The industrial baghouse manufacturing landscape is always evolving. Whether you own an Pneumafil dust collector, MikroPul baghouse, Pangborn dust collector or a custom dust collection system from IVI, Father Time is undefeated.

Is it time to replace your aging baghouse?

Even if you’re keeping a close eye on common issues in baghouse maintenance, an aging baghouse can expose your operation to employee health and safety risks, production shutdowns, regulatory compliance issues and more. And, if you’ve fallen behind on baghouse maintenance—and plugged ductwork, leaking pulse valves, damaged bags or other problems persist—it’s likely accelerating baghouse wear and tear and the risk your company is taking. If your dust collection system brand has changed manufacturers, regular maintenance becomes even more critical to avoid significant issues.

Aging baghouse indicators that affect all baghouse brands

While the lifespan of a baghouse is influenced by environmental conditions, particulate removal demands and maintenance, a typicaal baghouse lifespan is 20 years or longer. Whether you own a Pneumafil baghouse, MikroPul dust collector, Pangborn baghouse or ��һ��ݶ�custom solution that is more than two decades old, these indicators can help you assess whether it may be reaching its end of life.

• Overall deterioration: You may see rust, cracks, corrosion and other deterioration to your industrial dust collection system, hear unexpected noises or experienced reduced efficiency in particulate removal. This deterioration may indicate it is time for a baghouse replacement.
• Replacement parts access: Common parts that need replacing include bag filters, timer boards and diaphragm valves. Changes in the baghouse industry can lead to availability issues for critical system components for baghouse brands that are no longer manufactured. If finding baghouse parts or supplies for your aging baghouse is becoming more difficult, it may be time to consider a baghouse replacement.
• Maintenance costs: If your baghouse has been in use for decades, the costs to keep it running effectively and efficiently may add up. If maintenance costs are on the rise, a baghouse replacement may be needed.

Explore replacement options before a problem risks employee health and safety or causes a shutdown, further cutting into your bottom line.

Current system evaluation

If questioning whether a replacement is the best path forward, the first step is to evaluate the current dust collection system—whether it be an IVI, Mikropul, Pangborn or Pneumafil baghouse—or another brand manufactured during the last century. An evaluation can help you determine your baghouse’s current capacity and whether modifications can be made or a full replacement is necessary.

When replacement is needed

If modifications can extend the life of your baghouse, the ��һ��ݶ�team can explore the available options. If not, our experienced team can provide turnkey solutions. Across any industry and ranging from 50 to 1 million cubic feet per minute, the ��һ��ݶ�team is ready to design and engineer, fabricate and install a new long-lasting industrial baghouse solution for you.

MIKROPUL is a registered trademark of MENARDI MIKROPUL LLC, 4404-A CHESAPEAKE DR, CHARLOTTE, NORTH CAROLINA UNITED STATES 28216

PANGBORN is a registered trademark of PANGBORN LLC, 4630 COATES DRIVE, FAIRBURN, GEORGIA UNITED STATES 30213

PNEUMAFIL is a registered trademark of NEDERMAN CORPORATION, 4404 CHESAPEAKE DRIVE, CHARLOTTE, NORTH CAROLINA UNITED STATES 28216

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Transcript

��һ��ݶ�– 100,000 CFM Dust Collector Assembly

The Project
Foundry Application to Mitigate Dust Exposure
6 Months Before: Design and Engineering
4 Months Before: Fabrication
1 Week Before: 3-Person Crew Site Prep

The Crew
60 Years Crew Experience
Six-Person Installation Team

The Installation
Baghouse Assembly Built Up from Hopper
Custom Structural Steel and Staircase
Pre-Assembled Catwalk and Walk-In Plenum Access

Final Product
65-Foot Tall Assembly
90-Foot Tall Stack
1000+ Filters Installed
Meets EPA Standards

��һ��ݶ�– Metal Fabrication • Industrial Ventilation

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Transcript

Industrial Dust Collection Systems Start to Finish (And Beyond)

We design, build and install our own dust collection systems, as well as maintain other dust collection systems and ductwork and HVAC systems all around the country. It really sets us apart from any other contractor in the country, because there’s a lot of contractors that deal with just the engineering piece and rely on another company to install it.

