Project managers often make this mistake when searching for an industrial ventilation fabrication company.

Many project managers find themselves in a predicament after hiring the lowest bidder over the most detailed. They may need another metal fabrication contractor to come in after the first and do it correctly, effectively doubling or tripling their budget.

This guide helps you avoid the all-too-common pitfalls.

Tip #1: Ask about history and metal fabrication experience

There is no way around it: To become a skilled metal fabricator; one needs years of experience.

A competent custom industrial ventilation fabrication company will have a dense portfolio of projects, a long history of being in business and an experienced team. When you put in an inquiry, this should be one of the first questions you ask.

Tip #2: For custom metal fabrication, solicit a transparent, detailed project scope

Too often, when project managers sign with a company that offers the lowest bid, they later find the contractor was not detailed enough in their scope of work. That often results in a flurry of change orders or project rework. One way to avoid this mistake is by asking for a bid sample up front. This will allow you to see the detail at which a project is scoped and to provide feedback in advance of the bid being sent.

Tip #3: Ask if the company offers more than metal fabrication services

Engineering and design are typically handled by separate organizations. When different organizations handle various parts of the same project, disconnects in communication, process and progress can result.

IVI, on the other hand, is a full-service industrial ventilation design, engineering, manufacturing and installation company. That means the ��һ��ݶ�team oversees both engineering and design of your industrial ventilation system. This cuts the lags between handoffs lowering the risk of miscommunication. The result: Projects are more efficient and effective.

Ask the question up front, “Is your team capable of managing this project from start to finish? If not, what aspects are you willing to cover and how do you manage the transitions?”

Tip #4: Confirm metal fabrication equipment upgrade schedules

Any custom industrial ventilation fabrication company will be regularly updating and upgrading equipment for two reasons:

• Poorly updated equipment creates subpar products
• Equipment failures cause delays in project progress

Be sure and ask any prospective industrial ventilation manufacturer about current equipment, planned upgrades and if they have contingencies in place to mitigate equipment failure.

Tip #5: Find out how and when their project managers will be communicating with you

Last but not least, set clear expectations around how and when you will hear from your project manager. At what points in the project will they be communicating with you? How and when will delays or scope changes be addressed? Creating clear guidelines for communications up front sets you and your new project manager up for a successful professional relationship.

Bonus tip: safety plan

Does your prospective industrial ventilation fabrication company have a safety plan in place? Because safety incidents on a jobsite can affect your productivity, it’s critical to ask about safety training, safety plans and safety record.

Industrial ventilation company selection

Gathering the information outlined above can help you ensure the industrial ventilation company you select is the partner you want.

��һ��ݶ�has proudly been in the metal fabrication business for over 30 years, uses the most up-to-date equipment, and offers start-to-finish industrial ventilation design, engineering, custom metal fabrication and installation services on all of our custom projects.

Are you looking for an industrial ventilation fabrication company that can bring your idea to life? Get a quote today.

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Thank you for considering IVI, Inc. for your ventilation project. Whether you need a full ventilation system engineered from the ground up or have a maintenance need, your goal can be accomplished with the right solution at a competitive cost.

This guide covers the details required to:

• Assess your needs
• Define goals
• Establish timelines
• Identify resources
• Address challenges
• Determine costs
• Specify deliverables and exclusions

���ձ�’s experienced team is here to help you along the way, and we look forward to serving you from start to finish.

The Value of Proficient Planning

A detailed project scope sets you up for a smooth, successful ventilation project.

This initial phase of gathering critical information reduces your risk and helps provide the best outcome. With sufficient planning and complete information, you’ll avoid surprise costs and unexpected downtime. The scope can also be referred to throughout the project to keep contractors on task.

Why Does This Matter to You?

Imagine that a customer receives four quotes with a vast pricing range for an industrial ventilation system. They select the least expensive option, but don’t realize why the quote is so much cheaper. Because important details about their unique building layout are missing from the scope, they soon find out that the lower-cost “one-size-fits-all” system doesn’t fit. Frustrations build as additional quotes and change orders are needed to address the issues, the project gets behind schedule and ends up over budget.

Now picture a customer who needs a dust collector. Their project goals and deliverables aren’t clearly stated when they initiate the project. Trouble soon arises when the customer realizes their moist contaminant with heavy loading, which they didn’t mention in the scope, plugs the undersized cartridge collector they received. Due to the reduced system performance, targets aren’t met, resulting in costly fines and health risks to the employees. The relationship with the vendor becomes strained, time is consumed and costs rise as they work to correct the issue.

