Noise levels or sound levels are an important consideration in many industrial settings. Noise exposure can cause irreparable damage if the necessary safety precautions are not taken. OSHA standard 29 CFR – 1910.95 (a) addresses this very concern.
But when discussing sound levels, there are two terms that frequently come up – Sound Power, and Sound Pressure. So, what’s the difference?
Sound Power (measured in watts) refers to the rate at which sound energy (measured in decibels) is emitted, reflected, transmitted, or received over time. On the other hand, sound pressure is the local pressure change from ambient atmospheric pressure caused by a sound wave. From these definitions, we can see that sound power is what creates the sound wave, while sound pressure is the result of what we perceive after the sound wave reaches our ears.
A good way of conceptualizing this is to imagine a light bulb. Light bulbs use electricity to produce light, which means the power needed (also measured in Watts) to make the bulb shine is similar to sound power. The brightness of the light produced (measured in lumens) corresponds to sound pressure. Sound pressure is essentially what we hear or refer to as sound. This is what gets measured because it can be harmful to our hearing. If the sound pressure is too high and the ear is exposed for too long, it can lead to permanent damage, hence OSHA’s regulation mentioned above. This regulation is the result of testing performed to determine what time thresholds at which permanent damage to human hearing will occur due to exposure over a period of time. The higher the sound pressure level, the less exposure time necessary to produce irreparable damage. Within this regulation is included a time weighted chart that OSHA follow for noise exposure issues that serve as the metric by which they determine if a company is in compliance. If not, they may recommend engineering changes, work process changes or require the use of PPE (hearing protection) if the other types of controls cannot be implemented.
If you would like a way to measure noise levels in your facility, EXAIR has the perfect product – EXAIR’s Digital Sound Level Meter. We have a video blog covering its benefits and operation here.
Generally speaking, compressed air-generated noise within a facility can be rather prevalent and loud. So, if you would like to discuss how EXAIR’s quiet and efficient compressed air products can help reduce noise levels in your facility, then give us a call!
EXAIR Six Steps To Optimizing Your Compressed Air System
Since air compressors use a lot of electricity to make compressed air, it is important to use the compressed air as efficiently as possible. EXAIR has six simple steps to optimize your compressed air system. Following these steps will help you to cut electrical costs, reduce overhead, and improve your bottom line.
Step 1 – Measure the air consumption to find sources that use a lot of compressed air. Information is important to diagnose wasteful and problematic areas within your compressed air system. To measure air consumption, flow meters can be used to find the volume or mass of compressed air per unit of time. Flow rates are very useful data points to find problems like leaks, over-use in blow-offs, waste calculations, and comparison analysis.
Step 2 – Find and Fix the Leaks. One of the largest problems affecting compressed air systems is leaks. That quiet little hissing sound from the pipe lines is costing your company a lot of money. A study was conducted by a university to determine the percentage of air leaks in a typical manufacturing plant. In a poorly maintained system, they found on average that 30% of the compressor capacity is lost through air leaks. For a 100 hp compressor, you are losing 30 hp into the ambient air. To put a dollar value on it, a leak that you cannot physically hear can cost you as much as $130/year. That is just from one inaudible leak in hundreds of feet of compressed air lines. EXAIR offers an Ultrasonic Leak Detector to find those inaudible leaks to fix.
Step 3 – Upgrade your blow-off devices with engineered products. Here is a simple example. A 1/4″ copper tube blow off can consume as much as 33 SCFM (934 SLPM) when supplied with compressed air at 80psig (5.5 bar). It’ll give you a loud, strong blow off. If you replace that copper tube with an engineered nozzle, a Model 1100 Super Air Nozzle, you can reduce that flow to just 14 SCFM (396 SLPM) at 80 PSIG (5.5 bar). If you’re tracking your compressed air usage, you’ll see that replacing just one of them saves you 45,600 Standard Cubic Feet worth of compressed in one 5 day (8 hour a day) work week. At $0.25 per 1,000 cubic feet of compressed air, that’s a savings of $11.40 per week. Also, the noise level will be dropped to 74 dBA to make it comfortable when working nearby.
Step 4 – Turn off your compressed air when not in use. This step can be done using two simple methods, either by using manual controls such as ball valves or automated controllers such as solenoid valves. Manual controls are designed for long use and when switching on and off are infrequent. Ball Valves are one of the most commonly used manual shut-offs for compressed air and other fluids. The solenoid valves can be used for quicker shut-offs. With the cost of compressed air, every bit counts. If there are gaps in your operation, they can be triggered with different types of methods. EXAIR does offer an Electronic Flow Control that has an optical eye and timing sequences to trigger solenoid valves to blow compressed air only when it is required.
Step 5 – Install Secondary Receiver Tanks. Compressed air receiver tanks are an integral part of many compressed air distribution systems. Compressed air is stored at a high pressure after drying and filtration. A secondary receiver tank is located on the floor for pneumatic equipment or systems. Think of a receiver tank as a “capacitor”. It stores the energy within a system to be used in periods of peak demand, helping to maintain a stable compressed air pressure in your system. This improves the overall performance of the compressed air system and helps to prevent pressure swings. Rather than having to pull from the compressor, a secondary receiver tank can be sized to provide the short-term volume of air for a particular application.
