Tag: safety

Compressed Air Safety Fundamentals

Published on by jasonkirbyLeave a comment

Safety in the workplace is of paramount importance, and it is widely recognized that annual safety training is a common practice among organizations. A fundamental message from these training sessions is that safety is a collective responsibility, not limited to a select few. At EXAIR, we prioritize safety in all aspects of our operations. Our product line, particularly our Safety Air Guns, exemplifies this commitment, as they are engineered with safety considerations at the forefront. This emphasis on safety is critical, especially given the potential health hazards associated with the improper use of compressed air.

In the United States, the Occupational Safety and Health Administration (OSHA) is responsible for enforcing regulations that promote safe and healthy working conditions. This agency possesses the power to levy significant fines for any infractions. Among the frequent violations related to compressed air are those concerning air guns and blow-off devices, specifically detailed in 29CFR 1910.242(b), which addresses dead-end pressure and chip shielding, as well as 29CFR 1910.95(a), which pertains to permissible noise exposure levels.

The regulation 29CFR 1910.242(b) addresses the use of hand-held tools, particularly emphasizing that blow-off devices must not operate at pressures exceeding 30 PSIG when there is a risk of compressed air becoming dead-ended. In situations where there is no escape route for the air, it poses a serious risk of penetrating the skin and causing an air embolism. A potential remedy is to drill a hole to create an alternative escape route. However, this solution may introduce additional safety hazards, which will be discussed later. EXAIR’s air nozzles are engineered with fins that facilitate safe air escape, thereby preventing skin blockage. Consequently, users can operate the EXAIR Super Air Nozzles at pressures exceeding 30 PSIG with confidence.

The regulation 29CFR 1910.95(a) specifies the permissible sound levels for safe human exposure, emphasizing that extended exposure to elevated noise can result in irreversible hearing loss. However, the cross-drilled nozzle falls short in this regard, as it generates significant noise due to turbulent airflow, despite being suitable for dead-end pressure applications. In contrast, EXAIR’s nozzles are engineered to incorporate ambient air, resulting in a significantly quieter laminar flow. For example, the Model 1210 Safety Air Gun, equipped with the Model 1100 Nozzle, operates at a sound level of only 74dBA, which is comfortably below the noise exposure threshold for an eight-hour work shift.

If you have any inquiries about compressed air safety, or any EXAIR products, please feel free to contact us.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

The Hierarchy of Controls and How It Applies to EXAIR Compressed Air Solutions

Published on by Jordan T ShouseLeave a comment

In industrial environments, safety teams rely on the Hierarchy of Controls to reduce workplace hazards. Rather than relying on personal protective equipment (PPE), this process prioritizes eliminating risks at their source or engineering them out of the process. For manufacturers, maintenance teams, and engineers, applying the hierarchy of controls can significantly improve safety, reduce downtime, and increase efficiency.

Many compressed air applications—blow off, cooling, conveying, and static elimination—present opportunities to implement safer and more effective solutions using products from EXAIR.

What Is the Hierarchy of Controls?

The Hierarchy of Controls is a widely accepted framework in occupational safety used to minimize or eliminate exposure to hazards. It is commonly promoted by organizations like the Occupational Safety and Health Administration and the National Institute for Occupational Safety and Health.

The hierarchy ranks safety controls from most effective to least effective:

  1. Elimination – Remove the hazard entirely
  2. Substitution – Replace the hazard with a safer alternative
  3. Engineering Controls – Isolate people from the hazard
  4. Administrative Controls – Change the way people work
  5. Personal Protective Equipment (PPE) – Protect the worker with gear

While elimination and substitution are ideal, they are not always feasible in manufacturing environments.

Applying the Hierarchy of Controls to Compressed Air Systems

1. Elimination

The most effective control is removing the hazard entirely. In compressed air systems, this can mean eliminating unsafe blow-off methods like open pipes or drilled tubing that create excessive noise, dangerous dead-end pressure, and flying debris. Replacing these setups with engineered solutions from EXAIR Corporation removes many of these hazards while maintaining performance.

2. Substitution

Substitution replaces hazardous equipment or processes with safer alternatives. In many facilities, this involves switching from improvised blow-off devices to engineered products like air nozzles or air knives. These solutions reduce noise, improve airflow efficiency, and significantly lower compressed air consumption.

3. Engineering Controls

Engineering controls isolate workers from hazards through equipment design. Many EXAIR products function as engineering controls by improving safety and reliability in compressed air systems. Devices like safety air nozzles, cabinet coolers, and air knives help control airflow, reduce noise levels, and prevent unsafe pressure conditions.

EXAIR Electronic Flow Control

4. Administrative Controls

Administrative controls focus on improving procedures and training. This includes compressed air safety training, pressure guidelines, and routine system audits. While helpful, these controls rely on human behavior, so they are most effective when combined with engineered solutions.

5. Personal Protective Equipment (PPE)

PPE—such as safety glasses or hearing protection—is the last line of defense. It protects workers from hazards but does not remove the risk itself. Implementing engineered compressed air solutions can reduce many hazards before PPE becomes necessary.

Compressed air is one of the most widely used utilities in manufacturing—but it’s also one of the most misused. Improper blow off setups, excessive noise, and inefficient airflow can introduce safety hazards and energy waste.

With the right approach and the right equipment, companies can create safer, quieter, and more efficient processes—while maximizing the performance of their compressed air systems.

Solutions from EXAIR, help organizations move up the hierarchy by replacing unsafe methods with engineered products designed specifically for industrial environments.

Jordan Shouse, CCASS

Application Engineer / Sales Operations Engineer

Send me an email

Hierarchy of Controls Image courdsey of CDC.Gov

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
National Business Development Manager

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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