EXAIR Corporation Puts The “Safety” In Safety Air Guns

One of the most dangerous things you can do is depressurize a line full of a pressurized gas. If the charge pressure is high enough, it’s going to come roaring out, with tremendous force and velocity. Anything in its path is subject to that force & velocity. Objects small enough to become entrained in its flow can become hazardous projectiles. The noise it creates can be literally deafening. If the point of discharge is accidentally jammed against your body, the pressure can get through your skin. As if that wasn’t scary enough, the gas then has a free path inside your body…they call that an embolism, and it can kill you.

Why on earth would anyone want to do that on purpose? Well, it happens every day, in factories, businesses, and homes all over the world, when people operate compressed air operated blow off devices. Of course, there are numerous factors that can drastically reduce the risk of injury associated with compressed air blow off devices.

One of these is mandated by the government. The Occupational Safety and Health Administration (OSHA) regulates the outlet pressure of any compressed air device used in industry for cleaning purposes. Keeping the outlet pressure low mitigates the risk of puncturing the skin. There are various methods of compliance with this regulation:

  • Regulate the supply pressure to less than 30psig. This absolutely complies, but it severely hampers your ability to get much done, as the air flow will be too weak to blow off anything but lightweight debris, from a smooth, dry surface, with the device pretty much right up on top of it.
  • Use a device that provides a relief path for the air flow if it was to become blocked or obstructed. EXAIR engineered Air Nozzles are designed to do this…you can supply them with higher pressures but they provide a relief path for the air, meaning they can’t be blocked or dead-ended.
Regardless of the compressed air supply pressure, the design of EXAIR Super Air Nozzles prevents a dangerous pressure from developing at the outlet.

The same regulation – OSHA 1910.242(b) – also addresses the airborne projectile problem by mandating the use of appropriate chip guarding. There are a number of ways to do this as well…chief among these is personnel protective equipment (PPE). At a minimum, you absolutely, positively should be wearing safety glasses with side shields whenever you have a blow off device in your hand (and so should anyone working near you, for that matter). If an operator is blowing off small, sharp shards, an OSHA inspector is probably going to get grumpy if they’re not wearing a full face shield, long sleeves, and maybe even a durable apron. Alternately, the blow off device could also be fitted with guarding as well…something like the Chip Shields that are available for most EXAIR Safety Air Guns. These polycarbonate dish-shaped shields fit on a rigid extension between the Safety Air Gun and the Super Air Nozzle, and can be positioned at an optimal distance to keep solid debris and liquid being blown off away from the operator.

Chip Shields are available for most EXAIR Safety Air Guns (left to right): VariBlast Precision & Compact, Soft Grip, and Heavy Duty Safety Air Guns…
…and others. These are just a few examples of blow off devices that can be successfully fitted with an EXAIR Chip Shield.

Another OSHA Standard – 1910.95(a) is there to protect operators against that literally deafening roar associated with unregulated discharge of compressed air. While cross-drilled nozzles (most easily seen in the lower left hand image above) provide a relief path to keep the outlet pressure at a safe level if they’re dead-ended, they’re still for all intents & purposes, an open-ended blow off…and quite loud. EXAIR Super Air Nozzles reduce the sound level of their air flow by design…the entrained air (which makes them so efficient) also forms a lower velocity barrier layer in the flow, which makes them extraordinarily quiet. In fact, all EXAIR Super Air Nozzles except our largest High Force models comply with OSHA limits for 8 hour noise exposure limits. Most callers that we talk to about applications for those are in areas where hearing protection is mandated anyway…if you need more than 4 pounds of blowing force, you’re probably wearing ear plugs already.

If you use compressed air for cleaning, drying, blow off, etc., you really need to do it safely, and in compliance with published & established safety standards. OSHA WILL fine you otherwise, and, even worse, someone could get hurt. EXAIR Corporation is devoted to helping you get the most out of your compressed air usage, and safe use is key to that. If you have any questions about it, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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6 Important Factors when Choosing a Safety Air Gun

If you look at operating costs alone, compressed air can be just about the most inefficient method there is for cleaning parts. If you just look at the risks, it’s potentially very dangerous too. Don’t even get me started on the insufferable noise it can make.

