Remedy The Hazards of Detonation Spraying


Remedy The Hazards of Detonation Spraying

Protect your employees from the hazards of thermal spraying!

Thermal spraying is a coating process that combines a heat source and a coating material in powder or wire form, melts it, and sprays onto surfaces at a high velocity. There are many variations of thermal spraying such as:

  • Detonation SprayingDetonation Spraying
  • Plasma Spraying
  • Twin Wire Arc Spraying
  • High Velocity Oxy-fuel Coating Spraying (HVOF)
  • Warm Spraying
  • Cold Spraying
  • Flame Spraying

Thermal spraying provides wear resistant coatings to protect from erosion and abrasion, and provides different degrees of electrical conductivity. Thermal Spraying has been utilized by many industries such as: Transportation, steel mills, medical, military, computers, aerospace, and many more.

The benefits of thermal spraying are abundant, but execution of the process presents many hazards. The Fabricators & Manufacturers Association, Intl. says that thermal spraying creates toxic dust and fumes due to the atomization of molten metals, posing a dangerous environment for operators carrying out the process.   The Occupational Safety & Health Administration (OSHA) has acknowledged the dangers of explosive gas and carcinogenic fumes from detonation spraying, and recommend implementing their safety standards.  Implementation of a high quality dust and fume collection system and proper ventilation can provide a solution to this hazardous situation.

Solutions For Detonation Spraying Hazards

What can Imperial Systems offer the thermal spraying industry to improve the safety and security of their thermal spraying operators?

Imperial Systems is among the top dust collection equipment manufacturing businesses in North America.  The high quality and efficiency of our CMAXX™ Dust Collection System is how we provide those in the thermal spraying industry with the safety and security they desire.

Our CMAXX™ Dust Collection Systems are  designed with revolutionary PD Technology for maximum cleaning performance and has 10% more filter media than other same-sized vertical cartridge collectors, neutralizing and keeping the air clean while you work. The CMAXX dust collector system also allows for 20% more area around the cartridge filters which causes the dust to fall into the hopper before attaching to the filters. Our CMAXX™ dust collector offers these other features:

  • Vertical Cartridge Design for a longer filter life
  • Internal Velocities are 20% Lower – Best in Class
  • Increased Cleaning power with an energy efficient and High-Performance Manifold Mounted Pulse Valves
  • Fewer Internal Ledges for Material to Build Up
  • Slanted Inlet Design that prevents water build up on the top of the 90° inlet
  • Up to 40% More Cleaning Power – Up to Twice the Filter Life
  • 15 Year Manufacturer’s Warranty

Combine our quality CMAXX™ dust collector system with our DeltaMAXX™ Replacement Cartridge Filters and you have the solutions to those safety hazard problems.  Our DeltaMAXX™ Replacement Cartridge filters have nanofiber technology that stops submicron particles from embedding into the media, has the highest quality pleated media at a 99.9% efficiency, and are able to reduce the operational cost of your dust collector system with less pulse cleaning.

For more information on our CMAXX™ Dust Collector System and our DeltaMAXX™ Replacement Cartridge Filters contact Imperial Systems today!

Detonation Spraying | Detonation Sprayings

2 Methods to Extract Welding Smoke from Your Metalworking Facility

Imperial Systems helps you find the best dust collector system for your manufacturing facility.

Welding smoke and fumes in metalworking pose a significant risk to personnel and to the facility if not addressed in an effective manner.  While the recommended approach for controlling smoke and fumes depends on the process each facility uses, a successful solution always includes local containment and source capture.   Imperial Systems helps leaders in the metalworking industry to extract welding smoke before it becomes an active hazard in their buildings.

extract welding smokeSmoke and dust extraction is an integral component of metalworking and manufacturing safety. Below are some of the most common techniques employed in metalworking applications to extract welding smoke:

Local Containment

Local containment isolates the welding and metalworking processes from the rest of the site while protecting the contained area, such as a partitioned area that is maintained under negative pressure. The extracted air can either be pulled directly into a collector that incorporates a hood or routed through ductwork to a remote dust collector. In some cases, the filtered air can be recycled to create a push-pull airflow pattern which helps to extract welding smoke even further.

Source Capture

The most effective method to extract welding smoke, source capture extracts contaminants at or near their generation point.  Source capture is the most effective means of control and requires the least amount of energy to achieve. It can be accomplished through utilizing fume extraction arms or local fixed hoods on the grinding machines.

