EXAIR’s webinar will educate customers about the simplicity and effectiveness of improving efficiencies and safety on end-use compressed air applications. Attendees will learn how simple installation of an engineered compressed air product can benefit you with improved efficiencies, dollar savings and safety. Learn how to calculate compressed air cost and the data needed to determine savings. This presentation will also educate about important OSHA standards related to compressed air use.

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Intelligent Compressed Air:
Simple Steps for Savings & Safety

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q This webinar will be available afterwards at
www.designworldonline.com & email
q Q&A at the end of the presentation
q Hashtag for this webinar: #DWwebinar
Before We Start

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Mike Santora
Design World
Moderator
Dave Woerner
Application Engineer
EXAIR Corporation
Intelligent Compressed Air: Simple Steps for Savings & Safety
Meet your presenter

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Who Are We?
• EXAIR Corporation incorporated 1983, manufacturer of
intelligent compressed air operated products in
Cincinnati, OH
• We manufacture a wide variety of compressed air
products for cooling, cleaning, static elimination, or
conveying
• Largest selection of end use intelligent products in the
market.

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What We Need From
You?
• Please send the answers to these three questions in the
chat
• What’s your job title or responsibility that bring you here?
• What’s the compressed air usage in your plant?
• What’s the size of your compressor?

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Intelligent Compressed
Air: Why?
• Energy Expense
o What are the most expensive blow offs?
o Compressed air is typically the most expensive utility in a plant
o Air is free compressed air is expensive
• Safety
o Noise
• Thousands of workers every year suffer preventable hearing loss due to high
workplace noise levels
o Eliminate dead end pressure

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Where is your Money Best
Spent?
• Reducing demand
o Evaluate current use
• Replacing inefficient processes
o Quick payoff
o Ease of installation
• Increasing safety
o Avoiding costly OSHA fines

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The Usual Suspects

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Most Wanted

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Cost of Compressed Air

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Cost of Compressed Air
•

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Cost of Compressed Air
•

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Cost of Compressed Air
•

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Intelligent Replacements

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Inefficient VS. Engineered
¼ Open Copper Tube 1100 Super Air Nozzle
• Inlet Pressure: 80 PSIG
• Air Consumption: 33
SCFM
• Noise Level: 102 dBA
• Inlet Pressure: 80 PSIG
• Air Consumption: 14
SCFM
• Noise Level: 74 dBA

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Cost to Run 1/4” Tube
•
¼ Open Copper Tube 1100 Super Air Nozzle
•
An 1100 Super Air Nozzle saves $2.28 every 8 hour shift over a 1/4” copper
tube.

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Cost to Run 1/4” Tube
¼ Open Copper Tube 1100 Super Air Nozzle
An 1100 Super Air Nozzle saves $570 every year over a 1/4” copper tube.
Return on investment in 16 working days

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Case Study- 1100

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Case Study- 1100
1/4" Crimped Pipe
• Consumes 40.4 SCFM at
100 PSIG
• Costs $1,260.48 per year
to operate
• Saves 23.4 SCFM at 100
PSIG
• Saves $730.08 per
nozzle per year
1100 Super Air Nozzle
Replaced (40) 1100 Super Air Nozzles one time.
Now saving $29,200 every year.
Operational year 8 hours a day
250 days per year.

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Case Study- 1100
• Each 1100 Super Air Nozzle saves 23.2 SCFM.
• An air compressor produces 4 SCFM per horsepower.
• Each nozzle replaced reduced compressor load by 5.8
HP.
• Replacing 40 nozzles could save 232 HP of compressor.
1/4" Crimped Pipe 1100 Super Air Nozzle

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Safety Benefits

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Compliance with OSHA
Dead End Pressure
• 1910.242(b)
• Interpretation - The phrase "reduce to less than 30 psi" means that the downstream
pressure of the air at the nozzle (nozzle pressure) or opening of a gun, pipe, cleaning
lance, etc., used for cleaning purposes will remain at a pressure level below 30 psi for
all static conditions. The requirements for dynamic flow are such that in the case
when dead ending occurs a static pressure at the main orifice shall not exceed 30 psi.
This requirement is necessary in order to prevent a back pressure buildup in case the
nozzle is obstructed or dead ended.
• https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=DIRECTIVES&p_id=1742

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How EXAIR prevents dead-
end pressure?
• Multiple recessed orifices to prevent a build up of
pressure

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How EXAIR prevents
dead-end pressure?
Overlap to
provide
a path for the
air to escape

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Safety Benefits:
Noise Directive
• 29 CFR 1910.95(a)
• https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards&p_id=9735

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Noise Comparison
• Noise Level: 102 dBA • Noise Level: 74 dBA
¼ Open Copper Tube 1100 Super Air Nozzle
10dB increase = 2x as loud.
Construction Site 100 dBA
Classroom Chatter 70 dBA

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Noise In Workplace
• Nearly 30 million workers regularly exposed to dangerous levels.
• 2nd most reported occupational illness/injury.
• Nearly 125,000 workers since 2004 suffered significant, permanent
hearing loss.
• Occupational hearing loss costs top $242 million per year
(disability.)
• High numbers of exposed workers in agriculture; mining;
construction; manufacturing and utilities; transportation; and
military.
• Increased stress, reduced productivity, degraded communication
and concentration, more accidents/injuries.

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Intelligent Compressed Air
Products
• What make a product intelligent?
o Engineering
• Entrainment
• Quiet
• Safe
o Manufacturing
• Precision
• Quality
• Consistency

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Air Entrainment

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Benefits of Intelligent
Compressed Air Products
• Save $$$ in operating costs.
• Eliminate dead end pressure
• Decrease noise levels: safer, more productive.
• Utility rebates (check with your utility supplier.)
o DSIRE Website
• http://www.dsireusa.org/

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Next Steps- Optimization
• Flow Measurement
• Flow Management
o Electronic Flow Controller
o Turning off compressed air, when its not useful
• Leak Mitigation
o Find and Fix Leaks
o Lower system pressure
• Sound Measurement
o Identify hazards and inefficiencies

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Efficiency Lab
• EXAIR’s Intelligent Compressed Air Products vs Your
Current Installation
• We will test your product and ours for force, flow and
noise.
• All results confidential
• Report provided

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Mike Santora
Moderator
Design World
msantora@wtwhmedia.com
@DW_MikeSantora
Dave Woerner
Application Engineer
EXAIR Corporation
techelp@exair.com
Questions?
Intelligent Compressed Air: Simple Steps for Savings & Safety

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Thank You
q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
q Connect with Design World
q Discuss this on EngineeringExchange.com