Limiting Noise Exposure with Mufflers for Compressed Air

Mufflers come in many shapes and sizes. Each with their own benefits.

If you have ever walked into a manufacturing facility and heard the hiss or even worse the banshee scream of compressed air being exhausted to ambient, whether it be from a cylinder discharge, a timed drain going off, or a bypass valve being activated, they all could be hushed with a muffler. A muffler for compressed air comes in several shapes and sizes. EXAIR offers four separate types from stock to help attenuate the noise disruption within your facility.

The OSHA standard for allowable noise exposure is 29 CFR-1910.95(a) and outlines the number of hours per day any individual can be exposed to a particular noise level. These noise levels are expressed in decibels (dbA).

Hearing loss is the best known, but not the only, ill effect of harmful noise exposure. It can also cause physical and psychological stress, impair concentration, and contribute to workplace accidents or injuries.
Reclassifying Mufflers attenuating the exhaust of a pneumatic cylinder.

The first type I would like to showcase are the Reclassifying Mufflers. These are ideal for cylinder exhausts or valves which commonly contain an oil mist within the air stream which can easily contaminate the surrounding area. The patented design of the removable element separates oil from the exhausted air so virtually no atomized oil is released into the environment. They also attenuate the exhaust noise level up to 35 decibels. The filter element helps the exhaust to meet the OSHA Standard 29 CFR 1910.1000, a worker’s cumulative exposure to oil mist must not exceed 5 mg/m³ by volume in any eight hour shift of a forty hour work week.

The chart below helps to properly size the Reclassifying Muffler for a pneumatic cylinder. One key to proper installation of these mufflers is they must be installed vertically in order to properly trap and drain the oil.

Reclassifying Muffler Quick Pick Chart
Sintered Bronze mufflers are excellent choices for tight installation locations and are easily sized.

The next type of muffler to discuss are the Sintered Bronze Mufflers that are offered in ten different sizes. These are an excellent low cost solution which easily install into new or existing ports. Each size is designed to provide minimal back pressure and restriction for the individual port size. The quick pick chart below helps to easily select the correct size for attenuating the exhaust of a pneumatic cylinder. One key difference between these and the Reclassifying Mufflers is, these do not have to be oriented vertically as they do not collect the oil out of the exhaust air.

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The model 3913 – 3/4″ NPT Straight Through Muffler

If the process air needs to be directed or plumbed away from the operator then the Straight Through Mufflers are the ideal selection as they offer an NPT threaded inlet and exhaust. They are available in three standard NPT sizes from stock. These mufflers can be installed in any orientation and work well with our Vortex Tubes to help pass the cold air through while lowering the operating sound level of the tube. The average noise reduction of the Straight-Through Mufflers is 20 dB. This can easily reduce the noise level of an operation to below the OSHA standard requiring hearing protection for operators in the area.

The model 3903 Heavy Duty Muffler

The final option for mufflers from EXAIR are the Heavy Duty Mufflers. These are available in two sizes from stock and are constructed of corrosion-resistant aluminum with a stainless steel internal screen. These can be installed in any orientation and are ideal for protecting exhaust ports from contaminants that may clog or damage the device they are attached to. The typical noise reduction from installation is 14 dB with these mufflers.

These are available in two sizes from stock and are constructed of corrosion-resistant aluminum with a stainless steel internal screen. These can be installed in any orientation and are ideal for protecting exhaust ports from contaminants that may clog or damage the device they are attached to. The typical noise reduction from installation is 14 dB with these mufflers.

To summarize, EXAIR offers a multitude of options when it comes to lowering sound levels in operation areas that are caused by exhausted compressed air. Each of the mufflers discussed above are shipped same day from stock to meet your immediate need. If you are unsure of which muffler to use for your application, feel free to contact an Application Engineer.

Brian Farno
Application Engineer
Ph. 1-513-671-3322
BrianFarno@EXAIR.com
@EXAIR_BF

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

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

 

Super Sized Is Not A Problem At EXAIR

For many years we as Americans wanted to biggie size, super size, or mega size anything and everything we could.   For myself that mainly meant the fries and drink I used to get at any local fast food joint.   Now that I have hit my mid-30s and all of that has started to catch up to me, I don’t always want the large fry or any fries at all, instead I might try a new salad and trying to eat healthy.  Here at EXAIR, we don’t always associate bigger with better but we do always fill the need when we don’t have something off the shelf.

However, there are still occasions where going super size is necessary and this week, we did just that.   We had a customer ask if we can go bigger on our Super Air Wipes.   We simply asked how big they needed to go and what the reasoning is for it.  Turns out, the reasoning for the larger Super Air Wipe was a newly designed automated cell in a pipe manufacturing facility.   The stock 11″ was too small to fit the 11″ max. diameter piece through to blow off debris so they requested a 12″ Super Air Wipe.   To top off the customization, they were also in need of BP threaded air inlets.

Catalog 30 Stock Air Wipe Sizes

Within a matter of weeks our customer has gone from a product they didn’t know was possible, to shipping out to their site.  This is a one off, custom machined, Super Air Wipe that has a 12″ Throat Diameter.   The only parts on this that are from our standard stock are the bolts, stickers, and the connecting / hinge plates(The clam shell design requires these.).

