Transcript

淫乱社区 鈥� 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

淫乱社区 鈥� Metal Fabrication 鈥� 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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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鈥檚 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鈥檚 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

滨痴滨鈥檚 engineering and design team has years of experience designing and sizing industrial ventilation systems.  淫乱社区 can assist in the design of a new system or the redesign of an existing system.

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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 鈥渃ompacts.鈥� 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 鈥渂elieves 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.鈥�

, 鈥淢ost 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.鈥�

And he cautioned that even 鈥渟eemingly small amounts of accumulated combustible dust can cause catastrophic damage.鈥�

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 鈥渃atastrophic explosion.鈥�

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鈥檚 called again for the combustible dust standard in an August in the New York Times, in which he described dust explosions as 鈥渞eadily preventable with engineering controls, ventilation, training and other measures.鈥�

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

Those codes include the 鈥檚 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鈥檚 Next?

Responding to the CSB鈥檚 calls for action in this area, an OSHA spokesman told in early September, 鈥淲e 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.鈥�

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

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