淫乱社区 Engineers Explain the Importance of Baghouse Leak Detection Testing

Transcript

Who needs to do a baghouse leak detection test?

Anyone who owns or operates a dry-type dust collector, such as a baghouse or cartridge collector, needs to do a baghouse leak detection test.

How often do you need to do a leak detection test?

Leak detection tests should be done every time you do a filter change. Some regulatory requirements dictate that leak detections need to be done on an annual basis, or a six-month basis, and then also any time you suspect a leak in your system, a leak test is good to help diagnose where that leak is coming from.

What are the risks of not doing a leak detection test?

Filter changes are a fairly expensive operation, so not doing a leak detection test could mean all the money you spent on that filter change is thrown out because of an improper installation.

Additional reasons to conduct these tests, and reasons to mitigate the risk by doing them, is because a hole in your filter could mean a failure to comply with regulatory requirements.

Step by step: The baghouse leak detection system

Before conducting the test, you鈥檙e going to want to consult your safety department to ensure that all lockout, tagout and confined space procedures are followed for this procedure.

Step one is we are going to be inserting the dye into the system. In this case, we鈥檙e going to insert the dye (or baghouse leak detection powder) into the hopper here. [In your system, dye may need to be inserted into the collection ductwork.]

Now that our dyes have been added, we鈥檝e ensured that our filters are evenly coated, we are going to do an inspection of the clean-air side of our bags to ensure that none of the dye made it through or around the filters and ensure we have a nice, good installation.

Now we鈥檙e up on the clean-air section of the baghouse. Because this thing is so small, we can actually lift off the entire roof of it. So first I鈥檓 going to do a quick initial inspection to see if I see any dye. Usually, if there鈥檚 a major leak, you鈥檒l see it instantaneously. But now that we don鈥檛 see any, we鈥檙e going to actually do the blacklight portion and turn off the lights and see what we can see.

All right. Since in our test we didn鈥檛 see any leaks, we wanted to show you we scattered some dye around here and wanted to show you what it would look like if there was a leak and how vividly that shows up.

Whether you purchased your baghouse from 淫乱社区 or not, 淫乱社区 can assist in these leak detection tests and help diagnose problems and come up with long-term solutions.

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published regulatory change for mining facilities鈥� air quality related to respirable crystalline silica in April 2024, with changes taking effect June 17, 2024. Here, we鈥檒l answer your most pressing questions to help you meet the MSHA respirable crystalline silica standard in your facility.

Navigate the proposed respirable crystalline silica standard with a proven partner. Talk with an 淫乱社区 project engineer today. It鈥檚 the first step you can take toward meeting the proposed MSHA Respirable Crystalline Silica Standard.

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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.

淫乱社区, on the other hand, is a full-service industrial ventilation design, engineering, manufacturing and installation company. That means the 淫乱社区 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, 鈥淚s 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?鈥�

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鈥檚 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.

淫乱社区 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 淫乱社区. 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

淫乱社区鈥檚 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鈥檒l 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鈥檛 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 鈥渙ne-size-fits-all鈥� system doesn鈥檛 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鈥檛 clearly stated when they initiate the project. Trouble soon arises when the customer realizes their moist contaminant with heavy loading, which they didn鈥檛 mention in the scope, plugs the undersized cartridge collector they received. Due to the reduced system performance, targets aren鈥檛 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鈥檚 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鈥檚 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鈥檚 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鈥檚 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 淫乱社区鈥檚 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鈥檒l receive recommendations and a competitive quote to meet our ventilation needs.

Thank you for the opportunity to earn your business.

What Sets 淫乱社区 Apart

Dedicated from Start to Finish

淫乱社区 designs, builds and installs custom dust collection systems and maintains other dust collection systems, ductwork and industrial HVAC systems around the country. 淫乱社区 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.

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

淫乱社区鈥檚 mission is to get the job done safely and efficiently鈥攗ltimately resulting in a successful and more cost-effective project for you.

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What to Expect from an Industrial Indoor Air Quality Survey [VIDEO]

Transcript

After 淫乱社区 gets on site, we take a lot of different聽air readings and evaluate the the dust collection unit itself for wear and tear, the fan. So when we get聽back to the office we put together a pretty nice report basically laying out everything that we’ve聽seen on site. You know, giving you back all the data on your equipment so if your dust collection聽system has 20 points we basically give you a nice chart back that shows each point, what it goes to,聽the volume that it has, the static pressure at each point. Some indication on whether or not it’s doing聽its job and picking up the the particulate. So we give you all the basic information of what you聽have.

And then once we get through that we give you a section of recommendations pointing out all the improvements that could be made or we’re just generally stating that what you have is good, the design is acceptable and the volume is adequate what those are, we’ll actually go back through and say okay, these were the recommendations for this dust collector. We’ll put together an actual proposal on the cost to do that.

Being that we are a turnkey company we’ll put together a conceptual design, a price for it and then upon acceptance we would give you a final design deliverable along with an implemented solution.