Having a well-developed scope can help avoid these types of costly and time-consuming issues.

The Basics

The information you initially provide helps build the foundation for an accurate quote, the best solution and maximum cost savings. Your industry, goals and other details will be considered to develop a thorough understanding of your project, which allows your needs to be met. Let’s begin with an overview of your business and industry.

Preferred Contacts

• Who is the main point of contact for this project scope?
• What is your preferred method of contact? Phone / Email / Text / Video Conferencing
• Who else needs to be involved? e.g., EH&S, operations, engineering, project management, etc.

Work Site Details

• Where is the location of the work site?
• Will local labor be utilized?

Industry Details

• What is your industry?
• Which materials are involved?
• What special requirements come with your industry? (e.g., duct work material type, restrictions on finish and joint quality, high wear)

Define Your Goal

• What do you need to accomplish?

Project Scope Guide

Past and Present Challenges

Past challenges help provide a full picture of today’s project needs.

• What issues have you dealt with in the past?
• How have past issues been solved?
• How long has the issue been a problem?
• What is the current need?
• What issues do you foresee with your upcoming project or maintenance?
• What are the special requirements for your project?

Establishing a Timeline

It’s important to stay on track with minimal interruptions to your operations. By documenting your needs, a thorough plan will be devised to reduce downtime and keep you on schedule.

• What shifts do you operate?
• Do you have existing planned downtime for maintenance?
• Can installation take place during all shifts without interruption to production?
• When is your desired completion date?
• Is there flexibility with your desired completion date?

Existing Equipment Information

If your project involves existing equipment, a ventilation solution will be developed for the best fit and results.

• Provide existing equipment manufacturer data if possible.
• Provide equipment serial numbers if possible.
• Provide pictures if possible.
• Provide any known issues with current equipment or changes that have been made since original installation date.

Space Constraints

Spacing plays an important role in determining the right ventilation solution.

• What space constraints exist at your facility?
• Provide measurements if possible, using Imperial measurements.
• Provide pictures if possible.

Surface Preparation and Paint

The proper surface treatments will be determined for your industry. What are your surface preparation requirements?

• Galvanized
• Passivation
• Paint
• Other

On-Site Visit

Observing your production process in person allows a comprehensive and accurate assessment of your ventilation.

• Ideally, it’s best to assess your production and ventilation operations in action. Is this possible? Or must production be shut down?
• If possible, have operators, a foreman and the project contact on-site for the assessment.
• Air readings will be taken, and space constraints will be measured.
• Your processes will be observed, and you may receive recommendations to improve efficiency.
• The best solution will be determined for long-term results.
• Site constraints, unknown to the customer, may be identified with ���ձ�’s experienced teams extensive installation expertise.

What’s Next

Once you submit your project scope, your needs will be evaluated and additional questions may follow as needed. You’ll receive recommendations and a competitive quote to meet our ventilation needs.

Thank you for the opportunity to earn your business.

What Sets ��һ��ݶ�Apart

Dedicated from Start to Finish

��һ��ݶ�designs, builds and installs custom dust collection systems and maintains other dust collection systems, ductwork and industrial HVAC systems around the country. ��һ��ݶ�not only works on the engineering piece of your project, but also performs fabrication and installation as a dedicated partner from start to finish. This ensures a cohesive solution with a full perspective of the ventilation design and operations.

��һ��ݶ�has a rigorous safety program and follows protocols for each individual industry. Many ��һ��ݶ�staff members in the field are trained in cranes, rigging, a multitude of lifts and material moving equipment. ���ձ�’s extensive experience and vast number of nationwide collection systems ensures the knowledge and resources to get the job done right.

���ձ�’s mission is to get the job done safely and efficiently—ultimately resulting in a successful and more cost-effective project for you.

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Transcript

��һ��ݶ�Engineers Share the Keys to Proper Industrial Ventilation Hood Design

Hood design is very important and actually crucial for the functionality of a collection system. Improper hood design can cause a lot of issues and probably the most common one is the placement of the hood in relation to where the contaminant is being generated. A lot of times the hoods are too far away from the contaminant generation point to be effective.

