by Imperial Systems | Mar 20, 2017 | Uncategorized
Horizontal dust collectors are popular. They can fit a lot of filters into a fairly small footprint. Manufacturers will tell you that they work better. In reality, horizontal filters and dust collectors have some serious design issues. Donaldson Torit may be one of the biggest names in dust collection. But there are some serious flaws in their collectors. As many owners have found out, it’s a design prone to failure.
Filters in Horizontal Dust Collectors
Donaldson knows well that there’s a major problem with having horizontal filters on top of each other in a collector. They’ve tried everything, from suggesting you rotate the horizontal filters to designing new and weird filter shapes. But they can’t get around one basic problem. It’s the fact that dust that pulses off a filter will land on the filter underneath it. With each compressed air pulse, a shower of dust falls directly down on the next layer of filters.
This problem blinds off a large part of the horizontal filter. To try to decrease the area that blinds, Donaldson has produced oval and now triangle-shaped cartridges with less surface area facing upwards. This still doesn’t solve the basic design problem. It doesn’t make sense to filter dust just to drop piles of dust on top of your filters.
Filters in a horizontal collector cannot work at full efficiency because dust from the layer above them is always partially covering them. Some horizontal collector manufacturers recommend you rotate their filters to keep the side that’s facing up from blinding… but do you want to get into your collector and rotate dust-covered filters on a regular basis?
Yokes and Gaskets
In a horizontal dust collector, metal yokes support the filters. These yokes bolt to the tube sheet on one end. As you put the filters on the yoke, the first one presses back against the tube sheet. The last filter to go in presses against the door when it closes.
There are several places for this arrangement to go wrong.
- The yokes can easily bend while putting filters on or taking them off
- Yokes can pull away from the tube sheet, causing the gasket to leak
- Weight on the yokes can pull on and warp the tube sheet itself, causing more leaks
- The gasket sealing the filter to the door can fail if the yoke is bent
- The gaskets on the door and tube sheet ends, as well as the ones between the filters, provide multiple points of failure and leaks
Doors and Access
If you look at a horizontal dust collector, the first thing you’ll see is an array of doors. They’re usually round, only a little wider than the horizontal filter that goes in them. There are usually many of them as well.
Changing filters, or accessing anything inside the collector, means trying to work through these small round doors. Filters must be pulled off the yoke, and the ones in the back are difficult to reach. There isn’t that much room to reach in or access anything through these small doors.
Comparing a horizontal and a vertical collector, it’s easy to see how all of those small, round doors are a serious design problem. A vertical collector will usually have either one or two doors. When these doors are open, they give access to the entire space inside the collector.
With the doors of a vertical collector open, you can clearly see down into the hopper, and it’s easy to inspect for problems such as bridging. With the small round doors, it’s nearly impossible to see down into the hopper.
Clean Air Plenum Access
Because of the design of a Donaldson collector, there is no direct access to the clean air plenum. There are several reasons this can be a serious problem:
- You can’t reach a leak occurring on the clean air side for repairs
- No way to do routine maintenance or checks in this space
- If a leak lets dust into the clean air plenum, there is no way to access it for cleaning
If one of the yokes gets bent, or for some other reason a gasket seal on the tube sheet fails, dust will get into the clean air plenum.
On a vertical collector like the CMAXX, it’s easy to open the doors, access the clean air plenum, and get rid of the dust.
In a Donaldson or other horizontal dust collector, accessing the clean air plenum often requires a crane to remove ductwork so you can get in and cut an access panel.
If you can’t do that, the dust in the clean air plenum will continue to get blown back into your facility over time. If it’s a health or fire hazard, this is a major issue.
What are the Advantages of Horizontal Dust Collectors?
The major advantage of a horizontal dust collector is the ability to stack filters on top of each other. This can save floor space by making the collector taller instead of wider. This is one of the major selling points of Donaldson Torit and other horizontal collectors.
Besides size, the other advantages usually listed are higher efficiency and less maintenance. These vague statements don’t really tell you much: the horizontal filters in a horizontal collector lose efficiency more quickly than in a vertical one because the tops of the filters blind off.
Also, anyone who has ever dealt with the many gaskets, easily damaged yokes, and tiny access doors might argue about the “less maintenance”. There is less to maintain on a horizontal dust collector because you cannot access most of the collector to do maintenance on it. If you do need to do maintenance or troubleshooting on the hopper or clean air plenum, you won’t have an easy time doing it.
