by Erin Long | Jan 28, 2019 | Uncategorized
After you’ve installed your dust collection system, the big initial expense is over. However, you need to plan for your system’s regular maintenance, like replacing the industrial dust collector cartridge filters. Dust collectors that use cartridge filters have become very popular, partly because cartridge filter changes are easier.
Dust collector filters are the part of the system that clean the air traveling through the system. In a pulse jet collector with dust cartridge filters, the filter cleaning system removes dust from the surface of the filters.
All filters, though, will eventually become overloaded with particles and will need to be replaced.
Do they really have to be replaced? Why can’t you just clean them?
Can’t you just take out and clean the dust collector cartridge filters so they’ll work better again?
You can, and people do. But you shouldn’t, and here’s why.
You can measure the efficiency of a dust cartridge filter by its differential pressure. This means measuring the pressure on the dirty air side of the filter and then on the clean air side. This tells you how much the airflow is slowing down across the filters.
If your differential pressure is higher than the recommendation for your system, it’s time for a change. The filter cleaning system is not able to clean your dust collector filters anymore. It’s time to replace the filters.
There are companies that offer to clean your industrial dust collector filters instead of changing them. Usually, they do this by blasting them with high-pressure compressed air to blow the accumulated dust out of the filters. The problem is that dust collector cartridge filters are made of cellulose and polyester, which means a large part of the filter is cardboard. When you try to clean industrial dust collector filters this way, the high-pressure air will create holes in the filter material.
You might not be able to see the holes. It may seem like the filter cleaning worked perfectly. The filters get put back in the dust collector, and the differential pressure is much lower.
The pressure isn’t lower because the filters are clean, though. It’s lower because air is going straight through the little holes torn in your filter.
How big a problem are those little holes in the cartridge filters?
Cleaning your dust collector filters can put holes in them, but how much dust is really going to get through those tiny holes? The answer is “a lot”. Air follows the path of least resistance. The filter material has resistance. The holes don’t. The air going through the dust collector cartridge filters will go through the holes, taking dust with it.
This is a serious problem for several reasons.
First, dust will be getting through your dust collector filters. Depending on where your air is venting, it’s going out into the environment or back into your facility. Either way, this could result in fines or health problems for employees.
Second, dust that gets through the filters can build up in the clean air plenum. There should never be dust in this part of the collector. The dust in there will keep blowing out into the facility even if you fix the filters.
Third, the differential pressure will be lowered because air can easily get through the holes. This could make it look like the filters are clean and working well, even though they are damaged. This makes it hard to recognize that the dust collector filters are not doing their job.
You’re Not Saving Money by Cleaning Your Dust Collector Cartridge Filters
Industrial dust collector filters are made of a cardboard-based material that is not made to be cleaned and re-used. While it looks like the filters are cleaned and working better, what you’re really seeing is filters that have been damaged. Learn more about filter cleaning versus installing new filters and offline cartridge filter cleaning.
Instead of trying to save money by having your filters cleaned, contact Imperial Systems and ask us about DeltaMAXX filters. They last longer than the competitors’ filters, so you’ll save money on your industrial dust collector filters over time.
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![Weld Fume Extraction Guide [Infographic]](https://www.isystemsweb.com/wp-content/uploads/2019/01/fume-extraction-header-1080x675.jpg)
by Erin Long | Jan 23, 2019 | Weld Fume
This weld fume extraction guide takes a look at the many ways to collect and remove weld fume from a facility. When not properly taken out of the work area, weld fume can cause some serious health issues for welders.
Weld Fume Extraction Methods
- Ambient Collection – The entire roof acts like a hood and allows fume to rise and be collected towards the ceiling. Ductwork runs with inlets above the work area to clear the fumes.
- Source Collection – Welders manipulate an arm to the location where the welding is taking place and the arm removes the fume from the area.
- Hood Collection – Welders or robots work under a hood that contains fume to a confined space where the dust collector removes and filters it.
- Downdraft Collection – Work occurs on a grated table that pulls the fume out from underneath and vents it to a dust collector.
Health Risks Associated with Weld Fume
Welding Stainless steel
- Produces hexavalent chromium, a dangerous valence state of the element chromium. Chromium metal is added to alloy steel to increase hardenability and corrosion resistance.
- Causes lung cancer, allergies, and damage to the nose, throat, and respiratory tract
Welding Aluminum
- Produces ozone and aluminum oxide. TIG, MIG, and plasma-arc welding typically produce ozone, a highly toxic gas. Aluminum oxide forms from the base and filler materials and exists in the welding fumes.
- Causes bronchitis and aluminosis (aluminum lung), a form of pneumoconiosis that leads to pulmonary fibrosis
Consult a doctor if you experience frequent sneezing, coughing, runny nose, nosebleeds, chest tightness, or shortness of breath.
Weld Fume Extraction Equipment and Experts
The CMAXX Dust & Fume Collector by Imperial Systems is the best choice for removing weld fume from your facility and keeping your employees safe. Our sales and product engineers will design and dust and weld fume collector specifically for your application. Contact us today.
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by Erin Long | Jan 21, 2019 | Metal Cutting
Most of the companies we work with have a good record for factory safety. With OSHA safety regulations, there’s been a big push for factories to remove hazards from the work area.
One area that sometimes gets missed is the handling of dust and fumes. This is very important in metalworking industries. Metal dust creates unique problems, and a safety plan must take these into account. Here are some safety tips for factory workers as well as their plant leaders.
Factory Safety Tip #1: TREAT ALL METAL DUST AS COMBUSTIBLE
Unless you have had your dust tested, you should assume that metal dust is combustible.
Because of proper fire and explosion safety devices, many metal dust fires are confined to the dust collector. However, one example from the Chemical Safety Board (CSB) shows how improper handling of metal dust is a safety hazard.
The safety failure occurred in a plant in West Virginia working with titanium metal and powder. Titanium is a very combustible metal, and it was being stored in open containers throughout the facility. Sparks generated from a mixing machine ignited the powder. (See the CSB’s investigation of this incident here.)
Another explosion occurred on January 3, 2019 in a metal recycling factory. A machine shredding metal scraps into powder caused an explosion that blew out a wall and burned several workers. These types of incidents are obvious safety hazards.
Metal fires burn at anywhere from 5000 to 8000 degrees F. Once they have ignited, they are extremely hard to put out. The best factory safety solution is to do a hazard check of the facility and eliminate two key elements: the presence of loose combustible dust and the presence of ignition sources.
Manage the dust with a dust collection system equipped with proper safety features. A correctly designed dust collector is one of the most important pieces of factory dust control equipment. Getting rid of ignition sources might mean checking all machinery regularly for malfunctions or overheating. It also means having a safety plan in place for all repairs, especially hot work, done in the factory.
Factory Safety Tip #2: DON’T TREAT A METAL FIRE LIKE AN ORDINARY FIRE
Metal fires cannot be put out with water. They cannot be put out with commercial ABC extinguishers that are part of many factory safety plans. This safety tip can make the difference between extinguishing and fueling a metal fire.
Only a Class D fire extinguisher can put out metal fires. Why can’t you use water or other typical fire extinguishers?
Metal dust fires burn much hotter than other materials. If water from the factory fire safety system is sprayed on this type of fire, some of the water will turn to scalding steam. The rest of the water will break down to hydrogen and oxygen. Both gasses are flammable. It’s just adding fuel to the fire, as confirmed in this article by Fire Engineering.
Any facility that produces or handles metal dust should have a safety plan that includes Class D extinguishers. Another key safety tip is that there must be clear exits so people can escape quickly. A metal fire can burn very fast and destroy a building in minutes.
Factory Safety Tip #3: MAKE SURE YOUR SUPPLIER DESIGNS YOUR DUST COLLECTION SYSTEM FOR METAL DUST
Metal dust from cutting, welding, or grinding is very fine, often less than 0.3 microns. It is also usually combustible. Inside a dust collector and under pressure, it is explosive. A dust collection system that meets NFPA standards will improve plant safety.
Equip dust collectors that handle combustible dust with devices to detect, isolate, and extinguish flames or explosions. Without devices to isolate a deflagration and vent it away from people and buildings, factory safety could be at risk.
A key safety tip is to make sure that the company who builds and installs your dust collection system understands and can explain all of the required fire safety equipment to you.
Another important safety tip is to make sure to keep this equipment in good working order. This includes changing the filters when they need it and having regular inspections and maintenance on the collector.
By following these tips, you can greatly improve plant safety and decrease the hazards of metal dust and fumes.
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by Erin Long | Jan 17, 2019 | Uncategorized
The basic answer is that yes, a dust explosion is more likely during this season. The U.S. Chemical Safety Board found that since 1995, 7 out of 8 serious dust explosions occurred in the winter. February was the most dangerous month.
Why does dust explode more often in the winter? There are several factors responsible:
DRY AIR AND LOW HUMIDITY
When the air is cold and dry in the winter, dust contains less moisture. This means it can become airborne more easily. Clouds of dry airborne dust can ignite quickly. Make sure the dust collection system is in good working order and get rid of any escaped dust as soon as possible to prevent this situation.
What if you live in an area where the humidity is always low? This creates the same risks that dry winter air creates in other places. A combustible dust explosion is more likely to occur any time that the air is dry.
STATIC CHARGES
Dry air encourages static electricity charges to build up more easily than when the air is humid. A spark from static electricity can be enough to ignite a combustible dust explosion. Many of the dust collectors we’ve seen when doing maintenance visits are not properly grounded, or not grounded at all.
The best way to prevent the buildup of static electricity in the dust collection system (and other places) is to properly ground all dust-handling equipment. This is an important protective measure no matter what season it is.
The fact that so many systems are not grounded shows why your experienced professionals should design and install your dust collection system.
HOUSEKEEPING
Some facilities keep doors, windows, and vents open during warm weather, which increases natural airflow. In the winter, though, it means lost heat which means lost money. Most places are sealed up as much as possible in the winter to keep the cold out, but this also keeps the dust in. Shops that count on open doors and vents to keep the air clean in the summer might be at risk of a dust explosion in the winter.
Dust buildup inside the facility in winter can also cause a dangerous situation: the potential for a secondary explosion. These happen when dust builds up somewhere, which can happen on any flat surface.
This is more likely to happen in a closed-up shop in the winter. However, it can happen any time. Secondary dust explosions happen when a first, smaller explosion happens. This might not be that bad, but the secondary dust explosion can be much worse. The first explosion blows all the accumulated dust into the air, and then it can ignite in a much bigger explosion.
IGNITION SOURCES
Heaters get turned on in the winter. There’s a good chance they haven’t been turned on since last winter. They can act as an ignition source, especially if they have any faulty wiring. Just one spark is enough for ignition. This has led to some of the worst combustible dust explosions in recent history.
In already dry winter conditions, a spark from a damaged heater is even more likely to ignite an explosion. Sparks from static can also cause ignition.
DUST CONTROL
For dust to ignite, the classic “fire triangle” has to be present: fuel (combustible dust), oxygen, and an ignition source. If you remove any of those things, you can stop a dust explosion from occurring.
Because you can’t guarantee a lack of ignition sources, the best solution is to remove the fuel. A dust collection system fitted with appropriate NFPA safety devices can remove dust from your facility. With explosion isolation valves and other safety features, the dust collection system can also control a dust explosion and vent it safely.
As an added bonus, a dust collection system with high efficiency nanofiber DeltaMAXX filters can usually return air to your facility after filtering. This means that in the winter, the dust gets removed, but the heat stays inside where it belongs.
