Tag: OSHA

Noise In The Workplace

Published on by Russ BowmanLeave a comment

The Center for Disease Control (CDC) estimates that 22 million workers are exposed to potentially dangerous levels of noise at work every year. That’s “only” about 15% of the total number of people who are employed in the United States, but if you’re one of them, you should absolutely know the risks, and how to protect yourself. Obviously, high noise levels can cause hearing loss, but do you know what else it causes?

  • Cardiovascular disease. Constant noise exposure causes stress, and stress triggers the release of hormones that increase your blood pressure, which can lead to ischemic heart disease, strokes, and arrhythmia.
  • Sleep disruption. Studies show chronic noise exposure during the day can cause difficulty falling asleep, shortened sleep cycles, and frequent wake-ups during the night. All this leads to chronic fatigue and a host of long-term health issues.
  • Immune system suppression. While the exact nature of the relationship is unclear, recent studies have indicated that noise can cause changes in our immune systems.
  • Cognitive impairment: Continued noise exposure causes memory impairment, attention deficits, and reduced concentration.
  • Mental health issues. Not only does continued noise exposure release hormones like cortisol & adrenaline (causing the chronic stress that’ll literally break your heart; see above), it directly influences anxiety, depression, and irritability.
Don’t let this happen to you.

So, how do we protect ourselves? If you said “ear plugs,” you’re not wrong…but did you know that hearing protection in the form of personnel protective equipment (PPE) is considered the LEAST effective method of mitigating noise exposure? The National Institute for Occupational Safety and Health (NIOSH, a sister agency of the Occupational Safety and Health Administration, or OSHA) developed a hierarchy of controls…a “good, better, best” framework, if you will, of methods to address workplace hazards:

Even though hearing protection (the PPE in this case) is least effective, the intent of the hierarchy graphic is not to dismiss it, but to categorize it as a last resort. If all else fails (or, more often, comes up short,) ear plugs are your – and your hearing’s – best friend.

If the source of the noise cannot be eliminated (and let’s face it, an awful lot of industrial processes are necessarily loud), the next best thing to do is to substitute a quieter method or device. That’s where EXAIR comes in: the design of our engineered Air Knives, Air Nozzles, and Air Amplifiers exploits certain principles of fluidics to mitigate the noise levels associated with the rapid depressurization of compressed air when it’s blown for cleaning, drying, cooling, etc. The key to this is entrainment:

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

While this entrainment makes EXAIR products EXTREMELY efficient (the compressed air consumption ends up being a fraction of the total developed flow), it also creates a low velocity boundary layer around the primary high velocity & forceful airflow. This layer attenuates the sound level of that high velocity flow.

Compressed air use can be loud, wasteful, and dangerous, but it doesn’t have to be. If you’re looking for a quiet, safe, and efficient solution for your use of compressed air, give me a call.

Russ Bowman, CCASS

Application Engineer
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How One Customer Improved Safety and Reduced Noise with a Simple Retrofit

Published on by Brian FarnoLeave a comment

I recently had the opportunity to help a customer facing some serious concerns about their compressed air usage. They had just completed a safety audit conducted by a third-party firm, and one of the main issues identified was the use of handheld blow guns throughout their production floor.

“Thumb guns” are especially popular for blowoff because of their compact size, ergonomic design. and low price.

Even though the tools in question were commercially available and marketed as having “safety tips,” the auditors recorded noise levels exceeding 90 dBA—well above the acceptable threshold. The audit team explained that to maintain a safe work environment, noise levels needed to stay below 84 dBA, and the simplest way to get there was to address the blow guns being used.

That’s when the customer turned to us for help.

We discussed the application in detail, and it quickly became clear that EXAIR’s Model 1100 Super Air Nozzle would be a great fit. Not only does it significantly reduce noise levels—down to 74 dBA—but it also meets OSHA’s 30 PSI dead-end pressure requirement, ensuring operator safety in the event of a blocked nozzle.

This customer wasn’t focused on maximizing air output or performance—they simply wanted to make their environment safer for their team. What made this installation even better was the unexpected benefit: while addressing the safety concerns, it also reduced compressed air consumption. A win-win.

It’s always rewarding when we can help customers meet compliance goals and improve safety, but it’s even better when we can go beyond their expectations and help them uncover savings they weren’t even looking for.

Free testing. Verifiable data. EXAIR Efficiency Lab.

If you’re dealing with high noise levels or safety compliance issues around your compressed air applications, don’t hesitate to reach out. Our team is ready to help you find a solution that protects our people, meets regulations, and improves overall efficiency through the EXAIR Efficiency Lab.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Compressed Air Safety Dos and Don’ts

Published on by Russ BowmanLeave a comment

In the Navy, it was a universally accepted fact that NOTHING onboard the ship was “sailorproof.” Regardless of how it was designed, what it was made of, how many interlocks, mechanical stops, automatic shutoffs, etc., something had, any & all of those features could be overridden (by accident or on purpose) and cause a wide range of chaos, and/or damage, and/or injury. That’s why training and procedures are so important.

It’s the same in any civilian/corporate industry too – any device, tool, instrument, machinery, etc., can be inherently dangerous if it’s not used properly. And “used properly” for a LOT of those includes personal protective equipment, commonly known as PPE.

In the United States, the Occupational Safety & Health Administration (OSHA) publishes a couple of standards relevant to the safe use of compressed air:

Standard 1910.242(b) applies to the use of compressed air for cleaning. It states “Compressed air shall not be used for cleaning purposes except where reduced to less than 30 p.s.i. and then only with effective chip guarding and personal protective equipment.”

