Transcript

ÎĺŇ»˛čąÝ¶ů– 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

ÎĺŇ»˛čąÝ¶ů– Metal Fabrication • Industrial Ventilation

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Why Conduct an Industrial Ventilation Analysis

In an industrial ventilation analysis, we conduct an air quality survey by taking air readings of the ventilation system, as well as evaluate the dust collector, fans and all system components. From there, we develop a baseline rating of the entire system—a useful tool in determining what may need to be done, or not done, with your dust collection system. If you’re unsure whether an engineering study is right for you, here are the primary reasons to request an analysis.

Reason #1: Adding equipment

When adding equipment, you may need to expand the ventilation system. The best way forward is to start by evaluating the current system and its capacity. With that knowledge, you’ll then know whether your current system can handle more volume and how that may affect the collection volume from other equipment.

Also, adding equipment doesn’t automatically mean you need to add to your ventilation system. A ventilation analysis may show that you already have excess capacity. We may also be able to redesign the system to keep you from rerouting ductwork or buying a new dust collector.

Reason #2: Changing a manufacturing process

A manufacturing process change may mean greater particulate volume being directed to an area not equipped to handle the excess. If gone unchecked, particulate can build up in the ductwork, adding weight that can cause the duct to fail. And if the duct isn’t built to carry extra weight, facility damage and employee injuries may occur.

Reason #3: Becoming more energy efficient

Many companies are looking to be more environmentally conscious by using less energy. Even though an older dust collection system continues to do the job well, it may be costing more to run. Older fans, for example, can be a culprit. An engineering survey would show whether you could save energy and money with newer, more efficient equipment, depending upon your system design and layout.

Reason #4: Becoming silica standard-compliant

The silica standard is a high bar. If silica is part of your manufacturing process and you are having difficulty meeting the standard, there are a couple of things you should do. First, hire an industrial hygienist who will analyze your facility for silica risk. For example, the hygienist will take samples for every employee in every area of your plant for every shift. Once you have that information, we can then conduct an engineering study to review your entire system and determine how best to capture the silica.

What to Expect When Your Industrial Ventilation Analysis is Complete

Once we take the air quality survey readings and inspect your system, we develop a comprehensive written report of our findings. You’ll receive data on your equipment and ventilation system with indication of whether it’s collecting particulate effectively and where improvements, if any, are needed. We then:

• Request a follow-up meeting to discuss areas that need improvement
• Develop a conceptual design
• Develop a proposal that includes our costs based on our design
• Once agreed upon, implement the solutions

Getting an engineering study done is much like going to the doctor—it helps ensure everything is operating the way it should. If you believe an industrial ventilation analysis would benefit your company, contact us to schedule a survey.

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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 ÎĺŇ»˛čąÝ¶ůteam 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, ÎĺŇ»˛čąÝ¶ůhas 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 ÎĺŇ»˛čąÝ¶ůapart 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 ÎĺŇ»˛čąÝ¶ůhave 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. ÎĺŇ»˛čąÝ¶ůcan react quickly and come back with a engineered solution to correct the problem to keep the project on track.

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In this video, ÎĺŇ»˛čąÝ¶ůProject Engineer Doug Schauer discusses the ingredients that lead to a combustible dust explosion, industries most at risk for dust explosions and how to protect your facility. See how ÎĺŇ»˛čąÝ¶ůcan help through its design, build and install industrial ventilation services.

Transcript

What Causes Combustible Dust Explosions?

Combustible dust are fine particulates usually created in the manufacturing environment that present an explosion hazard under certain conditions when this dust is suspended in the air. Dust explosions can be fatal they can cause equipment damage they can even destroy your facility.

There’s five ingredients for a dust explosion.

• The dust itself which has to be combustible.
• The dust needs to be suspended in the air or it needs to be like a cloud of dust.
• The dust needs to be contained, and
• There also needs to be oxygen.
• Then of course the ignition source.

It’s called the dust explosion pentagon.

There’s a lot of dust out there and people don’t realize how many dust are actually combustible or explosive. It could be agricultural it could be carbon based, metallic dusts, chemical dust and even plastic dust.

Combustible Dust Explosion Protection

The best way to protect your facility from a dust explosion is if you do have a dust collector and if you’re installing it install your dust collector outside that way if there is an explosion it will be away from employees and your facility. One thing you can do immediately is just get to get it on your PM program. A lot of the facilities have a preventative maintenance program so you can as you’re looking at this equipment checking out the equipment you can check for dust that’s maybe accumulating, you can check for dust that’s puffing out of the equipment.

How ÎĺŇ»˛čąÝ¶ůCan Help Prevent Combustible Dust Explosions

We can help you. We can we can do some tests on your dust collection system. We can take air flow readings, we can balance your system so you get the proper collection. ÎĺŇ»˛čąÝ¶ůcan also help you out with a hazard assessment of your of your facility just to see what to see if you do have dust that are combustible. We can look at your equipment to make sure it’s operating properly, things like that. We can also take a sample of your dust and test it to see how explosive it is.