Industrial Ventilation Hood Design: What Sets ��һ��ݶ�Apart?

��һ��ݶ�takes the design of hoods very seriously. One of the things that sets us apart the most I believe is just our experience. And two things that we do to ensure that hoods are going to function properly when they’re installed are to first look at them through Computational Fluid Dynamic Modeling to see where air is going within the hoods. And the other thing that we do is we have built a test lab for trying out some of these hoods to ensure that they’re properly collecting the contaminant that we’re trying to capture.

The Science and Art of Hood Design

Hoods are kind of a unique balance of science and art. We use a lot of equations from industry publications on sizing and determining volumetric flow rate for our hoods. But there’s also an art to ensuring that these hoods fit within the applications and the needs of our customers.

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Transcript

Reasons For Engineering Studies

There’s a couple reasons why customers should contact us to do these evaluations and what the benefit from those are. After time goes on they realize or they notice that some areas of then plant just seem more dusty or there’s more smoke than there used to be. That could be that there was a process change. Or secondly, they call us in and we look at the ventilation and we might get into the system doing the evaluation and come to find out that a blast gate or an orifice plate was changed. And the volume that they think that they have at current equipment really isn’t true.

The Engineering Study Process

Each branch has to be balanced at the beginning of the system startup and that plays a role at the volume and the static pressure. So as soon as you touch one piece of this entire network, it directly affects every branch. When you’re changing the volume going to a certain piece of equipment, you could see a lot of dropout in your ductwork. And over time, that material drops out and fills up in your ductwork. You’re adding a lot of weight to a suspended piece of ducting that may or may not have had a hanger properly designed to support that weight.

Engineering Studies Ensure Optimal Operation

For us to get in there and see exactly what’s going on with the system and make sure that everything’s clean and clear, each branch has good volume, the fan is operating at a good point in the curve. It all kind of ties together just to make sure that it’s operating the way it should be.

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Types of industrial baghouse dust collectors:

• Pulse jet baghouse dust collector
• Reverse air baghouse dust collector
• Shaker baghouse dust collector

After learning about your facility, regulatory requirements and particulate matter you need to filter, the ��һ��ݶ�team taps decades of experience to identify the industrial baghouse dust collector that’s right for you. Here are the types of baghouses we consider:

Pulse Jet Baghouse Dust Collector

In pulse jet baghouse dust collector operation, puffs of pressurized air “pulse” incoming air through the filters for cleaning. Pulse jet dust collectors are the most common type of baghouse dust collector used in industry today.

Reverse Air Baghouse Dust Collector

Industrial reverse air baghouse dust collectors are typically used in wood dust applications with larger chips or when particulate matter has low densities and/or large aspect ratios. Reverse air baghouse operation involves a low-pressure reversed flow to backflush the air through the filter bags. Once backflushed, the filtered air is released back into the environment for recirculation.

Shaker Baghouse Dust Collector

Industrial shaker dust collectors are occasionally used for areas and facilities where it’s not practical to have compressed air. Mechanical shaker baghouses remove particles by mechanically shaking the filter bags. This causes the heaviest pieces to fall into a hopper while the smaller pieces are stuck against the inside or outside of the bags, depending on the design.

Shaker baghouse dust collectors are nearly obsolete and have limited applications due to required regulatory efficiencies and necessary maintenance.

Custom Design Baghouse Dust Collector Capabilities

Whether your facility requires a reverse air or pulse jet baghouse dust collector, ��һ��ݶ�has a custom design-build department which allows us to conduct both engineering and custom design in-house for any type of industrial baghouse dust collector. We can design a unique baghouse to fit your needs according to regulatory emission rates, particle type, explosion protection guidelines, the size and type of your facility and air-to-cloth ratios.

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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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1) What is a design/build solution?

���ձ�’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 ���ձ�’s design/build process?

When one of ���ձ�’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, ���ձ�’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, ���ձ�’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 ���ձ�’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, ���ձ�’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. ���ձ�’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?

���ձ�’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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Types of industrial exhaust fans

Axial fans

Axial fans, sometimes called “in-line” fans transfer large amounts of air with a lower rate of resistance by drawing air straight through the fan. Axial fans are generally not used for industrial ventilation systems with air cleaning devices because they do not generate a lot of static pressure.