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Transcript

Common Dust Collector Maintenance Issues

When we approach a plant, a lot of the most common maintenance issues we see, and the easiest to find, are going to be the worn out duct work or low velocities, low volumes in the system. Holes in the ductwork can compromise the performance of the dust collection system.

What you’re going to look for is where those holes are, what the sources are, what the total volume on the system is, see if there’s blanking in any of the filters. Then, take it back to the collector and check to make sure that all the filters are working, not leaking through the tube sheet, and then take it back even as far as the fan or the exhaust. We want to keep everything running as designed and that the volumes are where they need to, otherwise it can just further compromise the ductwork.

Routine Maintenance Matters

The dust collection systems, a lot of times, are a project that’s put in, they get a lot of attention when they get put in, and then there may be turnover of staff, there may be a long period with no maintenance, so it’s not high on the radar. It’s just something that sometimes just goes by the wayside.

A Team With Vast Dust Collector Maintenance Knowledge

What sets 淫乱社区 apart in our maintenance services is basically our knowledge of the systems. We do build our own dust collectors, we build a lot of our ductwork, we handle everything from the design, through the fabrication, through the installation, and then as well the maintenance.

Having a diverse staff, we have the ability to react quickly. Having our own fabrication shops in three different states also allows us to get anywhere in the U.S. within a fairly short turnaround.

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If you are interested in how 淫乱社区 can help your business, contact us.

Transcript

Mining Ventilation Systems and Material Handling Equipment

In the mining industry, 淫乱社区 provides industrial ventilation systems which include exhaust systems as well as make up air systems. In addition to ventilation systems 淫乱社区 provides material handling equipment which include belt conveyors, bucket elevators as well as all the transfer chutes between all of the pieces of equipment. It is an advantage for 淫乱社区’s customers to use us to do both the industrial ventilation systems as well as the material handling equipment.

It is critical how both of those areas react with each other and interact. Silica exposure is a great concern in the mining industry. Proper industrial ventilation systems as well as material handling systems can greatly reduce the exposure level. With the combination of dust collection systems as well as make up air systems, silica levels can be reduced to a point where personnel can operate within facilities.

Knowledge and Experience with Mining Ventilation Systems

What sets 淫乱社区 apart with industrial ventilation in the mining industry is we have knowledge and exposure to material handling equipment design, chute design, as well as the ventilation package. So even if you have an existing system, we can come in and make improvements to improve the dust collection as well as reduce silica exposure.

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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鈥攁 useful tool in determining what may need to be done, or not done, with your dust collection system. If you鈥檙e 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鈥檒l 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鈥檛 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鈥檛 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鈥檒l receive data on your equipment and ventilation system with indication of whether it鈥檚 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鈥攊t 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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Dust Collector Hood Types

Along with size and airflow rate, good hood design relies on the type of hood and where it鈥檚 located in relation to the manufacturing process. There are two primary types of dust collection hoods: enclosing hoods and capturing hoods.

Enclosing hood

An enclosing hood keeps the contaminant within the hood. These hoods completely or partially enclose a process so particulates cannot escape.

Capturing hood

A capturing hood is located next to the contaminant source. These hoods must be designed to draw and capture contaminant from outside the hood.

At 淫乱社区, we begin each design with the intent to use enclosing hoods, if possible, as they are better at helping to eliminate fine particulates, toxic contaminants and more. They also take less energy to do the job effectively.

淫乱社区鈥檚 Approach to Industrial Dust Collector Hood Design

Because hoods are so crucial to a dust collection system鈥檚 functionality, we treat each of our dust collection hood design projects as unique. In other words, we never copy hoods from project to project. Instead, we consider the combination of the contaminant鈥攊ts density, size and toxicity鈥攁long with the manufacturing process. That鈥檚 where ingenuity and engineering come into play. The ingenuity is making sure the dust collection hoods fit within customers鈥� applications and needs. The engineering is using proven industry equations to determine volumetric flow rate.

We start many projects with computational fluid dynamics (CFD) modeling to visualize air flow patterns and determine capture velocities within the hoods and to measure pressure drops.

In addition to CFD modeling, we also use our R&D test lab to simulate real-world applications. In the lab, we test either full-size or small-scale models to ensure they capture contaminants effectively before we fabricate and install full-size hoods.

Issues with Improper Dust Collector Hood Design

We鈥檝e seen first-hand the effects of improper hood design. The most common hood design error we see in the industry is placing the hood too far away from the where the contaminant is generated. A hood鈥檚 primary purpose is removal of dust and other particulates from the process. When a hood doesn鈥檛 do that properly, issues multiply.

We鈥檝e seen a specific instance of this in a tissue converting application where dust was settling on top of the hood rather than being pushed into the hood. This accumulating dust is hazardous for two reasons: It is a risk for fire and employees鈥� health and safety. In an industry where stringent production schedules rely on little downtime, maintenance crews had to stop production to clean the accumulated dust. It was a clear case of a dust collection hood not meeting design goals.