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Hood Types

Enclosing hoods:

An enclosing hood will completely or partially surround the point where contaminants are generated. An enclosing hood is typically preferred but may not be practical due to potential interference with employee workstations.

• A partial enclosing hood has two to three sides where an inward flow of air through the opening will contain the contaminant within the enclosure and prevent its escape. Examples include paint spray booths or grinder station.
• A completely enclosing hood has all sides and is preferred whenever possible. A laboratory hood is an example of this use.

Exterior hood:

Exterior hoods are placed next to the point where contaminants are generated without creating an enclosure. An exterior hood may be an opening on a welding table or slots on the side of a tank. The exterior hood should be located in the path of the emission if transferring larger particulates such as sand.

There are four main types of exterior hoods:

• Canopy: A one- or two-sided overhead hood that receives upward airflow from hot air or gas.
• Close-capture: Mounted directly over the source of a contaminant.
• Push-pull: A hood placed on the side of a push-pull ventilation system.
• Side-draft (also called lateral exhaust hood): This is not as efficient as other containment or down-draft hoods.

Hood Velocity Considerations

A specific velocity is required, depending on the type of contaminant being captured. To achieve the required velocity, carefully consider the hood’s shape, size and location.

• Face velocity: Velocity right at the hood opening.
• Capture velocity: Velocity at the dust generation source to capture the contaminant and transfer it into the hood.

Ergonomic Considerations:

An industrial ventilation system hood is one of the most important components of an individual’s workstation. A worker will be more likely to use the hood and the ventilation system properly if ergonomic elements are considered. Among these considerations are:

• Accessibility to parts within the hood
• Size, design and weight of objects handled
• Safety cables
• Overhead clearance
• Sharp edges
• Lighting
• Ease of cleaning

±őłŐ±ő’s engineering and design team has years of experience designing and sizing industrial ventilation systems.  ÎĺŇ»˛čąÝ¶ůcan assist in the design of a new system or the redesign of an existing system.

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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.

ÎĺŇ»˛čąÝ¶ůhas years of experience conveying all sorts of dusts. Whether you are designing a new system or troubleshooting an old one, ÎĺŇ»˛čąÝ¶ůhas the solution for your dust conveyance needs.

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Building and Managing a Dust Collection System

Many factors affect the performance of Dust Collection Systems. In a previous blog post, Dust Collection System Design Considerations – Part 1, we summarized five key considerations for the engineering and design phase of a dust collection system. The post was based on an Engineers Collaborative article, (Unfortunately, this is now only available via the Internet Archive.)

For this post, we return to that article to summarize its advice for managing the following phases of a dust collection project:

• Construction
• Startup
• Training
• Maintenance

The Construction Phase

Appropriately detailed engineering and design documents produced in the design phase help ensure the construction phase meets design intent, reducing future operating and maintenance problems.

During the construction phase, you should:

• Conduct fabrication checks: Inspect components for proper construction and gauge as they are being made, not just before they are shipped.
• Inspect the ventilation and exhaust system:
  • Make sure components do not block access to each other or to other plant services and equipment.
  • Repair or replace components damaged during shipping or installation.
  • Protect dust collector filters from weather and construction activities.
  • Before startup, ensure your ventilation or exhaust system satisfies engineering and design documents.

The Start-Up Phase

These elements need to be validated at startup:

• Airflow in the duct system: The dust capture hoods should exhaust the designed air quantities, according to standards in the Industrial Ventilation Manual published by the . The data collected during this air system balancing becomes the project’s baseline information.
• Industrial ventilation system safety components: Check that fire and explosion protection components, pressure gauges, and low-flow and over-pressure alarm systems are set up as intended in the engineering and design documents.
• Component baseline documentation: Record baseline information for all other system components, including dust capture hood static, dust collector and safety monitoring filter system (HEPA) static pressures, and main duct velocity pressure to ensure it complies with the level recorded in your state permit application.
• Industrial hygiene particulate air sampling: Monitor air for particulates to ensure that dust sources are controlled to the desired level. Make modifications to the dust control system components as needed and then update component baseline documentation.

Staff Training

Plant supervisory, production and maintenance personnel should be trained in the following areas:

• Safety features and components
• Air meter read-outs and alarms
• Baseline documentation for components
• Operating and maintenance instructions and recommendations
• Operation and use of dust capture hoods and dampers
• Preventive maintenance

Preventative Maintenance Activities

Component repair activities include greasing fan bearings and emptying dust collector hoppers on schedule, replacing obsolete dust capture hoods and ductwork, and repairing damaged dust control system components. However, these and other component repair activities should be supported by four critical activities:

1. Check system operating characteristics: Periodically inspect the system visually and ensure components’ operating characteristics, such as static and velocity pressures, meet standards set during the start-up phase. Analyze and correct any deviations.

2. Inspect explosion protection components: Inspect explosion relief or suppression systems to ensure they comply with manufacturers’ recommendations and applicable safety guidelines.

3. Consider the effect of product changes: Include maintenance personnel in new product discussions as changes to the processed dust can affect the dust control exhaust system’s performance.

