: their entrainment ability. The Super Air Knife’s design allows it to use the primary compressed air flow to entrain enormous amount of air from the surrounding environment. This entrained air not only multiplies the resultant flow rate produced, but forms an attenuating boundary layer, which effectively reduces the sound level produced by the high velocity compressed air.

The Super Air Knife entrains air at a rate of 40:1, relative to its compressed air consumption.
The Super Air Knife entrains air at a rate of 40:1, relative to its compressed air consumption.

If you’d like to find out more about how EXAIR Intelligent Compressed Air Products such as the Super Air Knife can reduce your air consumption AND your sound levels, give me a call.

Russ Bowman
Application Engineer
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