Not All Compressed Air Guns Are The Same

If you work in an industrial plant or manufacturing environment, chances are you use some type of compressed air gun for cleaning parts, work areas, etc. Many air guns purchased through large industrial suppliers are a common choice due to the cost of the gun but as the saying goes – “you get what you pay for”. These types of guns may be cheap to purchase but they are also made cheap and have parts that can break easily, like the trigger or nozzle. In many cases, the nozzles on these guns are also in violation of OSHA requirements, producing dangerous discharge pressures and loud noise levels, which can lead to costly fines or potentially deadly injuries.

EXAIR offers 5 different styles of Safety Air Guns that not only eliminate these concerns, but also provide a more efficient operation, which can reduce energy costs. All of our Safety Air Guns are fitted with our engineered Air Nozzles  which meet OSHA Standard 1910.242(b) for 30 PSI dead end pressure, as they provide a relief or safe path for the air to exit if the nozzle were to be blocked or pressed against an operator’s body so the exiting air pressure will never reach 30 PSIG. They are also engineered to entrain surrounding air across the profile of the nozzle, which produces a smoother airflow, ultimately reducing wind shear, resulting in much lower sound levels, meeting OSHA Standard 29 CFR 1910.95(a).

 

 

The Precision Safety Air Gun body is made of a durable high impact, glass reinforced nylon, providing for a lightweight, ergonomic operation. These guns feature a curved extension, ideal for delivering a powerful stream of air in hard to reach areas, like clearing debris from drilled holes. All of the nozzles used with these units are either 316ss construction for durable, corrosion resistance or PEEK plastic for non-marring applications. The air inlet is 1/4 FNPT and there is a convenient hanger available for safe storage.

 

 

 

Our NEW VariBlast Compact Safety Air Guns are ideal for light to medium duty processes, featuring a variable flow trigger to achieve different force levels ranging from 2.0 ounces up to 1 pound, depending on the nozzle. The body is cast aluminum and there are (2) 1/4 FNPT air inlets available, 1 on the bottom and 1 on the back of the gun, as well as a storage hanger, for easy installation. Nozzles are available in zinc aluminum alloy, 303ss, 316ss and PEEK plastic. These guns are available with aluminum extensions from 6″ up to 72″.

 

 

The Soft Grip Safety Air Guns are commonly used in long-term use applications as they feature a comfortable grip and long trigger which helps to reduce hand and finger fatigue. The cast aluminum construction is well suited for more rugged environments and again, features a hanger hook. These guns can be fitted with aluminum, stainless steel or PEEK plastic to meet the demands of a variety of applications and are available with 6″ – 72″ aluminum extensions for extra reach or Flexible Stay Set Hoses , allowing the user to aim the airflow to a specific target area. The air inlets for these guns are going to be 1/4 FNPT.

 

 

 

EXAIR’s Heavy Duty Safety Air Guns deliver higher force and flows than other air guns, as these units feature a 3/8 FNPT air inlet, which maximizes the compressed air flow to the engineered Super Air Nozzle. Like the Soft Grip, the durable cast aluminum body is designed for use in tough industrial processes, and the ergonomic and comfortable trigger are ideal for hours of use. Aluminum extension are available, again in lengths from 6″ up to 72″, but feature a larger diameter for optimal flow and superior durability.

 

The Precision, VariBlast, Soft Grip and Heavy Duty Safety Air Guns are ALL available with an optional, polycarbonate Chip Shield to protect personnel from flying chips and debris, further meeting OSHA Standard 1910.242(b) for the safe use of compressed air.

 

Lastly we offer our Super Blast Safety Air Guns. The Super Blast Safety Air Guns are ideal for wide area blowoff, cooling or drying a part, as well as long distances. They feature a comfortable foam grip and spring loaded valve that will shut off the airflow if the gun is dropped. These units use our larger Super Air Nozzles and Super Air Nozzle Clusters, providing forces levels from 3.2 lbs. up to 23 lbs. Depending on which nozzle is fitted on the assembly, air inlets will range from 3/8 FNPT up to 1-1/4 FNPT. Aluminum extensions are available in 36″ or 72″ lengths.