Types of axial fans

• Propeller fans: Most commonly used fan for general ventilation such as dilution ventilation or cooling.
• Tubeaxial fans or duct fans: Also a propeller fan made to fit in ductwork with cylindrical housing, usually without any type of straightening vanes and transfer air against moderate static pressure (up to 4”wg). They are best used for clean-air applications, such as exhaust ducts going through the roof.
• Vaneaxial fans: Share similar characteristics to a propeller fan. In contrast to tubeaxial fans, vaneaxial fans have a hub and airfoil blades mounted in cylindrical housings usually with straightening vanes on the discharge side of the impeller. Vaneaxial fans also handle larger static pressure (up to 10”wg). Like tubeaxial fans, vaneaxial fans are best used for clean-air applications.

Centrifugal fans

Centrifugal fans are said to look like “squirrel cages.” They transfer small amounts of air with a higher rate of resistance by drawing air through the center of the fan. The air is then released through the exhaust at a 90-degree angle. The fan blade determines the three centrifugal fan types.

Types of centrifugal fan blades

• Forward inclined blades: The blades curve toward the rotation direction and are quiet during operation. Due to the short curved blades, these fans are not recommended for dust or particulate.
• Radial blades: The blades are straight from the hub. They are shaped to resist material buildup, allowing them to be used for a variety of exhaust systems handling clean or dirty air.
• Backward inclined blades: The blades curve opposite the rotation direction, are quiet during operation, and have the highest mechanical efficiency of all fan blades. Because they are prone to buildup, fans with these blades are best for light dust or clean-air environments.

Fan selection considerations

Referencing the original equipment manufacturer is best when selecting the right fan for an industrial dust collection system. However, here are general guidelines to consider:

• Capacity, such as flow rate and pressure requirements
• Airstream, including materials handled through the fan
• Physical limitations
• Drive arrangements/power source
• Noise
• Safety and accessories
• Flow control

These considerations are explained in greater detail in “Industrial Ventilation Fan Selection – Part 2.”

���ձ�’s engineering and design team provides start-to-finish, air quality control solutions keeping costs affordable and efficiency high. Contact IVI today for assistance in selecting a fan for an industrial dust collection system or for any industrial ventilation need.

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However, as recommended in the , “the exact performance and limitations of a particular fan should be obtained from the original equipment manufacturer.”

Considerations for selecting a fan

Selecting a fan for an industrial dust collection system requires more than selecting the fan type. Other characteristics such as the airstream, operating temperature, drive arrangements and mounting, as well as those listed below, should also be considered.

Capacity

• Flow rate: The flow rate is based on system requirements. The flow rate should be specified as ACFM or SCFM. The air temperature, fan elevation, moisture content and other air density factors need to be provided to the fan manufacturer.
• Pressure requirements: The Fan Static Pressure (SP) or Fan Total Pressure (TP) based on the system pressure requirements. A system pressure drop calculation should be completed to determine the SP and TP values.

Airstream

• Material handled: If there is particulate or moisture in the air stream, the right fan wheel or blade needs to be carefully selected and depends on what is being conveyed.  Build up or corrosion of fan wheels can lead to safety concerns, decreased performance and bearing failure due to imbalance.
• Explosive or flammable material: Always refer to the standards of the and other governmental regulations when dealing with explosive or flammable materials. If there is a risk of explosion or flammability, non-sparking wheel material and special bearings and controls should be considered.
• Corrosive applications: A protective coating or special material, such as stainless steel, fiberglass or plastic may be required if used for corrosive applications.
• Elevated airstream temperature: An awareness of the maximum airstream temperature is required because the temperature affects the strength of fan materials.

Physical limitations

• Inlet size and location
• Outlet size and location
• Fan arrangement/ orientation
• Weight of the fan
• Ease of maintaining the fan
• The physical space available

Drive arrangements

• Power source: All industrial fans require a power source. If electric motors are utilized, a variable frequency drive (VFD) can be used to control fan speed.
• Direct drive: Direct drive ensures a consistent fan speed while offering a more compact assembly.
• Belt drive: The drive ratio allows for adjusting the speed of the fan. The system capacity or pressure requirements may require changes if there are modifications to the process, the hood design, the location of equipment or the air cleaning equipment. With belt driven fans, the motor can be located in a variety of locations/arrangements.

