General Imsubs

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Introduction to Compressed air Saving Blow off devices
3711/A, GIDC, Phase-IV, Vatva, Ahmedabad-382445, India Ph.: + 91-79-2584 0845 Fax: + 91-79-2584 1846 E mail: info@giplindia.com Web: www.giplindia.com
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Introduction
Compressed air is widely used in an industry for blow off operations. According to estimates, about 80% of blown air is wasted due to excessive thrust, narrow coverage and poor blow off devices. Approximate cost of compressed air generation at 5.5 bar is 1.25 paise per Cubic feet. Very few users have ever focused on hazards of using compressed air from conventional nozzles. At times conventional blow off product could be lethal. International safety norms are largely ignored due to lack of knowledge, which some times cost lives of operator and money to employers.
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General imsubs unique blow-off products to enhance compressed air utilization
Sr. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Description eX Blow Gun, for wider blow. Amplification Ratio 1:7 With plastic extension tube as standard accessory. Real Blow Nozzle, Adjustable flow, Aluminum, Amplification ratio 1:12 Real Blow Nozzle, Adjustable flow, SS, Amplification ratio 1:12 Real Blow Pipe , Amplification ratio 1:12, High penetration Real Blow High Thrust Nozzle, Amplification ratio 1:3 Vac Blow, dhc, unique deep blind hole cleaning gun with chip collection bag. Must for tool rooms & Machine shops, Suitable for 6 to 30 mm dia X upto 300 mm deep blind holes. Triggered Blow gun Pistol Shaped ergonomic blow gun, to adopt all types of Real blow nozzles and jets Metal extension tube for all nozzles, 450 mm Long, Increases reach of nozzles in difficult to reach area. Plastic Extension tube suitable for Ex-blow gun Compressed air operated coolant mist spray nozzle, Adjustable mist control, with Flexible air and water tubes Water flow control solenoid valve for mist spray nozzle. 12V DC / 24 V DC / 230 V AC Model number EBG-1 RBA-2 RBS-3 RBP-5 HTB-4 DHC-12 TBG-6 PSH-7 EXM-9 EXP-10 SPS-13 SVW-11 Page Number 6, 7 8 8 9 10 11
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Blow Off Products
Blow off products can be classified in three categories. Conventional blow off methods like home made pipe nozzles, Open pipes. Conventional blow guns with trigger Air amplifying products may or may not fitted on conventional blow guns. General Imsubs blow off products can be fitted on conventional blow guns of suitable type or they can be supplied with low cost triggered blow guns ergonomic blow guns shut off valves or slide valves. Blow off products can be further classified as 1. Medium thrust wide blow (EBG-1) 2. Low thrust narrow blow (RBA-2, RBS-3, RBP-5) 3. High thrust narrow blow (HTB-4) 4. Special purpose blow off devices like Vac-Blow dhc (DHC-12) General Imsubs portable blow off products are air amplifier based economical tough durable ergonomically designed meets international safety norms hand held or machine mountable
Which are so economical that its payback period is in hours.
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eX Blow Gun Model # EBG-1
eX Blow gun is highly ergonomically designed blow gun with trigger type shut off valve. Its hand gun shape reduces operator fatigue and high volume, wide blow reduces compressed air consumption in two ways, one, by reducing the time blowing operation takes and by shutting off compressed air consumption upon release of trigger.
Features of Model # EBG-1 1. 2. 3. 4. 5. 6. Amplification ratio 1:7 High volume of usable air Meets OSHA noise regulations Meets OSHA pressure regulations Ergonomically Designed shape With Extension tube & lightweight Strong, unbreakable and maintenance free
Advantages / Benefits to customers Saving of compressed air. Payback Period: 32 Working hours Fast cleaning action: cleaning-drying operations in much less time thus saving valuable time Noise level reduced EASY ON EARS HUMAN BEINGS. Safety: Prevents the chips like material ricocheting. Easy to use, Less fatiguing the operator/ With extension tube one can target the actual area of application. Highly Durable because of minimum moving parts & made of special polymers.
Conclusion: Above advantages of Ex-blow gun makes it an ideally smart choice for blow-off operations
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Standard Accessories for eX Blow Gun Model # EBG-1
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Real Blow Nozzles, Pipes and High Thrust Jets
While talking of advantages of an Ex-blow gun, one small thing is to be kept in mind that is its low penetrating wide blow. It may face trouble cleaning stubborn dirt particles from difficult to clean areas like narrow corners or deep grooves. Ex-blow gun is good where low penetrating wider blow of air is required. -So what about high penetration? For high penetration we recommend our family of Real Blow nozzles and jets.
Real Blow Adjustable Nozzle Model # RBA -2 & RBS - 3
Features of Model # RBA-2* / Model # RBS-3* Amplification ratio up to 1:12 Micro Adjustable Output Meets OSHA noise regulations Meets OSHA pressure regulations Machine Mountable
Advantages & Benefits to the customer Saving of Compressed Air Energy = Quick Pay Back Facility to have appropriate flow for particular application & thus minimizing wastage Minimizing Noise = Easy on Ears Safety is INCREASED Applicable even in automation
Gun Mountable Applicable in hand held usage as well Conclusion: Real Blow adjustable nozzles can be a smart choice where narrow and adjustable flow of air is required.
Accessories for Real Blow Adjustable Nozzle Model # RBA -2 & RBS - 3
Triggered Blow Gun TBG - 6 Ergonomic Blow Gun PSH - 7
Metal extension tube, 450 mm Long, Increases reach Model # EXM - 9
* RBA 2 is aluminum nozzle and RBS 3 is stainless steel nozzle
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Real Blow Pipe Nozzle Model # RBP 5
Features of Model # RBP-5 Amplification Ratio upto 1:12 Deep penetration Machine mountable Handgun mountable Meets OSHA noise standards. Meets OSHA pressure standards.
Advantages & Benefits to the customer Savings in Energy Efficient cleaning of deep crevices Versatility versatility Lower noise levels Reduced risk
Conclusion: In areas where a real high penetration is required, Real-blow pipe nozzle is highly recommended
Accessories for Real Blow Nozzle Model # RBP -5