 

 

For help selecting the best product to fit your particular application, please contact one of our application engineers for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

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

Explanation of OSHA Standard 1910.242(b)

Open air lines and homemade blow offs violate OSHA standard 1910.242(b) because of harmful dead end pressures. In 1972, OSHA established Standard 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 with the intent to protect workers from serious injury. They determined that when dead-ended against the skin, if the outlet pressure reached 30 PSI 0r higher,  it posed a risk of entering the bloodstream through the skin. This is commonly referred to as an air embolism – a serious condition which can be life threatening. Once air has entered the bloodstream, it can restrict the free movement of blood throughout the body, disrupting normal heart function, leading to abnormal heart rhythm, possible lung or brain damage, cardiac arrest, stroke or possible death.

OSHA explains that you can use compressed air for cleaning purposes, as long as the outlet or source is fitted with some type of relief device that drops the outlet pressure to below 30 PSI if dead ended. There are basically two ways to go about gaining compliance. The first is to regulate the operating supply pressure to less than 30 PSI, assuring that the outlet pressure doesn’t exceed the threshold. While this does comply with the Standard, it can negatively affect the performance by reducing the strength of the outlet flow, limiting the usefulness of the blowoff device.

The other method is to use some type of 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.

For example, EXAIR engineered air nozzles are designed so the outlet holes cannot be blocked directly. Any potential obstruction of the outlet air holes results in the air having an alternative exit path to avoid injury to operators and personnel.

sag-osha-compliant

With our Super Air Nozzles, the air exits through a series of jets, recessed behind an array fins so the exhausting airflow can never be blocked.

With the design of our Super Air Knife, the cap overlaps the body, leaving a gap on both sides of the knife, allowing the exhausting air to safely vent.

osha-sak

Picture of the Super Air Knife, showing how the cap overlaps the body and cannot be blocked, providing a safe exit path.

ALL of EXAIR‘s engineered products incorporate these principles, providing some type of relief, allowing for the air to safely vent well below the 30 PSI requirement, meeting and in many cases, exceeding the OSHA Standard.

To discuss how EXAIR can help you gain OSHA compliance to improve operator safety, avoid costly fines and improve overall efficiency, contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

EXAIR Air Guns Increase Safety And Reduce Air Use

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.

crushed-gun

Crushed guns create high pitch wind shear and provide no relief path for the air to exit safely

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.

1210

Model 1210 – Soft Grip Safety Air Gun

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.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

EXAIR Webinar: Intelligent Compressed Air Solutions For OSHA Compliance

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On September 13th, 2016 at 2 PM EDT, EXAIR will be presenting a FREE webinar. During the short presentation, we will be covering the OSHA Standards for the safe use of compressed air when used for cleaning purposes.

The first topic we will discuss will pertain to the OSHA Standard 29 CFR 1910.242 (b) limiting the outlet pressure of an open pipe, tube, air gun, nozzle, etc. to less than 30 PSIG. When dead ended against the skin, air pressure above 30 PSI, can introduce air flow into the body, otherwise known as an air embolism. An air embolism can be an extremely dangerous condition which can cause serious injury, such as a stroke or possibly death.

Secondly, we will discuss the OSHA Standard 29 CFR 1910.95(a) for permissible noise exposure levels. In the Standard, OSHA has set exposure limits (in hours) for varying sound levels (dBA). When employees are subjected to sounds in excess of the limiting guidelines, some type of engineered controls should be used to reduce the sound level exposure. We will provide some useful statistics, as well as help you identify some common culprits found in many processes.