Noise

• Noise: All fans produce a “noise.”
• Sound power & sound pressure: Noise level is measured in units called decibels (db). The noise level will vary depending on the speed, interconnected ductwork and point of operation. The sound pressure is a measurement affected by the fan’s location and other environmental factors.

Contributors to noise:

• The type of fan, flow rate, pressure and fan efficiency contribute to the noise generated by a fan.
• The quietest fans are usually those with a backward impeller design.
• The fans noise level can be increased on any type of fan if the airflow at the fan outlet or inlet is non-uniform.
• Silencers or noise enclosures can be added to fans to reduce noise.

For more information about noise, reference the “.”

Safety and accessories

• Guarding: In order to comply with governmental safety requirements, guarding must be included. Danger points to be considered include inlet, outlet, shaft, drive, belts and cleanout doors.
• Accessories: Accessories such as drains, cleanout doors, split housings, inlet boxes and shaft seals can provide assistance in the installation and maintenance of industrial dust collection systems.

Flow control

• Fan accessories: Dampers, variable pitch blades and speed control (VFDs) are three primary fan accessories and assist in managing an industrial dust collection systems flow rate.
• Flow rates: Properly controlled flow rates provide several benefits, including reduced energy demands.

These guidelines are defined in greater detail in the “Industrial Ventilation: A Manual of Recommended Practice for Design.” Additionally, extended information on flow rates and reducing energy demands will be detailed in the blog “Reduce Your Energy Demands with the Right Fan.”

Learn more about ���ձ�’s industry solutions. Contact us today for more information or to start planning your industrial dust collection system.

Resources:

“7.3.1.” Industrial Ventilation: A Manual of Recommended Practice for Design. 26th ed. Cincinnati, OH: ACGIH Signature Publications, 2007. 7-6 – 7-13. Print.

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The rate at which the dust is carried through the system is known as the conveying velocity. And the correct velocity helps with system safety and maintenance, as well as energy use. Too low a velocity and the danger is that dust will start to collect within the duct system; too high, and the threat is wasted energy and faster erosion of the ductwork. Sticky or moist dust could also smear the duct wall if the velocity is too high.

Dust Control Systems: Velocity Matters

So, it is important to maintain the conveying air velocity in every part of the duct within a reasonable range.  The determination of that range is dependent upon the kind of dust that is being transported. For example, an extremely fine, lightweight material that will not clump together, such as cotton dust, may need a velocity of 3,000 fpm. However, if you are handling something like lead dust, or other metalworking dust, you may need to accelerate the system to between 4,500 fpm and 5,000 fpm.

A good rule to follow: the heavier the dust, the higher the velocity. And the higher the velocity, the higher the potential operating costs. So, it really is good to understand the demands that will be placed on your system. For guidance on the appropriate velocity for your application, refer to the recognized industry resource: The Industrial Ventilation Manual from .

Too Slow: Dust Collection Can Be Dangerous

As mentioned, the collection of dust within the ductwork is really something that you want to avoid. This can happen when the dust is moving too slowly through the ductwork and starts to settle inside the pipes. As it collects, this dust can lead to a number of potential problems:

• It could fuel a combustible dust explosion
• Ductwork and hangars can fail due to the additional load or corrosion
• The system may not perform as well as expected as the ducts narrow due to the dust build-up

Too Fast: Abrasive Dust Wears on Ductwork

Dust moving too quickly through the system is also clearly a problem. Dust can be abrasive. This causes wear and tear on the ductwork, which will have to be replaced at some point at an additional cost. Transporting the dust faster may also require a bigger fan than you really need. These fans cost more and also have higher operating costs.

So, you don’t want that dust moving too fast or too slow. You are aiming for just right when you are designing your system.  The things you can do at the design stage to help control conveying velocities include:

• Sizing the ductwork to allow for adequate volume and velocity for the dust it will be carrying
• Calculating the static pressure level required to determine the size and power of your dust collection unit

Just the Right Speed Dust Collection Systems

So there you have it. Moving dust through your collection system too fast or too slow comes with undesirable costs and problems, from dust collecting within the ductwork to parts wearing out faster than necessary. When designing your system, make sure you have an accurate understanding of how fast you will need the dust to be transported through the system. And then design your system around that conveying velocity. It will save you money in the long run.

��һ��ݶ�has years of experience conveying all sorts of dusts. Whether you are designing a new system or troubleshooting an old one, ��һ��ݶ�has the solution for your dust conveyance needs.

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