Case Study: Dust Collector Fire Damage Assessment and Replacement
Situation: A customer experienced a fire in their dust collector resulting in the system being destroyed. Gulftech was brought in to assess the damage and provide options for replacing the system.
Assessment: Working with the customer and their insurance company, Gulftech determined that due to space constraints, replacing the system with an exact duplicate was the simplest option. The manufacturer was able to find the original drawings of the unit and provided a “plug-and-play” system that fit precisely into the limited space available for the unit.
Result: Gulftech provided expertise and labor to remove the fire damaged dust collector and install the new system. The customer was extremely happy with the result of the project, as it allowed them to get back up and running quickly.
Repair or Replacement? Making the right Choice?
In the event of a fire resulting from material collected in the dust collector hopper, the damage may be contained if the fire does not spread through the duct or surrounding materials. An initial inspection may indicate that the damage was contained quickly enough that your equipment can be returned to operation with only minor repairs. We recommend having a trained technician with experience in dust collector damage assessments take a closer look.
Equipment Repair vs. Replacement Options
When considering repair/replacement options, be sure to inspect the fan blower or impeller and all electrical components for damage. While some components may appear to have escaped damage, electrical wiring and other sensitive components may sustain damage that must be addressed. Pulse cleaning valves, gauges and other sensors may be damaged, be sure to inspect them carefully. Inspect connecting duct for heat warping or damage that might prevent a good seal. Inspect silencers or other after-filter components to sure they are still functional.
Safety Components: Many dust collectors installed prior to recent changes in fire code may no longer be compliant with current safety regulations. Gulftech will assist in identifying what areas of the National Fire Protection Association (NFPA) code apply to your dust collector, and recommend the safety equipment to make your system safe and compliant. Fire and explosion safety components include Explosion Vent Panels, Fire Suppression Systems, Explosion Isolation Valves and other features that Suppress, Isolate and minimize the risk and spread of fires and explosions that occur in facilities producing combustible dust.
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Ducted Air Cleaner for Wet & Dry Grinding in Metal Fab Shop
A metal fabrication shop was in need of a dust collection
system for a number of grinders.
The Requirement: Design a system that could capture
dust from a number of small grinders, as well as dust and mist from a large
Blanchard Grinder. Due to a lot of machines in a small space, the customer
asked that we come up with a solution that had a small footprint.
The Solution: Gulftech designed a ducted ceiling
mounted dust collection system with a separate module for the wet process and
one for the dry process. The ceiling mounted solution ensured a small footprint
and the least amount of ductwork to reach each workstation. The Blanchard
grinder required a custom, hanging hood with a swing-arm so that large parts
could be set onto the grinder and then the mist capture hood would swing back
in place to capture the mist. The hood was equipped with vinyl strip curtains
to control and contain the mist thrown up by the large grinding wheel.
The Result: The customer had an effective dust collection system with a small footprint that reduced the nuisance dust in the plant, creating a cleaner workspace!
Ducted Air Cleaner for High Speed CNC Smoke in Precision Metal Fabrication
The Requirement: A precision metal parts manufacturer
with several CNC machines was facing an issue with smoke produced from the high
speed CNC machining process. They needed a solution with a minimal footprint
capable of handling large amounts of smoke.
The Solution: Gulftech designed a ducted air cleaner
mounted from the ceiling for capturing the heavy smoke from the high speed CNC
process. Due to the volume of smoke produced and the high speed coolant spray,
Gulftech installed mist recyclers on each machine to reduce the amount of
coolant pulled in the air cleaner from the machine. The mist recycler had the
added benefit of increasing filter life of the air cleaners as well. The ducted
air cleaner offered a 3-stage filtration system with HEPA final filter to
capture the super fine smoke particles.
The Result: The new air cleaners captured 99.95% of
the smoke produced by the high speed CNC machines, resulting in a much
cleaner facility for the employees.
Click here for information on how Gulftech can help you with your filtration needs.
3D Duct Design and layout, design packages for turnkey systems
System Installations, upgrades, expansions of dust collection systems
Site Inspection, Troubleshooting and OSHA Compliance Assistance
Upgrading Systems for compliance with NFPA and OSHA
Service contracts to reduce costs for maintaining systems
OSHA Silica dust compliance
Example: Designing a fume extraction System for Injection Molding Operation
A medical device manufacturer with a large injection molding department needed a customized fume extraction system. The three most important needs were: a system that would effectively draw fumes away from the operators, keep the facility free of fumes, and not get in the way. Gulftech worked with the client to develop a design that met these requirements. Starting with a 3D design concept drawing offered an excellent way to communicate and determine the best options.
We will build a 3D design of your system and work with you on the best solution that fits your building, your budget and your timeline! Ask about our design packages, partially refundable with purchase of a system.
Consulting for Dust Collection Systems
Many of our clients are either upgrading their facility with new equipment, or looking at ways to optimize the equipment they have. Who doesn’t like to do more with less? A majority of dust collection and air filtration systems in operation are no longer compliant with current fire and safety codes for combustible dust. Still more systems suffer from worn out components and parts that keep them from operating at the level necessary for a clean facility. We will design the dust collection system that is right for you.
Existing Equipment: A consulting visit or discussion with Gulftech assesses your existing system and reviews troubleshooting, performance analysis, and safety compliance. Based on the reason for the assessment, we will offer a report with findings and recommendations. Based on the need and complexity of repair or retrofit, Gulftech can provide the necessary parts, repairs, or upgrades. https://www.gulftech.us/dust-collection-assessment/
New Equipment: If you are upgrading a new or existing facility and need new or more capable equipment, Gulftech works with you to design a system that fits in to an existing design. We also work with architect and engineering firms to design-build new systems for a complete design package. https://www.gulftech.us/stainless-steel-dust-collection/
Click here to request information about how Gulftech can help you with your dust collection needs.