There are some contractors that can just do the installation but not the engineering. Because of that we have a lot more experience than the average contractor when it comes to installation.

Dust Collection Installation Experience Across Industries

We have a rigorous safety program within our own industry as well as we are up to date and follow protocols for each individual industry. Many of our staff in the field are trained on cranes, rigging, multitude of lifts, forklifts, material moving equipment. Due to the experience and the vast amount of collection systems we work with all around the country, pretty much everybody knows how to do all of these various aspects of the project. So that enables us to get by with fewer people.

I think one of the reasons we can do that is we just have guys that have been around for a lot of years and know what they’re doing and we can get the jobs done safely, efficiently and ultimately it’s going to result in a more cost effective job for you.

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Dust Collector Installation Efficiency: How We Do It

How have we been able to do more with less when it comes to installation? It all goes back to our depth and breadth of experience as well as rigorous training.

We Have Broad Industry, Equipment Knowledge

Our roots in the foundry industry helped us hone skills in using heavy equipment and rigging as well as skills in installing a dust collection system in tight spaces. The high percentage of crew members who have more than 20 years of experience have helped us transfer this knowledge to industries like pulp and paper, mining, automotive and more.

Because of this broad knowledge, coupled with the large number of industrial ventilation installation jobs we’ve done across the country, most crew members know how to run the needed equipment, including cranes, forklifts and aerial lifts. Installation team members are cross-trained on needed equipment, so we can both work efficiently and bring fewer people to the site.

We Design, Build and Install

At IVI, we design, fabricate, install and maintain dust collection systems. That sets us apart from other companies that only engineer or only install systems. Because of this knowledge, our crew can identify and troubleshoot issues that might arise during install. And, if needed, the engineers who designed the system are just a phone call away.

We Focus on Safety

Dust collection installation comes with inherent risk—to employees and property. That’s why we focus on safety, ensuring our field crew and project managers are trained per standards set by the as well as the . In addition to this required training, we also conduct weekly staff Toolbox Talks and have in-house training on a variety of safety and hazard protection topics, from working in confined spaces to scaffold safety to hand protection.

Finally, we start each day at an installation site with a safety task analysis. During the analysis, we determine what safety hazards we may encounter and how to mitigate them so that we can reduce risk to our crew, as well as your employees and property.

A Single Point of Contact for Industrial Ventilation Installation

Not only do we heighten efficiency with a small, knowledgeable crew, we also pre-plan the install so you experience less downtime. When you’re installing a dust collection system, trust ��һ��ݶ�to work quickly without sacrificing quality. Contact us to get started.

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Transcript

Why ��һ��ݶ�Excels at Plan and Spec Projects

��һ��ݶ�excels at plan and spec projects because we have the experience of engineering and designing projects as a design-build contractor. When we’re awarded a project that is plan and spec our field crews, our project managers bring their experience on our own design-build projects to that project.

Industrial Ventilation Experience Across Industries

IVI’s worked on a number of different projects in a number of different industries. From foundries, to the pulp and paper, automotive, mining. We’ve even done some commercial HVAC work as part of bigger projects so there’s not many plan and spec projects we haven’t been a part of.

Making Industrial Ventilation Installation Easier

On plan and spec fabrication, ��һ��ݶ�with their experience on the field install side, fabricates to the knowledge that that field crew needs a quality product to install. Something that has been reviewed through our quality process to make sure ninety-degree elbows are 90 degrees, and that everything fits and is aligned properly for an easier install. Making sure that the fabrication matches the prints.

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Transcript

Industrial Ventilation Design to Find Solutions

A design-engineered solution is a project that does not have a defined scope. It can be as small as a duct work problem that has a moisture issue and is plugging to as large as a greenfield construction site that needs a completely designed and engineered ventilation system.

