EXAIR’s Flat Nozzles: Safe, Reliable, and Efficient

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.

2fsanfam2
From top to bottom: Model 1126, 1126SS, 1122, and 1122SS

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!

2san_blowaway
EXAIR 2″ Flat Super Air Nozzle “blows” away the competition!

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.

Tyler Daniel
Application Engineer

E-mail:TylerDaniel@exair.com
Twitter:@EXAIR_TD

Increase Safety and Gain OSHA Compliance By Using An Engineered Solution

In 1972, the US Department of Labor’s Occupation Safety & Health Administration (OSHA) established Standard 29 CFR 1910.242(b) to reduce the outlet pressure to less than 30 psi, of an open pipe, nozzle, air gun, etc. when being used for cleaning. The intent of this directive was to prevent injury to operators. They determined that 30 psi was the pressure in which the skin could be broken if the device were dead-ended against the operator’s body, causing an injury known as an air embolism…the dead-ended force of the air, under pressure, breaks the skin and introduces air flow inside the body. This is a VERY dangerous condition which can quickly lead to serious injury, possible stroke or ultimately death.

While OSHA doesn’t recommend any type or manufacturer of device, they do provide two methods you can follow to gain compliance.

The first would be to reduce the operating pressure below 30 PSI, as shown in the below line drawing.  This, of course, limits the strength and usefulness of the exhausting air flow before it reaches the nozzle and before it is used upon the application.

 

The other method indicates using a nozzle which includes a pressure reducer or a relief device which will reduce the air pressure to less than 30 psi if the nozzle is dead ended. All of EXAIR‘s products are engineered to meet or exceed this Standard. In the case of our Super Air Nozzles, the air exits through a series of jets, recessed behind an array of fins, so the outlet holes cannot be blocked directly, any potential obstruction of the outlet air holes results in the air having an alternative route to avoid injury to operators and personnel. This allows the full pressure (the highest energy) to reach the nozzle and the application

Open air lines and homemade blow offs violate OSHA standard 1910.242(b) because of harmful dead end pressures. If you would like to discuss how EXAIR products can help you gain OSHA compliance to increase personnel safety and avoid costly fines, please give me a call, I’d be happy to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Line drawings used from OSHA’s website

Engineered Nozzles Replace Segmented Coolant Hose for Ink Drying Application

flat nozzle loc line comparison
Segmented Hose on the left and an HP1126 1″ Flat Nozzle on the right

A common item that can be found in a majority of machine shops is the blue or gray knuckle-jointed hose used to dispense coolant on lathes and CNC machines. EXAIR also uses this same hose with our Cold Guns and Adjustable Spot Coolers for applications that cannot or do not wish to use liquid coolant as a means of keeping the heat down on their tooling. Since the cold air discharges at atmospheric pressure, this is an acceptable application. Another application is using this style of hose as a compressed air blowoff. This is NOT a proper use of the hose and is not only a considerable waste of compressed air but can also pose a safety hazard. Using this method for compressed air blowoff is not compliant with OSHA 1910.242(b) (a directive we blog about).

I was recently contacted by a customer in Indonesia that was using an array of (6) of these knuckle-jointed hoses with a ¼” round nozzle attachment for a blowoff operation. The customer had a series of rubber pads used in the construction of a toy castle. The pads were brought along by an overhead conveyor and a design was printed on the head of the pad. The nozzles were used to dry the ink before the pad made it to the next part of the process. This was a new product line and the processes involved were being evaluated for potential places to save on compressed air rather than adding overall capacity to their system. After using a variety of EXAIR products for other blowoff applications, they came back for another engineered solution.

After testing both a 1009-9280 (Adjustable Air Nozzle w/ 30” Stay Set Hose) and an HP1126-9280 (1” High Power Flat Nozzle w/ 30” Stay Set Hose), the customer determined that the airflow pattern from the 1” Flat Nozzle was more conducive to drying the rubber pad and purchased the remaining units to replace their original method. The compressed air savings was noticed immediately!!

For the old operation, they had to regulate the pressure down on the hose to 25 psig so that the hose wouldn’t break apart. (1) This hose , with a ¼” round nozzle, will consume 52 scfm at 25 psig of supply pressure. With (6) of these they were consuming a whopping 312 scfm!! Since the HP1126 is compliant with OSHA directive 1910.242(b) and will not break apart at higher pressures, they were able to operate at 80 psig while only consuming 17.5 scfm. They saved more than enough air for their new process and are evaluating whether or not they can turn off one of their smaller 25 HP compressors.

The new setup with the EXAIR engineered solution was able to save them 207 scfm of compressed air. Assuming a cost of $.25/1000 scfm and a 40 hr work week, this translates to an overall savings of $6,458.40 per year off of their utility bill.