One Source for Dust Collector Hood Fabrication, Design

At 淫乱社区, we believe metal fabrication is as important as hood design. When building our hoods, we use abrasion-resistant or heavy-gauge materials to ensure they stand up to applications where particulates may cause wear and tear. In addition to ensuring we have smooth welds that won鈥檛 trap dust, we also use our fiber optic laser to accurately and precisely cut slots out of our hoods. Our laser cutter not only leaves the finished product looking aesthetically better, it also ensures a more accurate slot for better performance.

If you have noticed dust buildup in your facility, an improperly designed hood may be the cause. Contact us to see how our dust collection hood design experts can help make your facility and manufacturing process cleaner and safer.

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When to replace baghouse filters

For the most part, there are only three reasons to change baghouse filters:

• When they can no longer be cleaned because dust has accumulated to the point of plugging the fabric鈥檚 air passages, keeping the vacuum from pulling in unwanted dust.
• When the bags have developed holes.
• When the regulates your company or industry to change bags.

While some facilities change bags once per year because their dust collectors capture large quantities of especially fine, hazardous dust, most of 淫乱社区鈥檚 customers can go two to 10 years before having to schedule dust collector bag replacement.

Facilities that change bags more than once a year may be doing so because of a unique situation鈥攖he collector is capturing an especially tough material, like a wet, corrosive or abrasive dust. Facilities that change bags often but are not in this situation likely have a dust collector that doesn鈥檛 correctly match their manufacturing process.

Checking your industrial dust collection system

If you鈥檝e just installed a new industrial dust collection system, it鈥檚 best practice to check the system regularly to ensure it鈥檚 running efficiently and the bags have been installed correctly.

Here鈥檚 how to tell whether dust collector issues may be related to the bags:

• High differential pressure: Bags that haven鈥檛 been installed correctly, or are retaining excess amounts of dust, will lead to high differential pressure within the baghouse. As it becomes more difficult to pull air through the bags, the difference in the pressure before air enters the bags and after exiting the bags increases.
• Baghouse dusting: Dusting is noted by a visible emissions plume coming out of the stack or by dust in the clean air section of the collector. Bags that are the wrong size or fabric for the particulate may not be installed correctly, may not be sealed or have holes that are contributing to the dusting.

Replacing baghouse filters

Dust collector bag replacement: A quick tutorial

Before removing filters:

• Obtain and follow a Confined Space permit, if required.
• Manually pulse down existing filters.
• Allow the screw auger and rotary air lock to remove waste.
• Conduct proper lockout-tagout per or requirements.
• Ensure employees are trained on hazards associated with the task and are wearing the proper personal protective equipment.

Removing old filters (pertains to top-load bags only):

• Open clean air section doors and remove pulse tubes and cages. (Note: 淫乱社区鈥檚 baghouses do not use hold-down hardware, but if your baghouse does, remove this hardware before proceeding.)
• Flex the bag鈥檚 seal toward the center of the tube sheet hole and drop the bags into the dirty air section.
• Remove all the old bags that were dropped by accessing the hopper. Count the bags to verify you have removed them all to avoid damage to your dust collector.
• Dispose of dirty bags in a dust-tight bag or sealable waste container.
• Close and bolt or screw shut access doors.

Installing new filters:

• Vacuum the clean air section to remove accumulated dust and debris.
• Drop new filters鈥攐ne at a time鈥攖hrough the tube sheet.
• When the filter is unfolded into the dirty air section, flex the snap band toward the center of the tube sheet hole. Do not bend the snap band at the seam.
• Place the filter snap bands on either side of the tube sheet, and push the band toward the perimeter of the tube sheet hole. You鈥檒l hear the snap when it鈥檚 properly sealed.
• Slowly drop the cage down the center of the filter until the venture sits snug on the filter. Gently step down on the venture to seat the cage. If you have hold-down hardware, reinstall it.
• When all bags have been replaced, reinstall all pulse tubes.
• Inspect all the bags for uniformity.

We also recommend testing your system using a fluorescent powder. Starting your industrial ventilation system using this powder will allow you to see whether it is making its way through to the clean side of the bag. If it is, the bag has not been installed properly.

When, and if, you need to replace bags, we also recommend taking the following steps to prevent maintenance and reduce production downtime:

• Keep a bag location replacement chart.
• If you have consistent bag failures, retain a typical bag for inspection.
• Retain bags with unusual or non-characteristic failures.
• Maintain an adequate supply of replacement bags.

By maintaining and changing your baghouse filters when needed, your dust collector will run more efficiently at a lower cost.

Contact 淫乱社区 for assistance

Unfortunately, many things can go wrong during a dust collector bag replacement procedure. Improperly seated bags can lead to poor dust collection, which can lead to failing government regulation tests and to excessive dust in your facility, which can adversely affect product quality.

If you are unsure about changing your own baghouse filters, contact us. We will not only change dust collector filters, we also can help analyze your system to help extend bag life, thereby reducing how often you鈥檒l need to do one of the dirtiest maintenance jobs in industrial ventilation.

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