When Camfil Air Pollution Control teamed up with a major auto parts manufacturer relying on dust collectors to keep the air clean in robotic weld cells, they discovered a way to dramatically reduce the time spent on dust collector maintenance. At first, the facility operators believed they had the perfect system since the vendor supplied them with complex computational fluid dynamics data proving the airflow performance. The vendor's intention was to assure the facility that their design would effectively prevent fires. But the truth turned out quite differently. The dust collection systems they installed resulted in frequent downtime, expensive maintenance, and even internal fires within the collectors. This was a major issue, as fires meant halting production lines for days at a time, which was both costly and disruptive. The company was constantly battling problems with its dust collectors, leading to significant downtime. Whenever the collectors caught fire—multiple times—the production lines had to be shut down for several days. When the differential pressure in the collectors increased, the fans would engage, preventing the filters from being pulse-cleaned. This forced staff to manually clean the filters during breaks, resulting in at least two hours of downtime daily. Furthermore, the filters needed replacing every six months, adding to the operational expenses and labor requirements. Adding to the troubles, the noise from the collectors' fans was a constant issue, drawing complaints from nearby residents. The fans inside the collector housings were also susceptible to overheating, which led to the expensive replacement of numerous 50-horsepower motors annually. Accessing the fans for maintenance was particularly challenging during winter when the collectors were placed outdoors. Realizing the urgency of finding a dependable dust collector partner to ensure smooth manufacturing operations around the clock, the facility managers reached out to Camfil APC. Wayne Zimmer from Camfil APC responded by bringing a Gold Series dust collector demo trailer to the site. He showcased the user-friendly maintenance and filter removal features, providing a hands-on demonstration. In the end, Camfil APC delivered a new Gold Series dust collector system with an entirely redesigned ductwork layout for the weld cells. This innovative system allows facility operators to safely reintroduce filtered air back into the plant through integrated safety monitoring filters. Thanks to the efficiency of the new system, the manufacturer hasn't had to purchase new filters in over three years. There have been no fires in the collectors, nor has there been any additional maintenance required for the fans or electrical systems. Impressed with these results, the company decided to install two more dust collection systems from Camfil APC. To hear the full story, check out Zimmer in this Preventing Downtime for Filter Cleaning video. Welding and cutting activities, whether manual or robotic, release harmful fumes (tiny airborne dust particles) that contaminate workshop air and pose health and safety risks to workers. Processes such as arc gouging, plasma cutting, and laser cutting generate these fumes, and the amount of fumes increases with higher production levels. The most effective method to reduce workers' exposure to dangerous metalworking fumes is by installing well-designed dust collection systems equipped with high-efficiency primary cartridge-style filters. In some cases, secondary safety filters might be necessary to capture specific particulates. Like this auto parts manufacturing facility after installing customized Camfil APC systems, many welding operations can often recirculate cleaned air back into the workspace. However, the reintroduced air must remain below OSHA permissible exposure limit (PEL) thresholds for metal contaminants generated from welding processes. Facilities that exhaust air outdoors must also comply with EPA emission standards. OSHA PELs are based on an eight-hour time-weighted average (TWA) for metals found in welding fumes. These regulations dictate the minimum filtration efficiency required for dust collectors. Even if the air meets PELs in a facility, some workers may still experience health issues from fumes. In such cases, exposure limits might need to be further reduced to ensure safe indoor air quality. The EPA’s National Emission Standards for Hazardous Air Pollutants (NESHAP) Rule 6X governs facilities that vent contaminated air directly outdoors. This rule covers hazardous air pollutants from metal finishing, including cadmium, chromium, lead, nickel, and manganese. Cartridge filtration is recognized in Rule 6X as an acceptable control device to eliminate visible emissions. Installing dust and fume collectors with high-efficiency cartridge filtration systems like Camfil APC Gold Series industrial dust collectors helps welding facilities stay compliant with EPA standards. For more insights on mitigating airborne particles in welding operations, click here. Paper Card,Cardstock Paper,White Cardstock,Coloured Card Jiangmen Yingzhihui Electronic Commerce Co., LTD , https://www.yzhprint.comFires, Filters, and Fans: A Troubled Combination
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