Metal extension tube, 450 mm Long, Increases reach Model # EXM - 9
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Real Blow High Thrust Jet Model # HTB - 4
Features of Model # HTB - 4 Amplification Ratio upto 1:3 High thrust air blow High thrust air blow Meets OSHA noise standards. Meets OSHA pressure standards. Hand gun mountable
Advantages & Benefits to the customer Savings in Energy Successfully cleaning stubborn dirt / chips Successfully used for ejecting pressed parts. Lower noise levels then open pipes Safe for operator Good for manual usage
Conclusion: Sacrificing air saving part, BUT it gives really high thrust for cleaning or pushing something. Again not compromising with safety be it noise or flying off chips. High thrust jet is an an excellently effective tool for high thrust air blowing
Accessories for Real Blow Nozzle Model # HTB - 4

Metal extension tube, 450 mm Long, Increases reach Model # Exm - 9
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VAC-BLOW DHC: Model # DHC - 12
Features of Model # DHC-12 Technically amazing product It does four operations at a time dislodging forcing Sucking out collecting Wide usable range Noise reduction
Advantages/benefits to the customer A technically very difficult task is accomplished very easily Cleaned hole in single operation Dislodge chips from internal walls Forcing chips out of the hole Sucking out all those chips Collecting of all chips to avoid it from spreading around in the plant. One Dhc-12 is sufficient for hole sizes Dia 6mm upto 30mm and depth upto 300mm Extremely silent comparing to normal cleaning of deep blind holes
When Your major concern is to clean machined blocks, deep drilled blind holes, tapped-threaded holes etc. our Model # DHC-12 is the Problem shooting product
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What is the difference between Real Blow Nozzle, Pipe and Jet?
Though all Real Blow Products works on same Coanda principle each products has distinctive features and makes it suitable for wide range of application. User may choose the best product according to the requirement of work space.
Sr. Feature Real Blow Nozzle
Aluminum / SS
Real Blow Pipe
Real Blow Jet
Remarks
Aluminum and brass are economical choice for less harsh environment. Where as SS is ideal for high temperature, corrosive and food processing industry. Adjustable flow is useful feature where compressed air line pressure could not be varied, still air blow needed is softer. Higher amplification could save considerable amount of expensive compressed air especially when blow off operation does not require deep penetration. User can choose nozzle or jet depending upon thrust requirement to ensure maximum saving.
1.
Construction material
SS
SS
2.
Flow Adjustment
Yes
No
No
3.
Air Amplification
Upto 12 times
Upto 12 times
Upto 3 times
4. 5. 6.
Thrust Penetration Noise
Adjustable Low Low to Medium
Medium Medium Low
High High High
Lower noise offers fatigue free work environment for operator Because dead end pressure of all General Imsubs blow off product is less than 2 bar (30 PSI), work area becomes safer than ever before.
7.
Meets OSHA safety standards Machine Mountable Compressed air saving Outlet can be ducted Can be used with existing blow guns
Yes
Yes
Yes
8. 9. 10. 11.
Yes Very High No Yes
Yes High No Yes
Yes Low Yes Yes To start saving compressed air just replace nozzle of existing blow guns with Real Blow nozzles or jets. Compressed air consumption could be reduced by as much as 80% by selecting right blow off device.
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Useful Compressed Air Data How to calculate compressed air consumption and savings:
Designing Air Amplifier based blow off operations:
Though it is known fact that Air Amplifier based blow off products can pay back its cost in few weeks, plant wide conversion still require little planning and study in order to achieve maximum savings and over come operator reluctance. Following steps helps to determine methodology of conversion of conventional blow off product to Air Amplifier based blow off products. Make complete survey of all blow off jets or locations where air is blown. Calculate air consumption per outlet. Grouping of blow off points as per size of orifice used will help to determine right air amplifying product for particular usage point. Select pilot points to be replaced by air amplifier based blow off products. If any outlet is using pure compressed air for drying or cooling purpose, installing General Imsubs air amplifying product will start saving compressed air immediately. Compare compressed air consumption of pilot points before and after installation of Air amplifying blow off products. Based on percentage of pilot points selected, plant wide calculation of compressed air could be calculated very easily. How does Air Amplifier based products justify its payback? Compressed air cost largely depends on cost of electricity and it may vary from state to state. But if you have never calculated cost of compressed air before, compressed air cost between 1.00 to 1.25 paise per Cu. Feet would be safe. (Rs. 1.00 to 1.25 per 100 Cu. Ft.) Multiply saving of compressed air in CFM with total minutes plant operates in a year. That is savings in compressed air. Deduct cost of filters, pressure regulators and cost of change in piping and layout from the savings of compressed air. Please take this figure in calculation only if you have installed any of these to convert your existing systems. You will realize that savings of compressed air is so much that adding new compressor may not be required for additional capacity expansion. Savings in capital cost would be visible only when you plan capacity expansion. Operating cost of air compressors comprises of Fixed charges and repairs (25%) and electric power charges (75%).
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Compressed air out put through orifice.
Pressure Kg/Sq. CM 0.07 0.14 0.21 0.28 0.41 0.48 0.62 0.83 1.03 1.38 1.73 2.07 2.41 2.76 3.10 3.45 4.14 4.83 5.52 6.21 6.90 7.60 8.27 8.62 10.35 Pressure PSI 3 1.02 2.03 3.05 4.06 5.95 6.96 8.99 12.04 14.94 20.01 25.09 30.02 34.95 40.02 44.95 50.03 60.03 70.04 80.04 90.05 100.05 110.20 119.92 124.99 150.08 1.60 2.25 2.77 3.18 3.89 4.17 4.73 5.37 6.01 6.99 7.98 8.97 10.03 11.02 12.01 13.07 15.05 17.10 19.12 21.12 23.17 25.22 27.20 28.12 33.42 Orifice Diameter mm Compressed air consumption in Cu. Ft per Minute 5 4.32 6.26 7.69 8.83 10.79 11.58 13.15 14.92 16.68 19.43 22.18 24.92 27.87 30.62 33.36 36.31 41.80 47.49 53.12 58.68 64.37 70.06 75.56 78.11 92.83 6 6.22 9.01 11.08 12.72 15.54 16.67 18.93 21.48 24.02 27.98 31.93 35.89 40.13 44.09 48.04 52.28 60.19 68.39 76.50 84.50 92.69 100.89 108.80 112.47 133.67 9 13.99 20.28 24.93 28.61 34.97 37.52 42.60 48.32 54.05 62.95 71.85 80.75 90.29 99.19 108.09 117.63 135.44 153.88 172.12 190.12 208.56 227.00 244.80 253.07 300.76 10 17.27 25.04 30.77 35.33 43.18 46.32 52.60 59.66 66.73 77.72 88.71 99.70 111.47 122.46 133.45 145.23 167.21 189.97 212.50 234.72 257.48 280.25 302.23 312.43 371.31 12 24.87 36.06 44.31 50.87 62.17 66.69 75.74 85.91 96.08 111.91 127.74 143.56 160.52 176.34 192.17 209.12 240.78 273.56 306.00 337.99 370.77 403.55 435.20 449.90 534.68
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Compressed Air Savings by various tricks and tips:
Pressure plays a vital role in conservation of compressed air. Example: If maximum pressure required by power tool or process is 6 bar. However due to inadequate line size, if plant is maintaining pressure higher than 6 bar means compressor works for longer for the same amount of compressed air. Also points from which air is blown gets air at higher pressure resulting in wastage of compressed air. Usually low pressure in line is due to inadequate size of pipe and hoses, leakage in air lines and insufficient compressor capacity. Organization must pay attention to these factor before increasing air generation pressure or installing new compressor. Improper piping lay out requires more bends and joints. Each joint has adverse effect on line pressure. Hence properly designed piping greatly reduce pressure drops. If flexible tube feeds any tool or process than choosing right size of hose reduces excessive pressure drop. All air blow point if provided with trigger type blow guns than compressed air saving could be as high as 60% because trigger type blow guns shut off immediately, else compressed air will flow freely for few seconds before operator shuts valve off. Air leakage has a very high hidden cost on operation. Leakage equivalent to 0.8 mm diameter could waste 46000 Cu. Ft. of compressed air per month at 6.5 bar pressure. Means Rs. 600 per month. And if leakage is equivalent to 1.6 mm, 3.2 mm and 6.35 mm diameter than wastage of compressed air will be 182000CFM, 729000CFM and 2920000 CFM respectively per month. If translated in Rupees it will be Rs. 2275, Rs. 9110 and Rs. 36500 per month. Replace leaky shut off valve immediately. Using good quality hoses and hose clamps can prevent expensive leakage due to cracks.
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Frequently Asked Question
Q-1 What are Air Amplifying Devices? A-1 Air Amplifying devices are such device which consumes very little compressed air for the higher volumetric output. Q-2 How that is achieved? A-2 Air amplifying devices are designed and made to use an unutilized energy of compressed air. When compressed air is passed through small orifice it attains very high velocity, which in turn mobilizes high amount of atmospheric air. Such effect is known as "COANDA EFFECT". Q-3 Where it is used? A-3 Such devices has numerous applications, where ever compressed air is used at least one of such device is useful. For example, blow off operations, cooling, conveying, extracting fumes and dust, vacuum cleaning and other countless applications. Q-4 How compressed air can be used for conveying and vacuum cleaning? A-4 As air amplifying devices mobilizes high amount of atmospheric air, it creates powerful vacuum on one end and high volume blow on another. Vacuum side can be used to pick up materials to convey. If such material is collected in suitable dust collection system with suitable porosity filter than it becomes vacuum cleaning system. Q-5 Why air amplifying systems are superior to conventional systems? A-5 There are many reasons, few of them are mentioned below: It consumes very little air than total output. It saves energy. There is no maintenance since there is no moving part. It can be used in hazardous area as there is no electricity at the point of application. They are portable and can be installed within minimum time without shutdown of any process. Pay back period of air amplifying devices is very small as it requires fraction of investment. Q-6 A-6 What is the quality of air required? Just like any other compressed air operated devices, filtered air is recommended.
Q-7 What is operating cost and maintenance? A-7 Operating cost largely depends upon the application; say if you use Real Blow instead of 3.2 mm Dia. open pipe than it consumes almost 1/4th of the compressed air than pipe nozzles still it delivers more than 6 times. So for the same given air flow one uses only 1/25 th of the compressed air. And maintenance, all air amplifying devices are virtually maintenance free as there is no moving part. Q-8 How long it can convey? A-8 Depending upon application, type of material conveyed, distance may vary, usually for lighter materials like powders and plastic pallets, 5 mtr. is the safe distance. Greater distance can be achieved by putting multiple units in series. Q-9 What will happen to my system if I pick up wet material? A-9 Nothing, as there is no moving part or electricity. It may require frequent cleaning. Please note that air amplifying devices are self cleaning to an extent.
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Q-10 What all materials it can convey? A-10 It can convey materials which are not having low flesh point and non volatile. From powder to granules to food grains to processed food powders to paper trims to wood saw to plastic parts to even nuts and bolts. Q-11 Can it be used in hazardous and RF sensitive areas? A-11 Air amplifiers are the best possible answer for such areas, as there is no electricity at the point of application so no spark, no RF interference. Q-12 How do I control suction and discharge? A-12 Just by regulating air pressure you can achieve infinite control over suction or delivery. Unlike multispeed motors they are stepless. Q-13 How do I choose right size for my material conveying? A-13 Depending upon weight of the material to be conveyed per hour and diagonal size of the part. Choose throat diameter 1.5 times larger than largest part required to be conveyed.
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Please visit http://www.osha.gov for more details
Regulations (Standards - 29 CFR)

Hand and portable powered tools and equipment, general. - 1910.242
(a)
Standard Number: 1910.242 Standard Title: Hand and portable powered tools and equipment, general. SubPart Number: P SubPart Title: Hand and Portable Powered Tools and Other Hand-Held Equipment
General requirements. Each employer shall be responsible for the safe condition of tools and equipment used by employees, including tools and equipment which may be furnished by employees.
(b)
Compressed air used for cleaning. 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.
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Work Sheet For Compressed Air Saving Achieved
Existing Blow off v/s Air Amplifier Based Blow Off Upgrading.
1 Machine & location 2 Blow off type, size & number 3 Pressure 4 Duty Cycle 5 Air Usage CFM Before 6 Cost of air per hour 7 Type of air amplifier type nozzle 8 Pressure 9 Duty cycle 10 Air usage CFM After 11 Cost of air per hour
Total Before Conversion (A)
Total After Conversion (B)
Total Savings PA in Rs. = Net Air Saving CFM X 60 (Hour) X Total Working hr PA X Cost of Air (about 1.25 paise per CFM) 100 Pay Back Period : Total Amount invested in Conversion days Savings in cost of compressed Air per year X 365
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Introduction to Compressed air Saving Blow off devices

Which are so economical that its payback period is in hours.

Real Blow Adjustable Nozzle Model # RBA -2 & RBS - 3

Metal extension tube, 450 mm Long, Increases reach Model # EXM - 9

* RBA 2 is aluminum nozzle and RBS 3 is stainless steel nozzle

Accessories for Real Blow Nozzle Model # RBP -5

Metal extension tube, 450 mm Long, Increases reach Model # EXM - 9

Accessories for Real Blow Nozzle Model # HTB - 4

Metal extension tube, 450 mm Long, Increases reach Model # Exm - 9

Real Blow Pipe

Real Blow Jet

Thrust Penetration Noise

Adjustable Low Low to Medium

Medium Medium Low

High High High

Yes Very High No Yes

Yes High No Yes

Regulations (Standards - 29 CFR)

Total Before Conversion (A)

Total After Conversion (B)

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