Leaders in Industrial Ventilation Design

What really sets ��һ��ݶ�apart in the industry is our full staff of engineers ranging from mechanical, environmental and civil engineers. Having this whole team of engineers in-house allows our customer to have one point of contact for their engineer solutions. Not only does ��һ��ݶ�have a full line of engineers on staff, we also have eight full-time designers that bring the engineered solutions to life.

During many plan and spec projects IVI’s engineering design services can aid the customer with unforeseen delays and obstructions within the project. ��һ��ݶ�can react quickly and come back with a engineered solution to correct the problem to keep the project on track.

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• Whether adding new equipment or improving efficiency is the reason behind the installation
• Evaluating duct network, fans, dust collector and baghouse efficiency
• What ��һ��ݶ�will evaluate and the different areas an industrial dust collector manufacturer can help in

Reasons to consider a new dust collector installation

Facility managers may consider a new dust collector installation for two primary reasons:

• New equipment: Adding equipment likely will add to the amount of particulate sources that need to be collected.
• Improve efficiency: Oftentimes, dust collection systems become inefficient, leaving behind particulates that should be collected. If maintenance issues are ruled out, a new dust collector installation can help improve the overall performance of the dust collection system.

Evaluating whether you need a new dust collector installation

When considering a new dust collector installation, the first step is conducting an evaluation of the current system. This evaluation will determine the system’s current capacity and what modifications need to be made to keep the system running efficiently.

The following areas are evaluated:

• Duct network: Ducts are examined to measure flow volumes, velocities, static pressures and physical wear and appearance. This network also is inspected for dropout.
• Fans: Fans are examined to determine flow rates, rpm and system static pressure. Based on the findings and needs of the collection system, fans may need to be resized or resheaved to change fan rpm. In addition, a motor change may be necessary to meet required fan speed or necessary static pressure.
• Dust collector: The size of the dust collector indicates whether it has the capacity to pick up contaminants from needed areas. This capacity may need to be increased if more particulate is required to be removed from the area.
• Baghouse efficiency: The evaluation determines whether the baghouse has adequate air-to-cloth ratio to capture particulate efficiently.

IVI’s evaluation

IVI, an industrial dust collector manufacturer, has the engineering resources to conduct a thorough evaluation of your industrial air ventilation system. If you are experiencing inefficiencies in your system, we’ll determine whether you have a maintenance issue or whether you need a new dust collector installation.

If it’s a maintenance issue, we can set up a regular maintenance schedule at your facility to ensure your system is running at peak efficiency. Because we’re an industrial dust collector manufacturer, we can also provide a turnkey solution, from evaluation to design and build, if you’re adding equipment.

Contact IVI to learn more about installing a new dust collector for your facility.

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Types of pulse controllers

Pulse controllers come in two types—a simple timer and an on-demand timer.

• Simple timer: With this pulse controller, an operator sets a timer for how often the pulse valve will pulse. With this type of controller, the bags are cleaned at the set interval even if they do not need cleaning. Typically, trial and error is used to set the frequency. This pulse controller is a lower cost option because its design is simple, and it is easier to set up. This controller works best with predictable or consistent loading, and it’s ideal for baghouses that need to be cleaned continuously.
• On-demand timer: For this pulse controller, the timer reads the differential pressure across the baghouse and initiates a pulse sequence once the differential pressure reaches a high set point. It continues to pulse until the pressure across the baghouse reaches the low set point. Once at the low set point, pulsing stops until the differential pressure reaches the high set point, and the sequence continues. Because filters are cleaned when needed, the advantages of an on-demand pulse controller are extended bag life and savings in compressed air.

Set up parameters for pulse controllers

Several parameters can be set on pulse controllers.