  • Do wear eye protection, at a bare minimum, in regard to the personal protective equipment, no matter what. If the debris you’re blowing off is sharp or jagged, a full face shield & long sleeves are likely called for as well.
  • Don’t operate a blowoff device in a manner where the static pressure at the outlet of the nozzle will reach or exceed 30 p.s.i. If you’re using an engineered product like an EXAIR Super Air Nozzle, it’s perfectly fine to use a higher air supply pressure than that. They’re designed so that the outlet pressure won’t exceed 30 p.s.i. no matter what the supply pressure is.
EXAIR engineered Air Nozzles, like the Model 1100 Zinc Aluminum Super Air Nozzle shown here, discharge the compressed air flow through a series of holes, recessed between an array of fins. This means that there’s always a relief path for the airflow, so the outlet pressure cannot reach a dangerous level.

Standard 1910.95(a) isn’t exclusive to the use of compressed air, but since the discharge of a high pressure gas to atmospheric pressure can create quite a racket, noise levels associated with the use of compressed air often exceed exposure limits published in this standard.

  • Do protect your ears, same as you do your eyes. This one is near & dear to me, because my Dad lost a significant amount of his hearing in his early 40’s as a result of occupational noise exposure, and I saw first-hand what an impact that has on quality of life…for him, and frankly, for us too. There are a number of ways to do this, and the National Institute of Safety & Health (NIOSH) ranks them in order of effectiveness in their Hierarchy of Controls.
  • Don’t make earplugs, earmuffs, headphones, etc., the first and only line of defense. Don’t get me wrong; they work GREAT when the right ones are used properly…”right” and “properly” being the key words there.
  • So, DO make selection, training, and enforcement of their usage a high priority if the source of the noise cannot be:
    • Eliminated – this can be a toughie, because whatever’s making the noise is very likely there for a reason.
    • Substituted – this is a much more common, and still highly effective method, as engineered products like EXAIR manufactures can dramatically lower noise levels while maintaining the effectiveness of compressed air usage.
Examples of some sound levels we’re all familiar with, and how some EXAIR products compare favorably.

In closing, my last dos & don’ts are: Do heed OSHA’s safety standards, so you don’t get a hefty fine for endangering yourself or the folks you work with. Frankly, if they catch you before anyone gets hurt, you got off light. If you’d like to find out more about how EXAIR Intelligent Compressed Air Products can improve safety with your compressed air usage, give me a call.

Russ Bowman, CCASS

Application Engineer
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Sound Level of Cicadas

Published on by Jordan T ShouseLeave a comment

At the time of writing this blog, Cincinnati is experiencing our usual 17-year brood of cicadas. Millions, if not billions, of 17-year cicadas have emerged in Cincinnati and Southwest Ohio, making spending any amount of time outside unbearable. My four-year-old’s favorite part of the day is swinging on the back porch, and he even wants to go right back inside after just a few minutes.

I stuck the EXAIR 9104 Digital Sound Level Meter inside of one of our bushes here at the office. Within a 3′ radius, I counted 10–15 cicadas crawling around pretty casually. And they were producing a whopping 90 dBA! And if i shook a branch and really got them worked up, it peeked over 101 dBA.

Now while it takes repeated exposures of sufficient duration to cause hearing loss. And in a few weeks these cicadas will be gone; you probably don’t need to worry about the 2025 cicadas affecting your hearing. Noise exposure is, however, a real issue for most manufacturing facilities. Due to this risk, OSHA strictly enforces standard 29 CFR-1910.95(a).

This directive outlines the effects of noise and limits exposure based on the dBA. The table below indicates the maximum allowable exposure time to different noise levels. Sound levels that exceed these levels should first be addressed by proper engineering controls, such as isolating the source of the sound from personnel or replacing the cause of the sound with something like an engineered compressed air nozzle. When such controls aren’t feasible, proper PPE must be worn to protect the operator.

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.

Hearing loss can occur in as little as 30 minutes when exposed to sound levels of 110 dBA or greater. Operators have a tendency not to use PPE as directed. If an OSHA inspector comes to your facility and notices that the sound levels exceed the maximum allowable level without PPE protection being worn, hefty fines will soon be following. In this example from the United States Department of Labor, a company was fined a total of $143,000 for failing to protect their employees.

EXAIR 9104 Sound Level Meter

In order to identify the places or processes in your facility that are causing the problems, you’ll need a tool to measure the sound level. EXAIR’s easy-to-use Digital Sound Level Meter allows you to measure and monitor the sound level pressure in a wide variety of industrial environments. The source of the loud noise can then be identified and isolated so that corrective action can be taken. For compressed air-related noise, EXAIR manufactures a wide variety of engineered compressed air products that can reduce the sound level dramatically. In many cases, EXAIR products are capable of reducing noise levels by as much as 10 dBA. Since the dBA scale is logarithmic, this equates to cutting the sound level in half!

If there are processes within your facility that are above these limits, and you’d like to eliminate relying on proper PPE, give an Application Engineer a call. We’ll help walk you through the selection process and make sure that when the OSHA inspector comes knocking you’re prepared! Sorry, but we will not be able to help you with your Cicada problems. We just have to let nature do its thing, and they will be gone in a few weeks. Until 2027, that is, when we get hit with the 10-year brood!

Jordan Shouse, CCASS

Application Engineer

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