If you have an application where you don’t think we have exactly what you need or maybe you need to go bigger, or smaller, than what we show in the catalog don’t move on and try to find something else.   Give an Application Engineer a call and we will see how we can tailor our products to your exact needs.

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

Video Blog: How To Rebuild Pressure Regulators

Today’s video blog is a how-to on rebuilding EXAIR pressure regulators.   Regulators can wear out over time and extensive adjustment as well as if they are not used on a clean compressed air supply.  If you have any questions on an EXAIR product, please contact an Application Engineer.

Thanks for watching!

 

 

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

Video Blog: Introducing The EXAIR Drum Cover: Model 6850

Below is a video showcasing the model 6850 Drum Cover.  The Drum Cover is a new product from EXAIR that will help to filter pneumatically conveyed products from the air used to move them.  If you would like to discuss a conveyance application or whether this product would fit your need, please contact an Application Engineer.

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

EXAIR’s Efficiency Lab can Help With your Energy Audit, Quantify Savings and Provide an ROI

I recently received an inquiry from a customer to test their current air guns through our Efficiency Lab service. According to the operators, the handheld blow gun they were purchasing from a commercial retailer was too loud and complaints were rolling in.  They were also hoping to save some compressed air in the process as they were performing an energy audit at the same time.

Commercial Air Gun w/ Cross Cut Hole
Commercial Air Gun w/ Cross Cut Hole

Cross Cut Hole Nozzle
Cross Cut Hole Nozzle

The gun they sent in looked fairly similar to our Precision Safety Air Gun but it did not have an engineered nozzle on the tip of it.   Instead, it was simply a cross cut hole in a piece of material.   The air inlet to the gun was a 1/4″ NPT just like our Precision Safety Air Gun, the extension on the gun was slightly longer, the only significant variance I saw was the tip.

EXAIR Model 1410SS-CS
EXAIR Model 1410SS-CS

The Model 1110SS Nao Super Air Nozzle and Chip Shield
The Model 1110SS Nao Super Air Nozzle and Chip Shield

To try and get as much information as possible I measured the O.D. and I.D. of the extension, the hole size was approximately .140″.  I measured the extension on our Precision Safety Air Gun just to see what is different, it came in at the same size.  So, I flow tested the competitive blow gun with their tip on it and came up with air consumption of 12.69 SCFM, noise level of 92 dBA at 3′ away, and a blowing force of 11.5 oz at 80 psig.   I then measured the same attributes of EXAIR’s model 1410SS-CS Precision Safety Air Gun at 80 psig inlet pressure.  The model 1410SS-CS measured 8.3 SCFM, gave 8.1 ozs of working force, and only produced a 75 dBA sound level from 3′ away.

The sound level reduction was a total of 17 dBA which is below the OSHA standard for allowable noise level exposure, as well as reduced their air consumption by 4.39 SCFM.  That is almost a 35% reduction in their compressed air usage per gun replaced.  After seeing these levels of reduction the customer had more than enough information to provide management with in order to replace the blow guns not just for noise level reduction but also because it will reduce air use and save money. A clear supportive role in their energy audit.

If you would like to discuss how EXAIR can provide some free force, flow, and noise level testing for your facility, please contact an Application Engineer or check out the Efficiency Lab page on our site.

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

Low Pressure Alarms Got You Down?

When the operating air pressure within a manufacturing facility drops it is easily noticed.  This is because the equipment that is depending on that air pressure to stay above a set point will generally stop working and halt in an alarm state safely.  (This is not always the case and in fact I have personally seen machines crash due to low compressed air pressure.)  This creates down time, safety hazards, equipment hazards and is all around not good for production.  This is why low pressure alarms are taken very seriously in most facilities.(See the video below.)

 

Sometimes the reason behind low air pressure in areas is easy to find.  If the alarm happens every time a machine reaches a point in the production cycle where air is used to blow parts off then the point of use blow off can be looked at to see how its efficiency can be maximized.   Other times it is not so simple.  There may not be a pattern to when the low pressure alarm goes off and therefore cannot be easily traced.   This is where the 6 Steps To Compressed Air Optimization comes in to play.  The best way to narrow down what area the fault is generating in is to get some base line measurements on the total air usage for the system by using a product like the Digital Flowmeter with USB Data logger.

EXAIR's Digital Flowmeter w/ USB Data Logger
EXAIR’s Digital Flowmeter w/ USB Data Logger

Once the baseline is known for the complete system, measuring the main branch lines for the systems will then need to be performed. This could be on the main header where it branches off to individual areas of the plant, or if it is a small shop any line that is off the main header.  By recording the usage over a period of time it will highlight use trends including low use/high use times and random spikes in demand you may not be aware of. The next step would be to then look further into the high use and random spikes. If a flow meter is placed on individual legs of the air system, it will be easier to determine what area of the plant is causing high use, or knowing what processes occur during the time period shown in the data.

By having flow meters on individual branches the cause of the high demand on the compressed air system will become very clearer, whether it be an open pipe blow off, stuck valve on a drain, or just an operator not paying attention, the cause will be able to be determined and eliminated.

EXAIR offers a full range of Digital Flowmeters with USB data loggers and we offer custom calibrations as well as sizes to fit virtually any compressed air piping you may have within your facility.   Feel free to contact an Application Engineer to discuss the possibilities.

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