The simple timer has just two:

• Time the valve is open: This time correlates to how much volume of compressed air is released through the valve. A quick pop of air, for example, is just .05 of a second.
• Time the valve is closed: This is the amount of time between pulses. It can typically be set to anywhere from one second to several hundred seconds.

Besides high and low pressure, as well as those listed above, the on-demand timer also has the following parameters:

• Alarm pressure: Alarms can be set to tell an operator there is an issue with a bag. A high pressure alarm indicates a plugged bag. As an example, a high pressure set point may be six, and an alarm may be set for nine or 10. Conversely, a low pressure alarm indicates a bag needs to be replaced because of a leak or a bag has fallen off.
• Pulse sequencing: Operators can set the order that the valves release air. IVI’s Ecollector™, for example, can have six to 16 valves, which can be programmed in sequence.

As an added note, when installing a pulse controller, avoid locations with direct sunlight or in close proximity to heat or an electromagnetic field as these can damage the controller.

Troubleshooting your pulsing system

If you experience issues with the pulse controller, there are several things you can check, depending upon the problem:

• Valves are not pulsing: Check the power to the timer, the differential pressure switch, header pressure, or the solenoid and/or diaphragm valve.
• Hissing sound from valves: This may indicate a possible compressed air leak.
  • If the solenoid air outlet is leaking, check:
    • The electrical connection
    • The sub assembly for debris
  • If the diaphragm valve outlet port is leaking, check:
    • The air line to the solenoid
    • Header pressure
    • The inside valve body for pitting and debris
    • The membrane for wear
• Bags are not cleaning adequately: Check the pulse pressure, on-time and off-time, and pressure set points. It may also indicate the need for a bag change.

We also recommend that you keep an adequate supply of dust collector filters and pulse valve kits on hand to avoid the cost that comes with having delays in production.

��һ��ݶ�can help with your pulse controller setup or troubleshooting. Contact us for assistance.

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1) What is a design/build solution?

IVI’s design/build solution is a turnkey industrial ventilation solution as the entire project is completed under one roof from the beginning designs, to the fabrication and installation of an industrial ventilation system. A design/build solution offers the opportunity to have the project’s specifications planned by the same team who builds and installs the system.

��һ��ݶ�handles all project management from beginning to end.

Types of design/build solutions

• Dust collection systems
• Baghouse dust collectors
• Cartridge dust collectors
• Mechanical separation filtration
• Fume collection systems
• Industrial ductwork
• Industrial exhaust stacks
• Storage tanks and sand silos
• Structural steel solutions

2) What is IVI’s design/build process?

When one of IVI’s customers has a problem; they are provided a quote for a turnkey industrial ventilation solution. The solution includes the engineering and design in addition to the fabrication and installation of the industrial ventilation system. ��һ��ݶ�will also include the selection and procurement of necessary equipment and sub-contractors as needed.

Upon approval of the quote, IVI’s team begins the process by visiting the site and custom designing an industrial ventilation system to maximize a long-term return on investment.

Upon completion and approval of the designs, IVI’s team fabricates and installs the system on-site with the most efficient use of resources possible.

3) How can a design/build solution save on costs?

Design/build solutions are more efficient because there is no overlap in the various steps throughout the process. The time savings alone will save an organization on costs.

While IVI’s customers have the final say in any project, its design/build team provides full-service project management from start to finish. As a result, IVI’s customers save time and internal resources.

4) What benefits can a design/build solution provide?

A design/build solution provides a finished system with very little unforeseen complications.

When the design is developed by an engineering firm and then installed by another contractor, crucial steps can be missed. IVI’s design/build solution manages each step of the project with one team. If there is a problem, finding a solution is simple.

��һ��ݶ�can expedite the process as they are designing the system, resulting in a simplified purchasing process and shorter lead-times.

5) Why is a design/build solution the best choice?

IVI’s design/build solution provides its customers with flexible options for each project; ensuring that its customers’ needs are fully satisfied from start to finish.

6) When is a design/build solution the best choice?

• When timetables are critical
• When costs and/or budgets are important

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