Lastly, we will show you how EXAIR provides engineered solutions that address both dead end pressure and noise exposure levels. All of EXAIR‘s blowoff devices feature some type of relief so if the exhaust airflow were somehow blocked or pressed against the skin, there is always a safe path for the air to exit, so the discharge pressure never exceeds 30 PSI. In addition, we will explain how our products reduce wind shear, ultimately lowering the sound level, save energy and help you gain OSHA compliance to avoid costly fines.

CLICK HERE TO REGISTER

Justin Nicholl
Application Engineer
justinnicholl@EXAIR.com
@EXAIR_JN

 

 

 

One Air Nozzle Saves $960 per Year – How Many Nozzles Could You Use?

A cardboard manufacturing facility was using a 3/8” outside diameter (OD) open tube to blow scrap cardboard off a conveyor. This scrap cardboard would occasionally be blown inside the roller area at the end of a conveyor creating a maintenance nightmare that required hours to disassemble and remove. To prevent this from occurring they installed another 3/8″ OD open compressed air tube to divert any cardboard headed toward the conveyor roller. The 3/8″ open tubing eliminated the scrap problem, but introduced a few new ones. The open hose is extremely noisy over (100 dBA). It does not comply with OSHA standard CFR 1910.242(b), which requires that a compressed air blow off device may not be dead ended at more than 30 PSIG. The most costly problem though is a 3/8″ open tubing uses a tremendous amount of compressed air.

They were using so much air in the facility that they were draining the system pressure in their facility. Obviously, they were going to replace the open tube with EXAIR 2” Flat Super Air Nozzle. Replacing this open blow off with an intelligent compressed air product, like the HP1125 High Powered Flat Super Air Nozzle or the 1104 Super Air Nozzle, would lower the noise level below 83 dBA. Also, those nozzles use significantly less air. They decided to use the model HP1125 for its thin profile to fit into the tight location. The only question was how much air and energy cost would they save. They could have easily installed a Digital Flow Meter on the supply pipe of the open tube to measure the change in flow once the EXAIR nozzle had been installed, but they wanted to try and estimate the air usage.

Using EXAIR’s test data, we know a 3/8″ OD open tube that is 18″ long will flow 68.5 SCFM at 80 PSIG. An HP1125 2″ Flat Super Air Nozzle utilizes 37 SCFM when fed with 80 PSIG inlet pressure. By removing one 3/8″ OD tube the cardboard manufacturer saved 31.5 SCFM of compressed air. With an electrical cost of $0.08 per kWh, compressed air costs $0.25 per 1000 SCF. Saving 31.5 SCFM reduces the manufacturers electrical bill by $0.48 every hour, $3.48 for every 8 hour shift, and $960 per year (250 working days, eight hours a day). If the manufacturer runs two shifts, the savings will double. The simple return on investment for this nozzle is 130 hours! How many projects can you measure a return on investment in hours?

2 Inch Flat

EXAIR’s 2 Inch High Power Flat Super Air Nozzle, HP1125

Take advantage of our free service – the EXAIR Efficiency Lab. Our Application Engineers will test any nozzle or device you choose to send in to the Lab using our calibrated testing equipment. We’ll compare the performance of your existing product (air consumption, noise, force, etc.) with an EXAIR Intelligent Compressed Air product. The results will be published in a comprehensive report, including a cost savings analysis with simple ROI. For most applications, EXAIR products can help you improve compressed air efficiency AND pay for themselves in a matter of weeks!

EXAIR intelligent compressed air products are easy to install, safe, and efficient. By installing these products instead of using unsafe open blow offs, your company can save thousands of dollar every year with minimal investment. While saving electrical expenses, we decrease the noise level which makes your production force a nicer place to work. We also comply with OSHA’s standards. Finally, we may be able to design the blow off better to consistently produce the quality product you expect. Call EXAIR today to discuss your application.

Dave Woerner
Design Engineer at EXAIR Corporation
DaveWoerner@EXAIR.com

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