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 Accessories – We’ve Got you Covered

When you work with us here at EXAIR, we strive to have all the ancillary items that you might need to make your installation a success, without having to find components at the last minute or perhaps using the wrong sized components. Each specific product line such as Super Air Knives or Line Vac air operated conveyors have specific accessories such as mounting brackets or plumbing kits which EXAIR has made to simplify the installation of those particular products. We also carry generalized accessories which work across all of the product lines so you do not have to use multiple vendors or purchase orders.

Silencing Mufflers – Per OSHA Standard 1910.95(a), a worker must not be exposed to sounds levels above 90 dBA for any eight hour shift of a 40 hour work week.  EXAIR offers several types of mufflers including – Reclassifying, Sintered Bronze, Straight-Through and Heavy Duty.  For reducing the noise associated with an EXAIR E-Vac Generator, Vortex Tube, Cabinet Cooler System, or the exhaust air from cylinders, valves and other air powered equipment, we’ve got a muffler that will help to keep the noise level at an acceptable level.

Mufflers

Solenoid and Manual Valves – The easiest way to reduce compressed air usage and save on operating expense is to turn off the compressed air to a device when it isn’t needed. EXAIR carries a wide assortment of solenoid valves, with offerings in the NEMA 4/4X classification, and supply voltages of 24VDC, 120VAC, and 240VAC.  We also have manual ball valves from 1/4 NPT to 1-1/4 NPT and a foot operated valve, with 1/4 NPT connections.

Valves

Swivel Fittings, Stay Set Hoses and Magnetic Bases – To provide a great degree of flexibility for positioning an EXAIR Super Air Nozzle, Air Jets or Air Amplifiers, EXAIR offers several items.  The Swivel Fittings have 25 degree of movement from the center axis, providing a total of 50 degree of adjustability.  The position is locked in place and holds until adjustment is needed. For applications where frequent re-positioning of the air device is required, the Stay Set Hoses are ideal.  Simply mount the hose close to the application, bend it to the shape preferred, and because the hose has “memory”, it will not creep or bend.  Lastly, the Magnetic Bases are another option for flexible, movable installations.  The base has a on/off valve, and a powerful magnet to hold in any vertical or horizontal mounting arrangement.

Swivels, StaySets,MagBases2

 

Hoses – EXAIR can provide hoses for your application.  For the Line Vac air operated conveyor applications, we offer conveyance hose – a durable, clear reinforced PVC hose, in diameters of 3/8″ to 3″ ID, and lengths up to 50′. On the compressed air side, we can provide 12′ Coiled Hoses with 1/8, 1/4, and 3/8 NPT connections, and also 3/8″ and 1/2″ ID hose in lengths to 50′.

Hoses

Filter Separators, Oil Removal Filters and Pressure Regulators – Perhaps the most important accessories for use on a compressed air device are filters and regulators. Filtering the compressed air of dirt, debris, moisture and oil will help to prevent build up inside the EXAIR products, leading to longer service life, and less time spent cleaning, while providing optimum performance. Regulating the air pressure allows for tuning of the performance, using the proper amount of compressed air to obtain satisfactory results.

Filter and Regualtors

If you have questions regarding accessories for use with 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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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 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

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

How to Meet the OSHA Compressed Air Standard

Every day we talk to customers who need to comply with OSHA regulations for using compressed air to clean up their shop or product. Back in 1972 on Valentine’s Day, OSHA published Directive Number STD01-13-001 standard 1910.242(b), which strives to provide guidance on how manufacturers can safely use compressed air for cleaning purposes to comply with the Walsh-Healey Act of 1936.  This directive laid out acceptable methods for complying with 41CFR 50-204.8 and 29 CFR 1910.242(b)

The two methods are very simple, but still many people have questions.  The first method (pictured below) is to regulate the line pressure from the compressor to below 30 PSIG.

Regulator Method

Figure 1 Regulator method Photo Courtesy of osha.gov

The second method is to install a nozzle engineered to reduce the static pressure of the nozzle to less than 30 PSIG.

OSHA Nozzle Method

Figure 2 Nozzle method Photo Courtesy of osha.gov

The first method reduces the danger by limiting the energy in the system to less than an amount which can injure a person.  OSHA determined that 30 PSIG was the safe limit for the amount of pressure the human body could withstand without causing severe injury. The problem with this method is that cleaning with compressed air at 30 psig is virtually impossible.  Which means at such a low pressure the operator must pass the nozzle so close to the chips and debris, he might as well use a broom or pick each piece of debris up with his fingers. This first method I will label the regulator method. The second method introduces a relief valve at the nozzle, so that an operator cannot block off all of the openings of the nozzle, and build up any static pressure on their skin. I will call this the nozzle method.

Commonly and cheaply, the nozzle method is done by cross drilling a hole in an open pipe.  This is a sometimes effective method for protecting employees from static pressure, but it also is great at producing a tremendous amount of noise and wasting a lot of compressed air every year. The noise produced by even a ¼ pipe with a cross drilled hole fed with 80 PSIG can easily exceed 90 dBA and consume up to 140 SCFM. The noise can be even louder, if there are burrs or rough edges from drilling out the pipe.  This is also a violation of OSHA standard 29 CFR – 1910.95 (a), if the employee is not using hearing protection.

Air Nozzle work

To meet this OSHA standard, EXAIR’s solution is to engineer features which cannot be dead-ended into a wide variety of compressed air products. We do this a variety of ways depending on the product.  For the Super Air Nozzles, we utilize multiple small orifices which are protected by raised fins.  The multiple orifices offer an escape path for the air in case a single orifice is plugged. The fins protect the orifices so that no one person can block more than one orifice at a time.

So if you are worried about an OSHA inspector knocking on your door, or maybe you aren’t sure if you should be worried, contact us.  The Application Engineering team here will help you determine what engineered solution you need to keep those pesky fines away.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

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