For cleaning parts, most folks are familiar with the use of an air gun. You can find the simplest of these in many industrial settings: a valve (often in the form of a handheld trigger device) fitted with a nozzle of some sort (often in the form of an open ended tube, pipe, or fitting to focus or direct the air flow). These have all three of the “downsides” I opened this blog with. Of course, these concerns can be mitigated to a high degree by using the right tool for the job. That’s where engineered products like EXAIR Safety Air Guns come in. Let’s look at how we can address these three “downsides”:

Efficiency: This is all about compressed air consumption. In the simplest of air guns mentioned above, consumption is only limited by the passages in the valve (or trigger) and the discharge fitting…and those limits are usually negligible. Modifying the ends (see examples below) to focus the air flow usually has minimal effect, because you’re not appreciably changing the total cross sectional area of the discharge opening:

Here are a few modified thumb trigger air guns that were sent in for Efficiency Lab testing. Left to right, compressed air consumption at 80psig supply pressure was 34.2 SCFM, 30.9 SCFM, and 28.2 SCFM. For comparison (more on this later,) EXAIR Model 1210 Soft Grip Safety Air Gun uses only 14 SCFM and generates a very similar flow pattern.

Safety: Remember learning about kinetic and potential energy in grade school? Well, when you compress air to 100psig, fitting all that air into a much smaller space creates a TREMENDOUS amount of potential energy:

The block on the left represents a cubic foot of air at atmospheric pressure. The one on the right represents how much space the first one takes up when compressed to 100psig. The energy imparted by this process HAS to be handled with care.

One problem with the thumb guns above is, if you were to jam into the palm of your hand and pull the trigger, a large component of that potential energy (pressure) turns into kinetic energy (force)…more than enough to break the skin and cause a potentially fatal condition known as an air embolism. In the United States, OSHA (Occupational Safety and Health Administration) regulates compressed air devices used for cleaning purposes. All EXAIR Safety Air Guns comply with Standard 1910.242(b) by providing a relief path to ensure that it cannot be dead ended, and thus never create over 30psi measurable at the outlet)

EXAIR Super Air Nozzles cannot be dead ended, ensuring the outlet pressure won’t reach OSHA limits, regardless of supply pressure.

Noise: Another problem is, another component is turned into sound pressure…discharging air from a direct opening is quite loud. OSHA standards address these with limitations on outlet pressure and sound level. All EXAIR Safety Air Guns comply with Standard 1910.242(b), which limits the outlet pressure (by providing a relief path to ensure that it cannot be dead ended, and thus never create over 30psi measurable at the outlet) and all but our largest Super Blast Safety Air Guns comply with Standard 1910.95(a) limits for continuous 8 hour sound level exposure.

Which brings us to the topic of this blog: How exactly did THEY (our customer who used to use the thumb guns above) select the right Safety Air Gun, and how can we apply that to getting the right Safety Air Gun for YOU?

These steps aren’t all-inclusive, and they don’t necessarily need to be followed in order, but if you call an EXAIR Application Engineer about selecting a Safety Air Gun, here’s what we’re gonna talk about:

Ergonomics: We offer five distinctive styles of Safety Air Guns:

From small part cleaning by hand, to wide area blowoff, and all points in between, EXAIR has a Safety Air Gun for most any application.

Our thumb gun user (as I alluded to above) chose the Model 1210 Soft Grip Safety Air Guns (top right). They had a number of typical industrial applications where the operators had the parts or surfaces to be blown off right in front of them. They liked the integral storage hook and rubberized hand grip, but the VariBlast Compact (top middle) or Heavy Duty Safety Air Guns (bottom left) were also considered. The VariBlast Precision (top left) and Super Blast Safety Air Guns (bottom right) were too focused or more powerful, respectively, than needed.

Airflow pattern: Honestly, I could make a good case for this being the first consideration. Selection of any blowoff product – be it an Air Nozzle, Air Amplifier, Air Knife, Air Wipe, etc., will largely depend on the size and shape of the airflow.

variety of airflow patterns…and effective distances…are available from EXAIR’s comprehensive line of Super Air Nozzle products.

Application specific concerns: Everything we’ve discussed so far has involved aiming the blow off stream away from the operator, in the direction the device is aimed. In addition to wide variety of engineered Air Nozzles, EXAIR offers a number of options for these products:

Atto Back Blow Nozzles can blow out recesses or holes as small as 1/4″ in diameter.
Scrape off, and blow away, stubborn debris with the Model 1244-48 Soft Grip Super Air Scraper.