Step 6 – Control the Air Pressure. People tend to overuse their compressed air for many blow-off applications. This can create excessive waste, overwork your air compressor, and rob other pneumatic areas. With Pressure Regulators, they give you control to set the operating pressure. By simply turning down the air pressure, less compressed air is used. As an example, a model 1100 Super Air Nozzle uses 14 SCFM (396 SLPM) of compressed air at 80 PSIG (5.5 bar). If you only need 50 PSIG (3.4 bar) to satisfy the blow-off requirement, then the air flow for the model 1100 drops to 9.5 SCFM (269 SLPM). You are now able to add that difference of 4.5 SCFM (127 SLPM) back into the compressed air system. If we use the average rate of $0.25/1000 cubic feet to make compressed air, this would be a savings of $135.00/year with an 8-hour shift. And, if you have many similar blow-off devices, you can see how this can really add up.
It is important to review and monitor your compressed air system. You can cut your energy consumption, improve efficiency, and save yourself money. The six steps above will help to diagnose the overall “health” of your compressed air system. EXAIR does carry some of these products to help you measure and analyze. You may have questions about the Six Steps to Optimize Your Compressed Air System, and an Application Engineer at EXAIR will be happy to help.
When we talk with customers about their EXAIR Products, we also discuss the quality of their compressed air. Many of our products have no moving parts and are considered maintenance-free when supplied with clean, dry compressed air. One of the most critical aspects of a compressed air distribution system is the dryer.
No matter where you are in the world, the atmospheric air will contain water vapor. Even in the driest place in the world, McMurdo Dry Valley in Antartica, there is some moisture in the air. As this air cools to the saturation point, also known as dew point, the vapor will condense into liquid water. The amount of this moisture will vary depending on both the ambient temperature and the relative humidity. According to the Compressed Air Challenge, a general rule of thumb is that the amount of moisture air can hold in a saturated condition will double for every increase of 20°F. In regions or periods of warmer temperatures, this poses an even greater problem. Some problems that can be associated with moisture-laden compressed air include:
Increased wear of moving parts due to removal of lubrication.
Formation of rust in piping and equipment.
It can affect the color, adherence, and finish of paint that is applied using compressed air.
Jeopardizes processes that are dependent upon pneumatic controls. A malfunction due to rust, scale, or clogged orifices can damage products or cause costly shutdowns.
In colder temperatures, the moisture can freeze in the control lines.
In order to remove moisture from the air after compression, a dryer must be installed at the outlet of the compressor. It is recommended to dry the compressed air to a dew point at least 18°F below the lowest ambient temperature to which the distribution system or end use is exposed. A dew point of 35-38°F is often sufficient and can be achieved by a refrigerated dryer (Best Practices for Compressed Air Systems). This makes the refrigerant dryer the most commonly used type in the industry.
A refrigerant dryer works by cooling the warm air that comes out of the compressor to 35-40°F. As the temperature decreases, moisture condenses and is removed from the compressed air supply. It’s then reheated to around ambient air temperatures (this helps to prevent condensation on the outside of distribution piping) and sent out to the distribution system.
With your air clean and dry at the point of use, you’re making sure you get the most lifespan out of EXAIR’s point-of-use Intelligent Compressed Air Products.
Both solenoid valves and ball valves function as on/off mechanisms to regulate flow within piping systems. Despite their similar roles, it is crucial to recognize the key differences between these two types of valves when selecting the most suitable option for your particular application.
Manual ball valves provide operators with the ability to manually shut off the air supply. We offer a range of full-flow ball valves, ensuring that there is no restriction on flow, with sizes available from 1/4″ NPT to 1-1/4″ NPT. These valves serve as an excellent solution for those seeking a straightforward and efficient method to manage air flow.
EXAIR stocks Solenoid Valves in a variety of sizes & voltages
Solenoid valves provide an electronic means to control the air supply, facilitating the development of more automated systems. Available in three voltage options—120VAC, 240VAC, and 24VDC—these valves accommodate a variety of flow rates and feature port sizes ranging from 1/4″ NPT to 1″ NPT. All models comply with RoHS and CE standards and are UL-listed, ensuring safety and reliability in their applications.
In addition to offering our solenoid valves as standalone products, we have incorporated them into various other solutions, such as our thermostat-controlled Cabinet Coolers and Electronic Flow Controllers, to deliver a comprehensive, ready-to-use option. Furthermore, these valves can be managed via a PLC, allowing for customization to meet specific application requirements.
It is advisable to turn off your compressed air system when it is not in use, even if you are utilizing the most efficient engineered products. This practice not only reduces energy consumption, leading to cost savings, but also contributes to the longevity of your air compressor. If you have questions about solenoid and ball valves, please do not hesitate to reach out.