207 scfm x 60 minutes x 8 hrs/day x 5 shifts/week x 52 weeks/year =25,833,600 scf

25,833,600 scf x ($.25/1000 scf) = $6,458.40

If you’re using an inefficient compressed air blowoff in your facility, give us a call. An Application Engineer will be happy to evaluate your process and determine the safest and most efficient solution. With same day shipment for stock items on orders placed by 3:00 pm EDT, we can get a solution out to you by the following day!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

EXAIR Heavy Duty Safety Air Gun Reduces Noise Level and Saves Air!

IMG-20170719-WA0014
Inside of the customer’s fin press

Just this week I’ve been working with an aerospace manufacturer that had some concerns about a cleaning operation on one of their fin press machines used for a stamping process. After each operation, they need to blow out the dies to remove any residual oil and debris. They were currently using a ¼” open copper tubing operating at 90 psi. Their reason for contacting EXAIR was due to a recent OSHA compliance training that their production manager had attended. He learned about OSHA 1910.242(b), a directive that we’ve written about many times in the past, that states compressed air devices used for blowoff must maintain a dead-end pressure less than 30 psi. Additionally, the sound levels were far too high to adhere to OSHA directive 29 CFR 1910.95(a). This was a major concern for them and a common theme that we hear from many of our customers. As this manufacturer is clearly aware, fines associated with failing to comply to OSHA directives can be quite costly. Their failure to adhere to this and a few other directives led to a total penalty of $33,800.00.

1360_csbox
EXAIR’s Heavy Duty Safety Air Gun with Chip Shield

After some discussion about the different types of solutions that EXAIR has to offer, we settled on the Model 1310-18-CS. At a sound level of just 74 dBA when operated at 80 psi, we were able to drastically improve upon the sound levels that he was previously experiencing. This was a very welcomed solution by his operators, as they were now able to clean out the dies without having to wear any hearing protection. The Chip Shield also added some additional protection so that no debris could come back towards the operator. In addition to addressing his sound level concerns, we were also able to save a substantial amount of compressed air. The 1310-18-CS will consume just 14 SCFM of compressed air at 80 psi. A ¼” pipe operated at this pressure will consume approximately 69 SCFM. This is an 80% reduction in compressed air usage for just one operation!!

If you have an application where sound level needs to be reduced or you’re looking to improve upon employee safety, EXAIR has the solution. Give us a call today to find out how we can implement a solution to keep OSHA inspectors at bay.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

EXAIR Back Blow Nozzle: An Overview

In certain applications such as blowing chips or debris out of a pipe or blind hole, it may not be possible to blow forward. The pipe may be too long, making it impossible to push the debris all the way down the pipe or the other end of the pipe may not be open. In either of these scenarios, the Back Blow Nozzle is the right tool for the job. An array of holes around the diameter of the Back Blow Nozzles provides a powerful 360° airflow pattern that will clear out any leftover coolant or chips from the machining process.

m4BB2017_1670x574
Small 1004SS easily clears debris

EXAIR has three different size Back Blow Nozzles; the 1004SS (M4 x .5), the 1006SS (1/4 NPT), and the 1008SS (1” NPT). The 1004SS is recommended for use on pipes as small as ¼” and up to 1”. The 1006SS can be used for a wide range of pipe sizes, from 7/8” up to 4”. The 1008SS nozzle offers the greatest overall force for stubborn or sticky materials stuck to the inside diameter of the pipe. This nozzle is suitable for use in pipes ranging from 2”-16”. As the Back Blow Nozzle will be blowing chips and debris back out of the pipe towards the operator, it is always recommended that a Chip Shield is used. The strong polycarbonate Chip Shield will keep them safe from flying debris and keep you in compliance with OSHA directive 1910.242(b). For visual representation of the performance of the Back Blow Nozzle, take a look at this short video clip that demonstrates its use.

All of EXAIR’s Back Blow Nozzles are available with extensions. For the 1004SS we have extensions from 6”-36”, and from 12”-72” for the 1006SS and 1008SS. The Back Blow Nozzle can also be installed on our VariBlast, Soft Grip, Heavy Duty, and Super Blast Safety Air Guns. With such a wide range of available sizes and configurations, we can tackle just about any internal pipe cleaning application. If you have a process in your facility that may benefit from the use of one of these nozzles, give us a call and get one on order today!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

 

OSHA Standard 1910.242(b) – Dead-End Pressure and Chip Guarding Explained

OSHA Standard 1910.242(b) discusses the use of compressed air for cleaning and blowoff. It states that the use of compressed air for cleaning purposes is prohibited if the dead-ended pressure exceeds 30 psig. This phrase means the downstream pressure of the air nozzle or gun, used for cleaning purposes, will remain at a pressure level below 30 psig for all static conditions. In the event that dead ending occurs, the static pressure at the main orifice shall not exceed 30 psi. If it does exceed this pressure, there is a very high potential for it to create an air embolism. An air embolism, left untreated, can quickly impede the flow of blood throughout the body. This can lead to stroke, heart attack, and sometimes death. Take a look at the animation below to see how an air embolism can affect the body.