4. Sample air for particulates: Periodic air sampling should be performed to ensure the dust control system is meeting standards set during the start-up phase. Investigate any deviations you find.

ÎĺŇ»˛čąÝ¶ůperforms all aspects related to the construction, start-up, training and maintenance of industrial ventilation systems to ensure customized dust collection systems operate at optimal performance.

Contact us for more information.

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Calls for Combustable Dust Standards

OSHA had been expected to issue a standard in the first half of 2014, but it missed that deadline. But according to its schedule for the remainder of the year, OSHA now expects to deliver a standard under the Small Business Regulatory Enforcement Fairness Act in December.

The CSB has been calling for this standard since 2006. More recently, CSB chairman Rafael Moure-Eraso called for the standard in July after the publication of a final report into the .

The ALS facility milled and processed scrap titanium and zirconium into dense disks called “compacts.” A fatal explosion at the plant seems to have started after sparks from metal-to-metal contact ignited metal powder in a faulty metal blender used to process zirconium. The CSB has created a to show how the accident may have unfolded.

After the release of that case study, Mr Moure-Eraso said the CSB “believes it is imperative for OSHA to issue a comprehensive combustible dust standard for general industry with clear control requirements to prevent dust fires and explosions.”

, “Most solid organic materials, as well as many metals, will explode if the particles are small enough, and they are dispersed in a sufficient concentration within a confined area, near an ignition source.”

And he cautioned that even “seemingly small amounts of accumulated combustible dust can cause catastrophic damage.”

In , the CSB notes that accumulated dust of about 1/32^nd of an inch, or the thickness of a dime, covering 5% of a room area is enough to fuel a “catastrophic explosion.”

Materials that can Make Combustable Dust

A wide variety of materials that can be :

• Food (e.g., candy, sugar, spice, starch, flour, feed)
• Grain
• Tobacco
• Plastics
• Wood
• Paper
• Pulp
• Rubber
• Furniture
• Textiles
• Pesticides
• Pharmaceuticals
• Dyes
• Coal
• Metals (eg, aluminum, chromium, iron, magnesium, and zinc)
• Fossil fuel power generation, such as coal-fired power plant

Components of a Combustable Dust Explosion

And five things need to come together for there to be a dust explosion:

• Combustible Dust (Fuel)
• Oxygen (Air)
• Ignition Source (eg, electrostatic discharge, electric current arc, glowing ember, hot surface, welding slag, frictional heat or flame)
• Dust Suspension in air exceeding the minimum explosive concentration (MEC)
• Confinement (eg, vessel, room, building, ductwork)

Mr Moure-Eraso’s called again for the combustible dust standard in an August in the New York Times, in which he described dust explosions as “readily preventable with engineering controls, ventilation, training and other measures.”

He recommended that voluntary, industry-supported national fire codes be codified and enforced through federal regulations.

Those codes include the ’s recommendations that companies:

• Control fugitive dust emissions;
• Design Facilities to prevent dust from migrating and accumulating; and
• Perform rigorous housekeeping to remove any dust that does build up.

Combustable Dust Regulations: What’s Next?

Responding to the CSB’s calls for action in this area, an OSHA spokesman told in early September, “We are continuing our efforts to move forward on combustible dust rulemaking, and OSHA has also put special emphasis on controlling combustible dust hazards through a national emphasis program, education and outreach.”

OSHA says it will use the information gathered from (NEP) in 2008 to produce the standard now expected in December.

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Many factors impact the overall effectiveness of the system. In order to ensure your dust collection system reaches peak performance, it’s critical to have the proper groundwork in the engineering and design phase.

In the article, the Engineers Collaborative identifies and summarizes five key considerations for the engineering and design phase. ÎĺŇ»˛čąÝ¶ůtakes each of these into account when we are developing custom solutions for our clients and is capable of performing all aspects related to industrial ventilation system design and engineering.

Key Considerations for Industrial Ventilation

• Provide detailed dust collection system engineering and design documents.
  Outline detailed engineering specifications and design documents, including design drawings. Inadequate engineering and design documents may add construction costs and lead to a poorly installed system.
• Specify the right construction materials.
  Identify the right materials for construction—for example, if you are removing corrosive dusts, you’ll want to use stainless steel rather than mild steel.
• Think about component location.
  Component location is often overlooked, but the system needs to be strategically placed to accommodate inspection and repair.
• Outline dust collection system component specifications.
  Be comprehensive in the systems approach and specify all components, including dust collectors, exhaust fans and other OEM components that are needed.
• Identify services and support for ventilation equipment.
  Engineering, design, fabrication and installation representatives should be available to address immediate issues in future operations and maintenance emergencies. Seek to hire firms that provide the dedicated personnel and teams in every phase of the system’s development.

Dust Collection System Considerations: Next Steps

These are only the guidelines for the engineering and design phase. A future blog post will review considerations for construction, start-up, training and maintenance. But with proper preparation to engineering and design, you’ll have a head start in making sure your dust collection system reaches optimal performance.

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