Tag: sound meter

Reducing Sound Levels

Published on by jasonkirbyLeave a comment

When touring a manufacturing facility, one of the most striking observations is the high noise levels present. The various operational processes contribute to an overall sound intensity that can exceed safe limits for workers. According to OSHA Standard 29 CFR – 1910.95(a), there are specific maximum allowable noise exposure levels based on both duration and sound intensity. Prolonged exposure to excessive noise can lead to significant hearing damage or even complete hearing loss if appropriate hearing protection is not utilized.

Sound

To assess whether sound levels in your facility are excessively high, consider utilizing EXAIR’s Digital Sound Level Meter Model 9104. This device is specifically designed to measure sound pressure levels in the environment, providing readings in decibels (dB) on both the A and C scales, with options for fast or slow response times. By employing this meter, users can pinpoint areas where noise levels may necessitate personal protective equipment (PPE) to prevent hearing loss. Additionally, it may help identify underlying issues that require repair, ultimately leading to a reduction in noise levels.

In contrast to the 98dBA sound level from this array of nozzles, the sound pressure level from an EXAIR Super Air Knife is only 69dBA.

Once measurements are taken, it becomes possible to pinpoint the specific applications that require attention, whether through repairs, mitigation strategies, or personal protective equipment (PPE) measures. Common culprits of excessive noise levels from compressed air include open pipe blow-offs, cross-drilled holes in safety air gun nozzles, liquid nozzles used for air blow-offs, and poorly designed air nozzles. By replacing these open tubes and cross-drilled nozzles with an engineered EXAIR Super Air Nozzle, you can significantly decrease both air consumption and noise levels.

EXAIR Super Air Nozzle entrainment

At EXAIR, we uphold the principle that safety is a collective obligation. Our commitment to producing high-quality engineered products emphasizes safety and efficiency. To ensure the well-being of your operators, we provide a variety of blow-off products specifically designed to reduce noise levels to safe standards.

 If you have any questions about reducing sound levels, or anything regarding EXAIR and our products, please do not hesitate to reach out. We would love to hear from you!

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

Week 2 Back To Basics — Find & Fix

Published on by Brian FarnoLeave a comment

Last week, we started with step one of the Six Steps to Optimizing Your Compressed Air System: measuring and understanding your usage. Once you know how much air is being consumed, the next step is clear—find and fix the leaks.

If you search for “compressed air leaks,” you’ll find no shortage of articles on the topic. One from the Department of Energy highlights just how costly leaks can be. For example, fixing only ten leaks in a single compressed air system saved one company $57,069. That’s a huge number—and it came from just ten leaks.

Every joint or connection in your system is a potential leak point. The size of the leak determines how much money (and efficiency) is lost. The most effective approach is to locate leaks systematically and eliminate them permanently.

There are several methods for leak detection, but the tool we recommend is the Ultrasonic Leak Detector (ULD). It can detect leaks up to 20 feet away and works even in noisy industrial environments. In fact, fixing just one leak the size of a 1/16” hole can pay for the ULD in a year—and that doesn’t account for the many other leaks you’ll uncover and repair.

If you’re using a Digital Flowmeter from step one, you’ll also be able to quantify the air you’ve saved once those leaks are sealed. The combination of measurement and action creates a powerful cycle of optimization.

That wraps up step two. Next week, we’ll continue with step three in the series. In the meantime, if you’d like to talk through leak detection or optimization strategies for your own system, don’t hesitate to reach out.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Is It Plugged In? Let’s Go Back To the Basics 1 of 6

Published on by Brian FarnoLeave a comment

Today, I want to kick off something a little different with the blog and start back at the basics. Over the next series of posts, we’ll walk through the Six Steps to Optimizing Your Compressed Air Systems. The goal is simple: to help you evaluate your current setup, identify opportunities for improvement, and put real numbers to the savings you can achieve.

Six Steps to Optimizing Your Compressed Air System

The first step to optimization is to measure and understand your compressed air consumption. There are several ways to do this, but one of the most effective is with our Digital Flow Meter paired with a Summing Remote Display or a USB Data Logger.

  • The Digital Flow Meter provides real-time data on compressed air usage.
  • The Summing Remote Display allows you to track cumulative usage over a 24-hour period (or longer).

By installing these tools, you can measure usage across your entire system or isolate a single machine. Once you start gathering data, you’ll quickly see the difference that EXAIR products can make in reducing consumption and improving efficiency.

With usage data in hand, you’re ready to move on to step two—stay tuned for the next installment. If you’d like to jump ahead or talk through your system directly, I’d be happy to connect.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Eliminate Costly Leaks with the Ultrasonic Leak Detector

Published on by jasonkirbyLeave a comment

The generation of compressed air accounts for approximately one-third of energy costs in industrial environments. According to the Compressed Air Challenge, around 30% of this compressed air is lost due to leaks. As a result, nearly 10% of a facility’s energy expenses are wasted because of poor connections, faulty air valves, and improper installations. Beyond the financial implications, these leaks can cause significant operational inefficiencies. A drop in system pressure can adversely affect end-user performance, reducing production efficiency. Furthermore, this pressure decline may lead to increased cycling of equipment, potentially shortening the lifespan of compressors and other machinery. If leaks diminish the supply volume, it may create a misleading perception that additional compressor capacity is necessary, further driving up operating costs.

When a leak occurs, it produces ultrasonic noise due to turbulence, typically at frequencies exceeding 20 kHz, which are inaudible to humans. The EXAIR Ultrasonic Leak Detector, model 9207, is specifically engineered to identify these frequencies and transform them into audible sounds using a method called “heterodyning.” This device is equipped with a signal strength indicator and a bar graph display, allowing users to detect even the smallest leaks. It comes with two attachments: a parabolic microphone that can detect leaks from distances of up to 20 feet, and a tube attachment for accurately locating leaks among multiple connections within a pipe. Once a leak is detected, it can be marked for subsequent repair.

The ULD features specialized attachments that effectively reduce background noise typically found in industrial environments. It includes “+” and “-” buttons, allowing for precise sensitivity adjustments of the meter. This advanced model significantly improves leak detection in hard-to-reach areas and complies with the IEC 61326-1 standard, ensuring reliable performance in the electromagnetic conditions commonly encountered in industrial facilities.

Implementing a leak protection program in industrial facilities can lead to significant cost savings with relative ease. Should you have any inquiries regarding the integration of the Ultrasonic Leak Detector into your existing leak protection strategy, please feel free to contact us for assistance.

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