With this in mind, there are only two options for staying within compliance of this standard. Either install an engineered solution that will reduce the air pressure to less than 30 psig if dead-ended, or regulate the pressure below 30 psig. For the vast majority of operations, regulating the input pressure below 30 psig is useless. The force and flow from the nozzle at this pressure is greatly reduced and likely not enough to be effective in most applications. All of EXAIR’s Safety Air Guns are designed so that the flow cannot be dead-ended. The fins on the Super Air Nozzles are not only useful in amplifying the force by drawing in ambient air, but they also prevent an operator from completely obstructing the airflow.

sag-osha-compliant
The fins of the Super Air Nozzle allow air to escape and prevent dead-end pressure from exceeding 30 psig.

In addition to being concerned about dead-end pressure, OSHA 1910.242(b) also states that compressed air used for cleaning should include effective chip guarding. By this, they mean that some method or equipment must be installed that will prevent chips and particles from coming back into the eyes or skin of the operator. In addition to offering OSHA compliant nozzles and guns, EXAIR also has Chip Shields that can be installed onto any of our Safety Air Guns. The polycarbonate shields protect the operator from any flying debris while performing a drying or blowoff operation. Simply add a “-CS” to the end of any Safety Air Gun Model number to have a Chip Shield installed on the gun.

1210peek-cs
EXAIR’s Model 1210-PEEK-CS with Chip Shield

The Occupational Safety and Health Act of 1970 does not contain any provisions that allow for the approval or endorsement of equipment. Alteration or the misapplication of what was once a safe piece of equipment would create a dangerous scenario that is out of the control of the original manufacturer. Any nozzles or guns marketed as “OSHA approved” should immediately throw up a red flag. Identifying and implementing a safe, OSHA compliant solution rests in the hands of the manufacturer themselves. If you’ve got questions about compressed air safety or have an existing blowoff in place that does not adhere to this OSHA directive, give us a call. We’ll be sure to recommend a solution that will keep your operators and wallets safe!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

 

EXAIR Leads the Way with Standards and Certifications

For over 34 years, EXAIR has been the industry leader in providing Intelligent Compressed Air Products to the industrial marketplace. While much of our focus is to ensure our products are engineered to provide optimal performance, we are also dedicated to manufacturing products that meet a wide range of standards and directives to promote safety in relation to plant personnel.

 

For instance, all of our compressed air operated products meet or exceed OSHA Standards 29 CFR 1910.242(b), requiring that the outlet pressure of an open pipe, nozzle, air gun, etc., when used for cleaning purposes, must remain below 30 PSI when dead-ended against the skin, as well as Standard 29 CFR 1910.95(a) as a way to protect workers from job related injuries related to dangerous sound levels of 90 dBA and higher.

 

 


Many of our products are also CE Compliant, meeting the mandatory requirements for products intended to be sold in the European Economic Area or “EEA”. For example our Electronic Flow Control and Electronic Temperature Control (ETC) meet the EU (European Union) Low Voltage Directive 2006/95/EC.

 

 

EXAIR electrically powered devices, like our Static Eliminators and Digital Flowmeters for example, comply with the “Restriction of Hazardous Substances” or RoHS Directive 2011/65/EU, including the amendment outlined in the European Commission decision L 214/65.

 

 

We are also committed to providing material that supports the conflict mineral free rule to help aid in the relief of illegal trade of exotic materials, like tungsten, gold, tin and tantalum in the DRC region. Using the CMRT 4.20 template, we document our supply resources to ensure we provide conflict free products, as outlined in Section 1502 of the Dodd-Frank Wall Street Reform and Consumer Protection Act.

 

Lastly, the European Union introduced the REACH program – Registration, Evaluation, Authorization and Restriction of Chemicals, as a method to register chemical substances being imported into the EU to protect people and the environment, per Regulation (EC) No 1907/2006 Title I, Article 3.  Also noted in the program, Title II, Article 7, they state that any product with a substance intended to be released under normal operating conditions, must be registered for quantities totaling more than 1 metric ton per year. Since EXAIR products do not intentionally release or contain any such substances, registration to meet the program is not required.

 

If you have any questions about any of these Standards or Directives or about which EXAIR products comply, please feel free to contact an application engineer for assistance. We’d be happy to help!

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN