OSHA Requires a Compressed Air Safety Shut-Off Valve

Did you know that OSHA Requires a

Compressed Air Safety Shut-Off Valve?

The OSHA Safety Standard Regulation 29CFR CHXVII Paragraph 1926.302(b)(7) states:   All hoses exceeding 1/2-inch inside diameter shall have a safety device at the source of supply or branch line to reduce pressure in case of hose failure.

Prevent dangerous air hose whips and accidents.   Protect your most important assets: Your employees and their equipment.

OSHA Compliant COMPRESSED AIR SAFETY SHUT-OFF VALVES offers simple but efficient protection to pneumatic systems in the event of a broken compressed air hose or pipe.  

Click here to see how to get the Safety Valves you need to meet OSHA standards.

Call us to order the safety valve and reels you need- 336-299-9999

_______________________________________________________

Another OSHA guideline publication states:
“Hoses, cables, and other equipment shall be kept clear of passageways, ladders and stairs.” 

OSHA says reduce your slips, trips and falls.
Slips, trips and falls constitute the majority of general industry accidents, which cause 15% of all accidental deaths, and are second only to motor vehicles as a cause of fatalities. The OSHA standard for walking and working surfaces apply to all permanent places of employment, except where only domestic, mining, or agricultural work is performed.www.osha.gov

Consider adding reels to increase safety & efficiency with your electrical cords, welding cables, air hose, oil, grease, liquid/water or fuel hoses.  This could be one of your most effective equipment additions you’ll ever make…as well as one of the safest!

For more about Hose Reels visit www.hosereels.biz


McGuire Air Compressors, Inc.

"Real People with Real Air Compressor Experience"
336-229-9999
compressors@mcguire.biz

For Industrial Champion Air Compressors, Pumps, Manuals, Dryers

www.industrialaircompressors.biz

Reelcraft Hose Reels for air hose and other industrial applications

www.hosereels.biz

Deltech Refrigerated Air Dyers to reduce harmful moisture in your compressed air system

www.airdryers.biz.

Three Biggest Pay-Offs in changing from mineral oil-based lubricants to Synthetic Compressor lubricants

In today’s competitive and challenging market - you need every advantage you can get! 

One simple, yet very significant advantage is selecting Quality Synthetic Compressor Lubricants over conventional, mineral oil-based lubricants for your air compressor.




Three Biggest Pay-Offs in changing from mineral oil-based lubricants to Synthetic Compressor lubricants.

#1.  Lower Your Electric Bill by increasing energy efficiency

Compressor Synthetic Lubricants can actually reduce energy consumption in many applications, up to 9% as compared to conventional mineral oils.

   Here's how...
> Compressor Synthetic Lubricants help minimize friction between moving parts. ( less friction = less amp draw )

> Energy can be lost due to "churn" as mechanical parts move through oil: Compressor Synthetics Lubricants have a lower viscosity when compared to mineral counterparts of the same ISO viscosity grade , resulting in lower churn energy loss than a mineral oil.



#2. Get a Better Return on Your Investment by extending equipment life

When you lower the energy consumption with compressor synthetic lubricants you decrease friction which means less wear. Less wear = longer life.

Whether your equipment runs in extreme hot or in cold conditions, Compressor Synthetic Lubricants are more effective over a wider range of operating temperatures than mineral-based products.

>In very hot conditions, Compressor Synthetics remain thicker for better protection.  Compressor Synthetics do not degrade in high temperatures as fast as mineral-based oils either. 

>In lower temperatures, Compressor Synthetics offer excellent flow characteristics, unlike mineral-based oils that tend to get too thick to flow well when cold and can limit protection to critical parts.



#3. Lower Maintenance Costs by using Less Labor & Materials

Compressor Synthetic Lubricants usually last up to 8-10 times longer than mineral oil equivalents. This translates into...
>Reduced oil purchases
>Less used-oil to dispose
>Fewer oil changes - fewer hours your maintenance team must spend on oil changes

>Decreased downtime because of lubricant-related problems such as valve maintenance.

Click here to learn more valuable tips>>


McGuire Air Compressors, Inc.

“Real People with Real Air Compressor Experience”

Email us: compressors@mcguire.biz
Call us: 336-229-9999

For Champion Air Compressors...

https://www.industrialaircompressors.biz/

For Reelcraft Hose…

https://www.hosereels.biz/

For Deltech Refrigerated Air Dryers…
https://www.airdryers.biz/

We need more air pressure! How do I figure out how much more we need?

­­­Does your air pressure keep dropping while you are using your tools & equipment?

Have you added or are planning to add new equipment which uses air?

Are your air compressors working hard all the time- but you just aren’t sure how to figure how much more horsepower you need?

When your business counts on air – you need to know the valuable formulas and steps to help accurately determine how many CFM you use. You also need to know how to accurately figure how much additional CFM and horsepower you need when considering a new air compressor?

Here are some specific formulas that can help you determine how many CFM you presently use and how many more CFM you need to meet your desired PSIG. We will show you how to take this information and use it to determine how much air compressor horsepower you actually need.

Find out how many CFM your air compressor delivers

1. STOP the compressor unit

2. CLOSE the outlet valve on the tank/air receiver

3. DRAIN the condensate from air receiver until there is 0 PSIG -
then close the drain valve

4. NOTE THE TIME- in minutes & seconds (Best to write it down.) Then START THE UNIT.
When the compressor unit stops and unloads – then NOTE THE TIME again – in minutes & seconds. Convert the minutes into seconds and then total the number of seconds it takes between START and STOP/UNLOAD.

5. NOTE the GUAGE PSIG reading

6. NOTE the Air Receiver/Tank GALLON SIZE

7. USE THIS FORMULA:

TANK GALLONS x .538* x PSIG divided by SECONDS

EXAMPLE:

You have an 80 gallon tank, your total start to stop/unload time was
3 minutes and 30 seconds. Change the minutes to seconds timed
(60 x 3= 180 seconds plus 30 seconds which totals 210). You will use the total number of seconds (210) and the noted 175 PSIG within the formula as shown below:

80 multiplied by .536 = 42.88
42.88 multiplied by 175 (Example PSIG) = 7504.00
7504.00 divided by 210 (total seconds)= 35.74 CFM delivered

The example shows that the air compressor is delivering 35.74 cfm

Your Response to this evaluation should be to compare this number with what your air compressor manufacturer says your CFM should be and evaluate how efficiently your compressor is running.
If your air compressor is within 10% of manufacturer's specifications, then the unit is OK, if not - repair unit and recalculate your needs.

 

Find out how many more CFM you need to raise your PSIG

1 What is your desired pressure ______?
(Our Example125 psig)

2. What is your present operating pressure_______?
(Our Example 70 psig)

3. Divide desired pressure by present operating pressure
(125 psig divided by 70 psig = 1.79)

4. This gives us the X-factor needed for this formula (1.79 )

5. Multiply present air compressor cfm (35.74) by your X-factor (1.79)
(35.74 X 1.79= 63.98 This gives you the total cfm needed –
which is 63.98 for our example)

6. Deduct your present cfm from the needed cfm
(63.98 minus 35.74 present cfm = 28.24)

7. This gives you the additional cfm needed to raise your psig to the level you actually need. (which is 28.24 additional cfm for our example)

 

Translate your answers into how much horsepower you actually need to operate

Divide your additional cfm needed by 3.5* (see the chart for your *actual compressor type & horsepower)
(28.24 ÷ 3.5 = 8.07 hp, which would be the additional horsepower needed for our example)

This will give you the additional horsepower you actually need.

(We will need to round up the 8.07 hp to 10 hp needed for our example. You will have to round up to the nearest standard
horsepower also.)

*CFM per compressor horsepower chart:

3.5.cfm per hp for small piston compressors ½-30 hp

4 cfm per hp for large piston 40 hp up & small screw compressors 2 hp-30 hp

4.5 cfm per hp for 40 hp-150 hp medium hp screws

5 cfm per hp for 200 hp-2000 hp large screw & centrifugal compressors

Note: Always buy CFM of delivered air at the PSIG you need…not horsepower.

Note: Always invest in at least 20% more CFM than your equipment needs. This will cover extra air usage for such things as air leaks and wear.

Follow these formulas and you can figure just how much more CFM and air compressor horsepower you really need to get the job done!

 

Compressor Terms you should know:

Cubic Feet Per Minute (cfm) - Volumetric air flow rate.

"psig" means pounds per square inch, GAGE pressure. Gage pressure is the absolute pressure of something, with the atmospheric pressure subtracted. In practice, when someone gives a pressure in just "psi" they probably mean gage pressure. If they mean absolute, they should be using "psia."

Gauge Pressure - The pressure determined by most instruments and gauges, usually expressed in psig. Barometric pressure must be considered to obtain true or absolute pressure.

Load Time - Time period from when a compressor loads until it unloads.

Unload - (No load) Compressor operation in which no air is delivered due to the intake being closed or modified not to allow inlet air to be trapped.

Receiver - A vessel or tank used for storage of gas under pressure. In a large compressed air system there may be primary and secondary receivers.

McGuire Air Compressors
“Real People with Real Air Compressor Experience”
336-229-9999
Email: compressors@mcguire.biz
or Champion Air Compressors...
https://industrialaircompressors.biz/

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

How to get the most out of your Air Compressor

Get the most out of your Air Compressor by establishing a regular, well-organized maintenance program and strictly following it.

Such a program is critical to maintaining the performance of a compressed air system and will save you time and money in the long haul. You should use the standard recommended minimum maintenance procedures for air-cooled reciprocating compressors as listed in the checklist below.

One person should be given the responsibility of ensuring that all maintenance is performed properly, on schedule, and is adequately documented.

IMPORTANT:
Before performing any maintenance function:
• Switch main disconnect switch to "off" position to assure no power is entering unit.
• "Lock Out" or "Tag Out" all sources of power.
• Be sure all air pressure in unit is relieved. Failure to do this may result in injury or equipment damage.

DAILY MAINTENANCE OR (every 8 hours)
1. Check oil level of both compressor and engine if so equipped. Add quality lubricating oil as required.
2. Drain moisture from tank by opening tank drain valve located in bottom of tank.
3 Check for any unusual noise or vibration
4. Turnoff compressor at the end of each day's operation. Turn off power supply at wall switch.

WEEKLY MAINTENANCE OR (every 100 hours)
1. Clean dust and foreign matter from cylinder head, motor, fan blade, air lines, intercooler and tank.
2. Remove and clean intake air filters.
3. Check V-belts for tightness. The V-belts must be tight enough to transmit the necessary power to the compressor

MONTHLY MAINTENANCE OR (every 500 hours)
1. Change crankcase oil if using CHAMPLUB hydrocarbon based reciprocating oil.
2. Check entire system for air leakage around fittings, connections, and gaskets, using soap solution.
3. Tighten nuts and cap-screws as required.
4. Check and clean compressor valves, replace worn or damaged assemblies & gaskets
5. Pull ring on all pressure relief valves to assure proper operation.

ANNUAL MAINTENANCE OR (every 4000 hours)
1. When CHAMPLUB synthetic lubricant is used, lubricant change intervals may be extended to every 4,000 hours or annually whichever occurs first (change more frequently in harsher conditions).
2. Maintain lubricant level between high- and low-level marks on bayonet gauge. (Discoloration or a higher lubricant level reading may indicate the presence of condensed water). If lubricant is contaminated, drain and replace.

Click Here to Download a Free Reciprocating Maintenance Service Record Checklist Sheet

For your next order of Compressor Lubricants and Filters –
call 336-229-9999…
Or click here for SERVICE KITS and Lubricants

McGuire Air Compressors
336-229-9999
Email: compressors@mcguire.biz

http://www.industrialaircompressors.biz/

https://www.airdryers.biz/

https://www.hosereels.biz/

Top 7 Air Compressor Related Formulas

Anyone who works with or helps maintain an industrial air compressor should have these valuable compressor related formulas. Print them out and keep them handy…you might need one of them next week!

1. Formula To Find: Belt Length
Compressor Flywheel OD + Motor Pulley OD X 1.57 + 2 X Shaft’s Center To Center Distance In Inches

2. Formula To Find: Motor Pulley OD
Compressor Flywheel OD X Compressor Rpm’s / Motor Rpm’s

3. Formula To Find: Tank OD
Measure Circumference / 3.1416

4. Formula To Find: Volume Of Tank In Gallons
Tank OD X OD X .785 X Tank Length In Inches / 231

5. Formula To Find: PSIA Pressure
14.7 + Gauge Pressure

6. Formula To Find: Compressor CFM Using The Time Method
Tank Gallons X .536 X PSIG Increase / Total Seconds

7. Formula To Find: Motor Max AMP Draw Before Damage Begins
Motor Data Plate AMPS X Data Plate Service Factor


FORMULA SYMBOLS & DEFINITIONS:
/ = divide
X = multiply
+ = add

AMPS = Abbreviation of the plural for Ampere, a unit of electrical current

CFM or cfm = Abbreviation of Cubic feet per minute - a unit of measurement of the flow of a air/gas or liquid that indicates how much volume in cubic feet pass by a stationary point in one minute.

OD = Abbreviation for Outside diameter is a dimension commonly used to specify the size of tubing or pipe.

PSIA or psia = Abbreviation for Pounds per square inch absolute (including atmospheric pressure)

PSIG or psig = Abbreviation for Pounds per Square Inch Gauge

RPM or rpm = Abbreviation for Revolutions per minute is a unit of frequency of rotation: the number of full rotations completed in one minute around a fixed axis. It is used as a measure of rotational speed of a mechanical component.

McGuire Air Compressors
“Real People with Real Air Compressor Experience”
336-229-9999
Email: compressors@mcguire.biz
or Champion Air Compressors...
https://industrialaircompressors.biz/

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

TOP TEN Compressed Air "Rules of Thumb"

Here are our TOP TEN Compressed Air "Rules of Thumb" that we've come up with throughout our 44+ years of experience. These are the things that our compressor customers seem to ask about most.

1. Air Compressor CFM delivery per Horse Power at 100 PSIG:
• For "home owner" type of air compressors---2 to 2.5 CFM per HP
• For Industrial Air-cooled 2-stage air compressors----3.5 CFM per HP
• For Small Vane & Screw air compressors (25 HP or less) 4 CFM per HP
• For large Piston, Screw & Centrifugal air compressors--4.5 to 5 CFM per HP

NOTE: THE MORE CFM PER HP - THE LESS ENERGY USED.

2. Air Receiver Size needed for these types of inlet control:
• Modulating Control------------ 0 to 1 gallon per CFM
• On-Line/Off-Line-------------- 3 to 4 gallons per CFM
• Stop-Start / Variable Speed--- 4 to 6 gallons per CFM

NOTE: THE MORE AIR STORAGE - THE LESS ENERGY USED


3. Amperage per Horse Power:
115 Volts-------1 phase--------10 amps per horse power
230 Volts-------1 phase-------- 5 amps per horse power
208 Volts-------3 phase-------- 3 amps per horse power
230 Volts-------3 phase-------- 2.5 amps per horse power
460 Volts-------3 phase-------- 1.25 amps per horse power
574 Volts-------3 phase-------- 1 amp per horse power

NOTE: THE MORE ENERGY EFFICIENT THE MOTOR - THE LESS ENERGY
IS USED.

4. Air Piping Size by CFM and Pressure Drop:
• Compressor Room Header--0.25 PSIG pressure drop per 100 feet of piping
• Main Line---------------0.5 PSIG pressure drop per 100 feet of piping
• Loop Line---------------1 PSIG pressure drop per 100 feet of piping
• Branch Line-------------2 PSIG pressure drop per 100 feet of piping

NOTE: THE LESS AIR PRESSURE DROP - THE LESS ENERGY USED.

5. Size Compressed Air Line Filters to be twice (2x) your compressor CFM flow rate.
• This will lower your pressure drop approximately 2-3 PSIG and save 1% on energy costs.
• Elements will last twice (2x) as long and save on maintenance costs.

6. Lowering Compressor Pressure settings 2 PSIG will result in a 1% energy savings.

7. Lowering Compressor Inlet Air Temperature 10° F will result in a 2% energy savings.

8. The average energy cost to operate an air compressor is approximately $0.10 per horse power per hour.

9. Compressed air system leaks totaling the size of a ¼" orifice, at 100 PSIG, running 24 hours a day will waste approximately $15,000 worth of electrical energy a year.

10. Using Synthetic Compressor Lubricants can save you up to 9% of the energy cost of operating your compressor.


>>>>Click here to learn more about basic air compressor maintenance>>>>

McGuire Air Compressors
336-229-9999
email: compressors@mcguire.biz

https://industrialaircompressors.biz/

https://airdryers.biz/

https://hosereels.biz/