At Imperial Systems, we are dedicated to providing the highest level of quality, safety, and value in each one of our products.  This means that we aim to design and manufacture solutions that metalworkers like you can rely on.  By using Imperial Systems DeltaMAXX™ filters with the CMAXX™ Dust Collector system and its EvenLock Technology, you can help extract welding smoke while also enjoying the following benefits to your business:

  • Protected and improved worker health and job satisfaction
  • OSHA & EPA regulation compliance
  • Increased productivity
  • Energy conservation and financial savings
  • Improved quality in parts and production
  • Extended life of your machinery
  • Reduced housekeeping needs and costs

If your facility is at risk from dusts, fumes, or other flammable materials, contact Imperial Systems today at 800.918.3013.

Imperial Systems Effective Solutions for How to Isolate a Deflagration

Don’t choose a sub-standard product to isolate a deflagration. Save time and money by choosing the right arrester first from Imperial Systems.

When making a purchase decision in the metalworking industry, you must take into consideration both the quality of the product being purchased as well as the effectiveness and safety for the end-user–your employees. Today’s advances in dust collection systems have lessened replacement costs and injury or death due to faulty equipment.

isolate a deflagrationYou may already know that Imperial Systems prides itself on engineering outstanding, high quality products to keep buyer’s employees and businesses safe from dust collection and air pollution. With the current competitive economic environment, it’s imperative for businesses in the metalworking industry to focus more on a dust collection system that lasts a long time.

Together with our CMAXX Dust Collection System, our DeltaMaxx IDA (In-Line Deflagration Arrester) Cartridge filters have brought breakthrough safety features that offer exceptional protection to isolate a deflagration.

How To Isolate A Deflagration With Imperial: Quality You Can Rely On

Regardless of types, all flame arresters operate on the same principle: removing heat from the flame as it attempts to travel through narrow passages constructed of metal or other heat-conductive materials.

Our DeltaMAXX IDA filters are installed in your dust collection system to inhibit flames from progressing through them, thus assuring that you’ll isolate a deflagration.  IDA filter applications protect systems which collect and/or filter gases emitted by liquids and solids. If an combustion occurs, a flame inside or outside of the system could result, with the potential to do disastrous damage.

Fortunately, a quality, new flame arrestor standard has been introduced by Imperial Systems to isolate a deflagration. Our advanced safety features have arrived, and with the use of IDA DeltaMAXX filters explosion risks are reduced significantly. In all testing situations, each filter was able to isolate the flammable dust and completely stop a flame front without fail every time.

The Imperial Systems Difference

Imperial Systems primary advantage is our investment and dedication to technology at the forefront of the industry. For those in the metalworking business hoping to increase profits, one of the best long-term strategies is through the investment in the highest quality equipment. The hazard of dust, fumes, sparks, and machine malfunctioning cause risks not only to safety but also profits.

When you choose the DeltaMAXX IDA Filter from Imperial Systems, you choose certified technology which has made innovative advances through the extinguishing of dangerous and non-isolated flame. Investing in the best technology for your business makes financial sense and safety sense when you need a product that will isolate a deflagration and protect your employees.

Reach Out Today

Our network of Imperial Systems Inc. representatives are all highly trained problem solvers with specialized training in supporting our clients.

If you’d like to request a quote or schedule an assessment  based on your needs for a hardworking, high-quality dust collector filter which is both OSHA and NFPA regulated, get in touch with us today at 724.662.2801 or by finding out more about us.

At Imperial Systems, we specialize in advanced safety solutions you can count on.

Working With OSHA to Stop Combustible Dust in Your Facility

Imperial Systems helps you find the best dust collector system for your manufacturing facility

Almost any material can become combustible when broken down into dust and suspended in the air at the right concentration levels. Dust from seemingly innocuous materials – such as food (e.g., sugar, flour, feed, etc.), wood, paper, plastics, pharmaceuticals, metals, and more – can become an explosion hazard if not properly monitored and eliminated. As a result, leaders in a wide range of industries and processes, including agriculture, manufacturing, pharmaceuticals, textiles, power generation, recycling, and 3D printing, are investing in Imperial Systems dust collectors and filters to stop combustible dust before it becomes an active hazard in their facilities.

stop-combustible-dustThe following recommendations from OSHA are provided to help you assess your facility and stop combustible dust hazards:

  1. Inspect your facility surfaces regularly for accumulated dust. OSHA inspectors flag accumulations of 1/32nd of an inch (about as thick as a paper clip) over a surface area equal to 5% of the floor area or more for an immediate cleaning. Regular cleaning rounds can also reveal sporadic increases in dust particle build up, alerting you to potential equipment maintenance needs.
  1. Ensure the accessibility of all areas of your facility. OSHA strongly recommends a written plan with cleaning frequencies established for all horizontal surfaces. You must be able to access every horizontal surface of your plant safely — including ductwork, beam and joist surfaces, and the space above suspended ceilings—to assess dust buildup levels.
  1. Position your dust collectors appropriately.  According to OSHA, dust collectors with a volume greater than 8 cubic feet should be placed outside of buildings to help stop combustible dust displacement.
  1. Confirm that all electrical wiring and equipment is approved for use in your facility’s conditions. According to OSHA, “The use of proper electrical equipment in hazardous locations is crucial to eliminating a common ignition source.”
  1. Control potential ignition sources. Post “No Smoking” signs. Control static electricity by bonding and grounding equipment. Provide personal protective equipment as needed, not only as a protective barrier for the employees but also to prevent ignition from static electricity.
  1. Perform regular preventive maintenance on all safety and production equipment. Machines and tools that are in in bad repair are a common cause of ignition.
  1. Train site leaders and employees to recognize and prevent ignition hazards. Training should take place before they begin employment and be refreshed periodically to update or review material. Site leaders and employees should also know the overall safety programs ignition source control and to stop combustible dust.  Encouraging employees to report unsafe practices also helps to develop a company culture of safety.

If your facility is at risk from fine dust, powders or other flammables, contact Imperial Systems today at 800.918.3013 for dust collectors and filters that will stop combustible dust before it endangers your business.

stop combustible dust | stop combustible industrial dust

The Science of In Line Deflagration Arrestor Safety

Imperial Systems is a leader in the industry for safe, effective dust collector systems and in line deflagration arrestors.

The development of in line deflagration arrestor devices and systems has been instrumental in increased facility employee safety and explosion protection in industrial dust collection systems.  As a leader in the industry and provider of our proprietary DeltaMAXX In-Line Deflagration Arrester Cartridge Filters, Imperial Systems presents this guide to the science behind flame front causes, and how an in line deflagration arrestor can protect your facility.

Whenever a flammable mixture of vapor or gas comes in contact with an ignition source, a flame front will develop. The flame in line deflagration arrestorwill continue to burn through the vapor or gas until:

  1. The flame’s fuel supply is consumed.
  2. The heat sustaining the flame’s combustion is removed.
  3. The system’s oxygen concentration fluctuates either too high or too low to facilitate continued burning.

If a flame front is propagating slower than the speed of sound in the vapor, it is called a deflagration.  A deflagration may develop in the atmosphere (known as an unconfined deflagration) or in an enclosed area, such as a ductwork system (known as a confined deflagration).  A confined deflagration (e.g. – an ignition in a run of pipe) starts at low speed and pressure; as the flame front travels in the pipe, its speed and associated pressure increase. In ductwork with multiple bends, the flame accelerates until it transitions into a stable detonation.

An in line deflagration arrestor is a passive safety device designed to prevent the spread of flame fronts through lines and duct configurations, and between tanks and combustion units. Regardless of types, all in line deflagration arrestors operate on the same principle: This is also known as “flashback”.

All flame arrestors work using the same basic process:

  • Disperse the flame front.
  • Release its energy.
  • Cool flame to below the ignition point of the vapor within the system.

When correctly installed, an in line deflagration arrestor will extinguish flame fronts travelling from either direction. Such devices can be employed in many industries, including metalworking, pulp and paper, mining, power generation, and bulk liquids transportation, among others.  The installation of flame arresters should be considered for activated-carbon absorbers, vacuum pumps, and other equipment that emits flammable vapors and/or can serve as an ignition source.

In order to safeguard workers in the metalworking industry, Imperial Systems tested our CMAXX System numerous times with the IDA DeltaMAXX filters.  In all tests across the board, each filter was able to isolate the flammable dust and completely stop a flame front consistently every time.   

For more information, contact Imperial Systems today at 800.918.3013.

The Cost of Procrastinating on Your Spark Arrestor Purchase

Delaying your spark arrestor decision may cost you– We can help you reduce the risk

warningHow much is your procrastination costing you?  In some industries, putting decisions or actions off for a later date can have negative, if relatively mild, consequences.  A deadline is missed, an opportunity is lost.  A client or partner may even be disappointed. While these consequences may be difficult for those having to deal with them, they pale in the face of the cost of procrastination within the metalworking industry.  

Unlike other businesses, your metalworking company is a high-stakes situation every single day.  With the potentially explosive combination of combustible dust and sparks flying, it is imperative that you act immediately to implement all of the required and recommended safety equipment, including dust collection systems with sealed ductwork and an effective spark arrestor.

Of course, each of these pieces of equipment represents a major investment for your business, and it is important to do your homework and decide which one is the best fit for your business.  However, letting that pending decision intimidate or hold you could be a serious hazard.  

In this blog, we will lead you through:

  • The Risks of Combustible Dust & Sparks
  • The Role of A Spark Arrestor in Risk Prevention
  • The Features & Benefits of the Imperial Systems’ Spark Arrestor

Understanding The Risk of Combustible Dust & Sparks


what_materials_are_involved_in_combustible_dust_incidents_-_graphicIn the metalworking industry, it’s not secret that the materials you work with day in and day out can create a serious risk for combustion.  In fact, metals make up 20% of the materials involved in combustible dust incidents. And between 2008 and 2012, the United States Chemical Safety Board documented 50 combustible dust accidents, which led to a total of 29 fatalities and 161 injuries.


Unfortunately, as of 2014, metals and manufacturing were among the top industries being cited by OSHA for combustible dust, flammable dust, and other explosible dust hazards. This tells us that, although the risk is clear, it may not be clearly understood by those in the industry.

Five simple elements are required for combustion to occur:

  • Heat
  • Fuel
  • Oxygen
  • Dispersion
  • Confinement

image-300x275With each of these factors occurring effortlessly within most metalworking shops, tragedy lurks only a moment away.  This is why, in 2006, the US Chemical Safety Board recommended a comprehensive combustible dust regulatory standard for all industries, be added atop the initial regulations which were developed in the grain industry in 1987.

Clearly, the risks are both real and nearly ubiquitous.  They need to be taken seriously by all within the affected industries. One of the best ways to do this is to evaluate your workspace and ensure that it has all of the equipment necessary to meet OSHA, NFPA, and other regulations.  Additionally, you should regularly evaluate your equipment to ensure that it is in good working order.  

The Role of A Spark Arrestor in Risk Prevention

At its most basic, the role of a spark arrestor is to prevent the emission of flammable materials from combustion.  Sparks, in various forms are the major cause of combustion in combustible dust accidents:

Screenshot at Jan 07 19-37-37Because sparks are often carried along through the exhaust gas stream, it has not cooled from its temperature of 600 degrees Fahrenheit by the time it arrives at the solids separator.  At this point, it can be deposited onto the filter element surface, positioned as a glowing risk of combustion. The filter element surface is at high risk for combustion, no matter what material it is made of, because of it’s role in collecting tiny metal particles and dust that are produced by nearly every manufacturing and metalworking process.  Even a simple spark is enough to insight disaster.

This is why OSHA’s ignition control recommendations regarding combustible dust include the following:shutterstock_243589588

  • Control smoking, open flames, and sparks
  • Control mechanical sparks and friction
  • Use separator devices to remove foreign materials capable of igniting combustibles from process materials
  • Separate heated surfaces from dusts
  • Use an equipment preventive maintenance program.

OSHA’s injury and damage control methods also include:

  • Separation of the hazard (isolate with distance)
  • Segregation of the hazard (isolate with a barrier)
  • Deflagration isolation/venting
  • Specialized fire suppression systems
  • Explosion protection systems;

A Spark Arrestor is an instrumental part of these methods, working to minimize risk by cooling and thus extinguishing sparks before they reach the filter surface.  In the diagram below, note how the hot spark enters the arrestor which both cools and collects debris, before allowing the cooled ember to pass through.

Spark Arrestor internal view copy

The spark arrestor fits within the full dust collection system as the first line of defense.  They take up little or no extra space, but provide powerful results.  

The Features & Benefits of the Imperial Systems’ Spark Arrestor

At Imperial Systems, our highest priority is to provide the best solutions in dust collection and air pollution.  We are determined to provide the best protection for your workers, your plant, and the environment.  For over a decade, we have been serving metalworking businesses like yours all over the United States and Canada.

In an effort to provide fully comprehensive dust collection equipment, we have debuted our Spark Arrestor.  It’s standard features include:

  • Heavy duty construction
  • No maintenance
  • Clean-out door
  • Fully welded construction
  • Easy install into any system
  • Can be installed in horizontal or vertical configurations
  • No moving parts
  • Carbon steel or stainless steel available
  • No water required
  • AVAILABLE IN SIZES: 6 in. to 40 in

Additionally, you can opt for raw inlet and outlet edges, rolled angle flange for bolt together ducts, or clamp together for clamping duct.

As with all Imperial Systems’ products, you can count on the highest quality materials, top safety features, and unbeatable value.

The Cost of Procrastination

So back to our original question.  If you haven’t yet decided on a spark extinguisher for your metalworking business, what is that procrastination cost you?  Let’s take a look at the numbers:

From 1996-2005, 106 explosions resulted in 16 fatalities, 126 injuries, and an estimated cost of $162.8 million in damages to the facilities.

And we know, from previously cited studies, that sparks are a major cause of such explosions.  Will you absolutely face a combustible dust explosion if you put off your decision about a spark extinguisher?  Perhaps not.  But is it really worth the risk?

If you are ready to take the next step towards improving the safety of your workplace with an industrial spark arrestor, you can contact Imperial Systems today at 800.918.3013 or by emailing us at info@isystemsweb.com.
At Imperial Systems, we know that spark collection is only one of the many challenges that metalworkers like you face every day.  What other safety and production challenges are you facing in your business?  What actions have you taken to try to solve these issues?  Share your ideas and experiences with us in the comments section below.  

Snuff Out Explosions with Imperial Systems DeltaMAXX (In-Line Deflagration Arrester) Filters

Stop an explosion before it starts!

In the air filtration, dust collection, and fume extraction industry we’re here to provide the metal industry with the top of the line dust collections systems. Our business is really about keeping you, the metalworker, safe! That’s what we do at Imperial Systems, and we never stop innovating and improving our collection systems and filters to ensure that you work in a secure environment.

In-Line-Deflagration-FiltersDust collection systems have come a long way, but that doesn’t mean we stop perfecting our systems. That means we continue to eliminate the dangers that are faced in the metalworking industry. That’s why at Imperial Systems we’ve improved our CMAXX dust collector systems when combined with our DeltaMAXX In-line Deflagration filters.

What Our DeltaMAXX In-line Deflagration Filters Avoid

We work diligently to improve our dust collection systems to avoid what the Occupational Safety & Health Administration identifies as the Dust and Fire Explosion Pentagon. To avoid the explosion pentagon we’ve adhered to  the safety protocols put in place by OSHA and NFPA, but we want to go above and beyond what’s expected.  Our DeltaMAXX (In-line Deflagration filters) are designed to stop a flame front in its tracks. Combined with our CMAXX Dust collection systems the Dust and Fire Explosion Pentagon doesn’t stand a chance.

Don’t just take our word for it.  Backed by third party testing, we had our CMAXX Dust collection system and the IDA DeltaMAXX filters go through test after test after test to see if the In-Line Deflagration filters were able to isolate a deflagration and stop a flame front. Each time the IDA filters did not disappoint. The third party testing showed one hundred percent of the time the flame front being forced through the IDA DeltaMAXX filters with the explosion vent covered.  After the tests were performed there was no sign of any trace of flame or spark transmission downstream from the filters or in the clean air plenum.

Taking the testing further, the CMAXX dust collection system was tested without its explosion venting, to see if it could withstand a deflagration of cornstarch at 185 KST with pressures exceeding 4 PSI.  The results showed the explosion diverting through the DeltaMAXX IDA filter again.  The internal cages of the filters remained in perfect shape and the seals were not deformed or melted.  This proves once again that in combination, our CMAXX dust collection system and our  DeltaMAXX IDA filters avoid the combustible dust hazards of the metalworking industry.

If you’re still looking looking for a solution to your combustible dust hazards, Imperial Systems is your answer! Contact us today at 800.918.3013.

In-Line Deflagration Filters | In-Line Deflagration Filter