Here on the EXAIR Blog we frequently discuss dead-end pressure as explained in OSHA Standard 1910.242(b). This directive states that the when compressed air is used for cleaning purposes, the dead-ended pressure must not exceed 30 psig. When pressures greater than this occur, there is potential for an air embolism. This animation shows and explains how an air embolism can affect the body.
EXAIR’s Flat Nozzles adhere to this OSHA directive. The Flat Nozzles consist of three primary components: the body, the cap, and the shim. The thickness of the shim will dictate the flow and force through the nozzle and can be easily adjusted. The cap slightly protrudes from the body and shim, creating a gap when it is pressed up onto the skin. By ensuring that there is always an avenue for that air to escape, there is no potential for it to be dead-ended.
EXAIR’s flat nozzles are available in two sizes: 1” and 2”. Each size has a shim set that can be purchased for adjusting both the flow and force from the nozzle. These nozzles are available in both zinc/aluminum alloy as well as 316 grade Stainless Steel. They can be used by themselves, installed on our Safety Air Guns, or in conjunction with our Stay Set Hoses that allow for easy re-positioning.
You may have seen (or used) the plastic flat nozzles that come in a variety of different colors. EXAIR’s flat nozzle is a safe, efficient, and more robust replacement that will maintain a similar airflow pattern at a dramatically reduced operating cost. Where plastic nozzles may become damaged or break off, the rigid construction of EXAIR’s Flat Nozzle will not. In addition to be safe, durable, and reliable, EXAIR’s flat nozzles also offer a reduced sound level compared to these styles of nozzle. Reducing sound is another directive that OSHA 29 CFR 1910.95 covers. If you’re using an unsafe nozzle in your facility, OSHA can quickly begin assessing fines for each violation. They don’t announce their visits beforehand, so make sure you do your due diligence and assess your compressed air blowoff products yourself!
If you would like to discuss how to make your compressed air use safer and more efficient, give us a call. Our team of highly-trained Application Engineers is standing by, ready to help you make the switch to an Intelligent Compressed Air Product.
EXAIR’s Engineered Air Nozzles and Air Jets provide a simple solution to lower compressed air usage and reduce noise levels for compressed air blowoff operations.
Why Air Nozzles and Jets – When compared to commonly used open copper tubes or pipes, compressed air savings can be as high as 80%. And with less compressed air, sound levels are greatly reduced. A 10 dBA noise level reduction is typical. All EXAIR Air Nozzles and Jets meet the Occupational Safety and Health Administration (OSHA) maximum dead end pressure and sound level exposure requirements. They also carry the CE mark.
EXAIR Nozzles are engineered to take advantage of the Coanda effect to amplify the airflow up to 25 times or more. Compressed air is ejected through the small orifices and surrounding air is entrained into the main stream. The resulting air stream is a high volume, high velocity blast of air at minimal consumption. EXAIR manufactures many styles, from the very small, but powerful Atto Super Air Nozzles, to the largest 1-1/4 NPT Super Air Nozzle. Also offered are 1″ and 2″ wide Flat Super Air Nozzles, and the Back Blow style for cleaning out tubes, pipes, channels or holes from 1/4″ to 16″ in diameter.
EXAIR Air Jets utilize the Coanda effect (wall attachment of a high velocity fluid) to produce air motion in their surroundings. A small amount of compressed air (1) is throttled through an internal ring nozzle above sonic velocity. A vacuum is produced, pulling in large volumes of surrounding, or ‘free’ air, through an around the jet (2). The exit flow is the combination of the two air sources (3).
EXAIR manufactures Air Jets in two types, High Velocity, and Adjustable with materials of construction of brass and Type 303 Stainless Steel. The High Velocity Air Jet uses a changeable shim to set the gap, controlling the force and flow of the air. The Adjustable does not use a shim, and has a micrometer gap indicator and locking ring to allow for varying force and flow performance.
If you have questions about Air Nozzles and Jets, 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.
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).
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.
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.
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.
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.
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.
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.
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.
Nothing is being delayed, especially a shipment from EXAIR. If it’s in the catalog, it ships on time, 99.97% of the time, for 17 years & running. This has nothing to do with this blog; I just never get tired of bragging about that.
Today I wanted to write about installing EXAIR products, but hey, it’s Friday, so I thought I’d start with something that would get your attention. If you’re still reading, I guess it worked.
We talk to users…and potential users…all the time about how to install an Air Knife, Air Nozzle, Vortex Tube, etc. And the answer is…it depends. But, it’s almost always quick and easy.
Consider the EXAIR Super Air Knife. There are a few ways to hold one in place:
*There are 1/4″-20 tapped holes, every 2″ along the bottom. These can be used to bolt it to just about anything you want to bolt it to.
*The 1/4″-20 cap screws can also be replaced with fasteners of sufficient length to allow use of a bracket. In fact, this is what we use for…
*The Universal Air Knife Mounting System – it’s a quick and convenient way to support an Air Knife. It’s especially beneficial to precisely position the Super Air Knife for optimum performance.
*Last but not least, Super Air Knives 24″ and longer need to be plumbed to both ends for proper performance. If you hard pipe it in, it’ll be as well supported as the piping.
Then there’s our Super Air Nozzles:
*With standard, common NPT threads, these are easy to install anywhere you have an existing air line. You can get NPT adapters for darn near any threaded connection, off the shelf, from a friendly local air compressor or hydraulic/pneumatics shop.
*We’ve got Stay Set Hoses in lengths from 6″ to 36″ – these let you reposition the Air Nozzle at will. It’ll “stay set” until you bend it again.
*Our Swivel Fittings can be used with any of our Super Air Nozzles, as well as our Air Amplifiers, for sturdy, yet easily repositionable, installation.
Recently, I was able to work with a gentlemen from a stamping company that produces small metal stamped lids for the cosmetic industry. He was frustrated because the current blow off setup, a copper tube and nozzle (shown below), was too weak and narrow to be effective with parts ranging from 1″ to 2.5″ wide. Whenever a lid did not get completely discharged, the machine would jam and double hit on the next cycle, ruining (2) parts in the process, not to mention, potentially damaging the the tooling.
After reviewing the process, which is very high speed, we wanted a strong, concentrated blast of air that matched the part profile to maximize the air flow contact patch. We agreed the model HP1125 – 2″ High Power Flat Super Air Nozzle would be a good nozzle to implement and test. In addition to the Nozzle, the customer ordered the model HP1132SS Shim Set, to allow for flow and force adjustment of the nozzle to obtain the best possible performance under production conditions. The HP1125 nozzle provides 2.2 lbs of force with the standard .025 patented shim installed, and can be decreased or increased by changing the shim to .020″ or .030″ thick. Preliminary testing has proven successful, and reliability testing and data collection is underway.
Newly released, the EXAIRHigh 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.
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.)
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.