If you’re looking for a portable, hand-held compressed air blow off product that’s quiet, safe, and efficient, look no further than EXAIR Corporation’s extensive line of Safety Air Guns. If you’d like to find out more, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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Video Blog: Laminar and Turbulent Flows

I have written blogs about laminar and turbulent flows as related to the Reynold’s number.  Now, let’s demonstrate the difference between the two flows and the advantages of laminar flow from EXAIR’s engineered air nozzles; as demonstrated by our VariBlast Safety Air Gun.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

EXAIR VariBlast® Safety Air Guns

VariBlast

EXAIR has been manufacturing Intelligent Compressed Air Products since 1983.  In that time, we have engineered many products for new and existing markets that required better efficiency, versatility, safety, and effectiveness.  In this blog, I will discuss the features and benefits of the VariBlast Safety Air Guns.

To start, the unique feature that sets the VariBlast apart from other small air guns is the force variability.  Unlike the “all or nothing” blowing forces with most air guns, this valve is designed to control the opening to allow for a variable force with the same nozzle.  This will help you to not “overuse” the compressed air blowing. The VariBlast Safety Air Guns are made from a durable cast aluminum construction for tough industrial use.  They have a rugged ergonomic grip with a user-friendly trigger.  The compressed air inlets are located in two different positions to best fit your area.  They also have an easy storage handle to hang the Safety Air Gun nearby.  In addition to the VariBlast Safety Air Guns, EXAIR has options to enhance the features.  Here is a list of them:

Air Nozzles:

Air Nozzles can make or break an air gun in safety, efficiency and effectiveness.  EXAIR Air Nozzles are OSHA compliant for noise and dead-end pressure.  We offer nine different types of air nozzles with the VariBlast Safety Air Gun; making it very effective for a range of applications.

Chip Shields

Chip Shields:

OSHA 1910.242(b) requires chip guarding when compressed air is used for cleaning and blowing.  EXAIR offers Chip Shields with the VariBlast Safety Air Guns to meet this requirement.  They are made from a polycarbonate disc which is practically unbreakable.  It protects the operator from any blow back of shavings, debris, and coolant.  They come standard with a durable rubber grommet that squeezes the extensions and can be adjusted for greater protection.

Extension Pipes:

For those far away targets and hard-to-reach areas, EXAIR offers aluminum extension pipes to attach to the VariBlast Safety Air Guns.  They can range from 6” (15 cm) to 72” (183 cm) in length.  This light-weight and durable material allows for easy handling when reaching high above your head or spanning across unsafe areas.  With the EXAIR air nozzles at the end, the blowing force is not sacrificed as the back pressure will create a high velocity air stream.

Coiled Hose

Coiled Hoses:

To get the proper amount of compressed air from the piping system to the VariBlast Safety Air Guns, EXAIR offers Coiled Hoses.  They are made of a durable abrasion-resistant nylon material that is 12 feet long (3.6 meters).  They have swivel fittings to allow for easy uncoiling, and a spring strain relief to keep the hose from kinking at the ends.  The coiled design makes it easy to reach around the work area and retract back to the substation.  This will help to keep the hose off the ground where potential dangers could occur.

Regulator and filter

Filter Separators/Regulators:

To improve the VariBlast Safety Air Guns, EXAIR offers a series of filters and regulators.  The filters will remove dirty particles and liquid water from the compressed air that can affect the performance as well as contaminate the surface that you are cleaning.  The regulators are used to control the amount of air pressure used by the VariBlast Safety Air Gun; making them even more efficient.  The idea for compressed air savings is to use the least amount of compressed air to do the job.  The filter and regulator combination will allow you to control the proper amount of clean dry air to be used.

Not all air guns are the same.  A check list should be created for any air gun.  Is it safe, efficient, quiet, durable, ergonomic, and flexible?  The VariBlast Safety Air Guns meet every item on that list.  This is why the EXAIR VariBlast Safety Air Gun was awarded the Silver award by Plant Engineering in 2019.  To go even farther, EXAIR has a promotion where we will be giving away for free a model 1126 1” Flat Super Air Nozzle, a $48.00 value, from now until the end of September 2020 with qualified purchases.  (Check it out HERE).  If you expected more from your current air guns, you can try any of the EXAIR Safety Air Guns.  An Application Engineer is available to help recommend the best air gun for your application.  You will not be disappointed.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb