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 Greg | Aug 15, 2016 | Case Studies
Product: Dust Collection System Filters
Application: Capture dust and fumes from powder coating process
Customer: Small powder coating shop in rural Alabama
The Challenge: Bobby, the owner of the company had concerns about static charges building up inside their dust collector. Powder coating is an electrostatic process and his equipment was causing small “flash” ignitions within the collector. This was an obvious safety issue and he knew he needed help in finding a cartridge filter that could be grounded. His current filter supplier was not able to solve the problem.
The Solution: He discovered Imperial Systems and discussed the issue with one of our Aftermarket team members. Once they understood Bobby’s concerns, they were able to determine the correct filter medium and other modifications to address the problem. A DeltaMAXXTM aluminum spunbond cartridge filter with a connected ground wire was the solution for this type of problem. Once the new filters were installed and grounded properly, the static discharge was alleviated. Bobby was very pleased with the results. “We’ve had no more problems with static and the filters are doing exactly what they’re supposed to do”.
He was very appreciative of our help and will definitely contact Imperial Systems for any future filter needs.
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by Greg | Mar 27, 2016 | Case Studies
Case Study – Weld Smoke Extraction Problems at This Metal Fabrication Facility Solved with the CMAXXTM Dust and Fume Collector
Product: CMAXXTM (CM020) Dust Collector (Total of 3 units)
Application: Capture weld smoke and fumes
Customer: Masaba, Metal Working Fabricator of Bulk Handling Equipment for Mining, Aggregate, Agriculture, etc.
The Challenge: Masaba’s manufacturing facility has a high ceiling that would become filled with smoke and fumes from their various welding bays. The old roof mounted system that was used to extract the weld smoke and fumes from the facility was not working properly. This system was a hybrid HVAC unit that incorporated industrial air filters. The weld smoke being produced during daily production proved to be too much for the current air extraction unit. The return air into the facility was not being filtered adequately, which defeated the purpose of the system altogether.
The Solution: The President of Masaba, Jerad Higman, was not satisfied with the current situation. As a business owner, he cared very much about his employee’s health and having a clean working environment. Though the air quality was good enough in the shop, Jerad wanted to make it even better and decided a new, more effective system design was needed. He called upon top industry dust collection manufacturers, Camfil Farr, Donaldson Torit, and Imperial Systems, Inc. to provide the best solution to his facilities’ air quality problems. He knew each company was capable of solving the problem, but after meeting with Imperial System’s President, Jeremiah Wann, and hearing his ideas about mitigating all the weld smoke issues, Jerad knew he had found the right company.
A relationship of trust quickly developed between Jerad and Jeremiah as they worked together on the design and layout for the new system. “I had a great experience in working with Jeremiah and Imperial Systems”, Jerad says. “I really liked the fact that they are an American owned company and were always available when we needed them.”
The installation of an ambient weld smoke system was the ultimate choice to clear Masaba’s facility of dirty air. Imperial Systems installed three exterior CMAXXTM (CM020) collector units and associated ductwork as part of the new system. Masaba manufactured the hoods that covered each welding bay. Once everything was connected, it didn’t take long after the system start-up to see the built up weld smoke dissipate. The new CMAXXTM system was moving and recycling the total air volume inside the shop six times per hour. The return air was being filtered properly by the DeltaMAXXTM filters, resulting in cleaner air and healthier environment.
Jerad Higman was amazed at the difference. “I was very impressed at how effective the CMAXX collectors were operating.” He goes on to say, “To this day, I have not experienced any problems with them and I would highly recommend Imperial Systems products to anyone that has issues with the air quality in their shop. Their level of expertise and service is just outstanding.”
For more information on how CMAXXTM Dust and Fume Collection systems can benefit your facility, call one of our experienced team members at 800-918-3013 or visit Imperial System’s website today.
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by Greg | Feb 8, 2016 | Case Studies
Product: BRF Baghouse (8BRF 152-10 with after filter plenum)
Application: Capture dust and fumes from pulverizing PVC regrind
Customer: PVC recycling for door and window frame industry
The Challenge: Due to rigid air quality control guidelines set by the state of Nevada, our customer’s facility expansion plans, which included pulverizing PVC regrind that they produce, needed a solution to control dust and fumes created from that process.
The Solution: The customer never had to deal with such stringent air quality control guidelines before, and they needed a guarantee that a dust collection vendor could meet and exceed the Nevada requirements. After meeting with several companies, all of whom could not guarantee results, they contacted Imperial Systems. Upon traveling to their facility in Ohio, Imperial not only guaranteed results but proved it as well. How did they do this?
Jeremiah Wann, President and CEO of Imperial Systems, built a smaller version of the after filter plenum and asked to tie it into the discharge from two of their Pulverizers. “Our main concern was a blue smoke/mist that is created during this process,” says Kurt K., Director of West Coast Operations. Once the filter plenum was connected, Kurt was convinced. “There was no smoke or mist visible, and the odor was gone.”
They purchased a BRF (8BRF 152-10) to handle the collection of the dust and fumes created by the pulverization process. Due to Nevada law, a licensed mechanical contractor had to be used for installation. Imperial Systems sent a technical supervisor to oversee installation, and everything went extremely well.
As far as operation results? “It has performed exactly as we were told it would,” says Kurt. “The system has been in operation for over a year now, and there is no hint of dust or fumes from the system’s discharge.”
Kurt recommends Imperial Systems to anyone that has dust and fume issues. “Our collector has done exactly what Imperial said it would do, and in business, that is the bottom line.”
He also had this to say about the level of service he received from the Imperial Systems team. “I have been very satisfied. Everyone I had dealings with has been helpful, knowledgeable and pleasant. Imperial worked everything out to my satisfaction, which made it a good experience overall.”
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by Greg | Jun 4, 2015 | Case Studies
Product: CMAXX (CM-016) Application: Cement
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Imperial System’s CMAXX Dust Collection System helps out a nearby Automotive and Construction Chemical Plant.
The subject of this case study is one of the largest manufacturers of industrial, automotive, and construction specialty chemicals. The company focuses its products into markets such as: concrete, waterproofing, roofing, flooring, and industrial manufacturing. They distributes their chemicals to businesses such as Home Depot as well as contractors, auto manufacturers, and other industrial companies.
Challenge:
After experiencing industrial hygiene and reliability issues with the prior dust collection system, this company sought to find an industrial dust collection manufacturer the company could build trust with.
The goal was to find a responsive company that packages both great customer service as well as having a dust collector with reliability traits and easy to maintain service. Imperial Systems CMAXX Industrial Dust Collector fit the bill.
Solution:
Beginning their search with local distributors, they reached out to a few companies that ultimately did not have neither the knowledge nor the dust collector the company wanted to put their long term trust into. After reaching out to a mutual distributor that both Imperial Systems and them have a relationship with, the group was were blown away by Imperial System’s CMAXX Industrial Dust Collector.
Ultimately what sold the job was not only the design and style of the CMAXX Industrial Dust Collector, but the responsiveness and personal interactions that they valued so much.
Results & Benefits:
According to the plant engineer, the CMAXX is running flawlessly and has improved efficiency and air quality around the shop.
When asked “What the benefits they experienced from working with us is?” the response was simply, “Improved operations and an ongoing partner. The CMAXX is easy to use, reliable, and has saved us energy costs while enhancing our clean-air recovery”.
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by Greg | Mar 3, 2015 | Case Studies
Product: CMAXX (CM-010) Application: Plasma Cutting
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Fed up with their Horizontal Cartridge Collector, the World’s Largest Manufacturer of Sawmill Equipment Makes the Switch to a Vertical Cartridge Collector.
A few fires, poor production, and strict OSHA guidelines will cause any company to rethink their current dust collection and safety solutions. Thankfully, Imperial System’s CMAXX Dust Collector was able to live up to being one of the most user-friendly and advanced technological Industrial Dust Collector in the business.
As the world’s largest manufacturer of recycling and sawmill equipment, and a distributor to major national cities, logging and sawmill industries, the demand for equipment is constantly in the fast lane. The company manufactures 95% of its equipment in-house and employs over 350 welders to work shifts 10 hours a day/ 5 days a week.
Originally, Morbark had purchased a dust collector that housed horizontal cartridge filters to clean-up their shop’s plasma cutting and weld dust, but the horizontal filters had been trapping burning embers on the filter media; resulting in multiple fires.
Multiple dust collector fires and changing OSHA guidelines were the driving force behind the company seeking out a new, more advanced, dust extraction system for their plasma cutting table.
“When the rules changed and you were not allowed to blow plasma dust outside, we couldn’t use a water table because they did not work for our application. 95% of parts are manufactured in shop – so getting rid of the waste and scrap is one of the biggest challenges we have – we needed to get a dust collector that could work with our plasma cutting table.”
When researching multiple dust and fume extraction companies, Dave, the maintenance manager, had three main goals in-mind he wanted the company’s new dust collector to accomplish:
1. Reduce the tedious filter-change out process
2. Find a dust collector that would lower the chance of another fire.
3. Find an efficient dust collection solution that would help save the company money and reduce downtime.
After hearing about Imperial System’s through the company’s laser cutting table manufacturer, Dave knew Imperial could get the job done. Dave went ahead and purchased a CMAXX, model number CM-010, to clean-up his plasma cutting dust.
1. Simplicity of Maintenance
Using the CMAXX’s filter removal tool, as well as the system’s Even-Lock Technology, the maintenance manager has had a much cleaner and faster experience with changing filters in his new dust collector compared to the previous solution.
“When changing filters on our old dust collector, there were 12 different holes I had to unbolt just to change one filter. So simplicity of maintenance was huge and the CMAXX has delivered.”
2. Drastically Decrease the Chance of a Fire with Vertical Cartridge Design
The CMAXX’s vertical cartridge design and Pulse Distribution Technology allows for the dust to pulse off 100% of the filter media from the vertical cartridge filters and easily fall into the hopper.
3. Less downtime means more money
Due to the CMAXX’s simplicity of maintenance and 100% pulse cleaning on each filter, the CMAXX is able to clean more efficiently while drastically reducing the downtime of filter change-outs.
Imperial System’s vertical style CMAXX Dust Collector was able to get the job done at the manufacturing shop. In fact, to ensure there would be no chance of a fire, the company also purchased a Spark Arrestor from Imperial System’s to extinguish the sparks before ever entering the dust collector.
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