DON’T HAVE A WINTER WHERE YOU ARE?
Not everyone can be lucky enough to enjoy the ice, snow, and frigid weather of a Pennsylvania winter like we are. Maybe where you’re located, there isn’t really a cold season where the doors are closed or the heaters are on.
Do you have a dry season? During any time when the humidity is low, you have an increased risk of a combustible dust explosion.
Besides, steps, like grounding your equipment, removing ignition sources, and cleaning up your dust, are always a good idea no matter where you’re located.
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by Erin Long | Jan 7, 2019 | Uncategorized
Imagine that you’re doing an online search for “dust collector”. You’re going to get a lot of results. Some will be for large commercial dust collectors. However, some will be for small units made to fit in a home garage. How do you get through the maze of search results to find the dust collector that you’re looking for? First of all, what do you need your dust collector to do? Commercial dust collection systems, like the ones we make, are a major investment. Let’s look at some examples of who needs a commercial dust collector and who needs a smaller and less expensive solution.
Consider These Scenarios
“My home business produces a lot of sawdust and it’s a mess.”
Jim has a one-man woodworking business and operates it out of his garage. He cuts, saws, and sands wood. As a result, his work produces a lot of sawdust, which he knows is a fire hazard as well as a mess. However, Jim does not need a commercial dust collector. So, if he does a search for home dust collection system, he’ll find lots of options that will do the job for him.
“The three of us weld and grind metal a lot during the work day.”
Anne owns a small metalworking business. She does a lot of welding. In addition, she has two employees who weld and grind metal for part of the day. To stay safe, Anne and her employees definitely need dust and fume collection. There are many search results for small business dust collector that will offer Anne some good options. In this case, a commercial dust collector is too big and too expensive for her needs.
“We’re getting a lot of fumes in the shop and I’m worried about everybody’s health.”
Adam is the owner of a metalworking shop. He has ten employees, but plans to add more. They usually spend the entire work day welding and grinding. The shop also has a laser cutting table. As a result, air in the shop is often cloudy with fumes. Opening the doors helps a little in the summer, but it’s a huge waste of heat in the winter. Even in the summer, the cutting table creates a cloud of fumes. Therefore, Adam’s business might want to invest in a commercial dust collector system. This system would be a good investment because it would be able to handle the dust from the welding and grinding. It would also be big enough to deal with the cutting table. If Adam searches for commercial dust collection systems, he will get results that are more in line with his needs.
“We’ve got dust going everywhere and it’s a huge problem for our business.”
ABC Company is a food processing company that packages powdered food products. Most noteworthy, many of these are combustible. The company has some small dust collectors located over some of the conveyors. However, they have dust built up around the facility and when loads are dumped into bins, dust goes everywhere. This company absolutely needs to look at a commercial dust collector. They have a serious dust problem that’s coming from many different applications in their building. Consequently, a high danger of having a large fire or explosion exists. They are also in danger of serious OSHA fines for the fire hazard. Above all, their dust collection system needs to have solid flame and explosion protection equipment for their combustible material.
“We got fined because our current system isn’t efficient enough for new standards.”
Batteries R Us is a large company that manufactures batteries for vehicles. They have a commercial dust collector in place already. However, they recently got fined for an EPA violation because their system was not capturing enough of the lead dust from their process. Also, their dust collector is old and was installed before some of the newer EPA and OSHA regulations were put in place. To get back into compliance, this company needs to invest in a new, updated commercial dust collector. Plus, the new system will need to have HEPA filters to catch the maximum amount of lead dust.
Get Expert Advice for a Commercial Dust Collector
For any business, a commercial dust collector system is a serious investment. However, if that’s what it takes to keep people healthy and keep your facility safe, it’s worth it. You might only need a small home unit, or perhaps only one or two small portable units for your small shop. But if you’ve got big dust and fume problems and you need to make a major investment to help solve them, please allow us to help you plan the best system for your needs.
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