Choosing the CMAXX
A vertical collector like the CMAXX has none of the design flaws of Donaldson Torit and similar collectors. The single gasket where the filter meets the tube sheet greatly decreases the number of places you can get a leak. The clean air plenum and hopper are easy to access.
Everything in a vertical collector is easy to access: with a large door that opens to let you reach all the filters at once, you can easily get to every part of the collector. Filters are supported by sturdy lift rails that hold the filters securely against the tube sheet.
Because the filters in a CMAXX are not stacked on top of each other, dust that is pulsed off drops straight down into the hopper, instead of landing on other filters. The filters maintain a higher efficiency over time.
With all the advantages of a CMAXX, it seems clear that it’s a better choice. The people who may appreciate it the most are the people who have to maintain the system. After all, if you’re trying to fix a problem, you’d probably rather do it through one wide-open access door than through a whole bunch of little round doors not much wider than a filter.
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by Imperial Systems | Mar 6, 2017 | Uncategorized
Check out our first Issue of Dusty Jobs Newsletter. Articles include How to Troubleshoot a Diaphragm Valve Leak and story about a “greenhorn” draftsman.
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Download DUSTY JOBS | Issue 1 PDF
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by Imperial Systems | Feb 16, 2017 | Uncategorized
Hydraulic fracturing (“fracking”) is a process used to extract oil and gas by high-pressure fracturing of rock or shale. Exposure to respirable crystalline silica is a major hazard in this industry. Massive amounts of sand are used in the process, and silica exposure is a constant issue.
NIOSH has identified silica exposure as the single biggest health issue in hydraulic fracturing. Their research also demonstrated that silica levels on these sites are so high that standard respirators are not sufficient for protection. With a 2018 deadline for hydraulic fracturing sites to comply with new OSHA limits for silica exposure, new tactics for silica dust control are needed.
SILICA IN THE HYDRAULIC FRACTURING PROCESS
The hydraulic fracking industry uses huge amounts of sand (silica). Most grains are 2 mm or smaller in size. By some estimates, the average site requires somewhere between 1 and 7 million pounds of sand over its lifetime.
After high-pressure water and chemicals are pumped into the rocks to create fractures, the spaces must be filled with sand to keep them open and allow oil and gas to flow. So much sand is used in this industry that mining and production of “frac sand” has become a major industry of its own.
(Frac sand production: This chart illustrates the spectacular rise in the production of frac sand in the United States. Data from the United States Geological Survey Minerals Yearbook, Silica, 2011)
AREAS OF HIGH SILICA EXPOSURE
image: National Institute for Occupational Safety and Health/Centers for Disease Control and Prevention/OSHA/CDC
Massive amounts of silica move around a hydraulic fracturing site. NIOSH has identified several points in the silica moving process that create the largest amount of silica dust. These areas are:
- Open hatches on sand movers
- Through side ports on sand movers during refilling
- Depositing sand onto transfer belts
- Sand moving on transfer belts between movers, hoppers, and blenders
- Blender hoppers that mix sand
- Accumulated dust stirred up by vehicles driving around the site
NIOSH strongly recommends that engineering controls be put in place to control silica exposure at these points. They emphasize that the silica exposure at these points in the process is so heavy that respirators do not provide enough protection.
HYDRAULIC FRACTURING SILICA EXPOSURE; CONTROLLING DUST ON SITE
In some situations, newer equipment has been designed to minimize silica dust release. In other situations, older equipment can be modified or rebuilt to these designs.
For many companies, especially with the industry still recovering from the severe drop in oil prices several years ago, these expensive modifications aren’t reasonable.
Another option is to install dust collectors directly on the equipment. A collector specially designed for hydraulic fracturing equipment can be fitted on sand movers, transfer belts, and blenders. With these systems installed, the amount of silica dust released is much lower.
Controlling silica release at these points of capture can decrease silica exposure all over the site. With less silica dust escaping, the overall amount of fugitive silica dust around the site is more manageable. This helps with the amount of dust raised by vehicles or wind all over the site.
https://blogs.cdc.gov/niosh-science-blog/2012/05/23/silica-fracking/
http://geology.com/articles/frac-sand/
https://www.osha.gov/dts/hazardalerts/hydraulic_frac_hazard_alert.html
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by Imperial Systems | Feb 8, 2017 | Uncategorized
Lung disease from inhaling sand or rock dust is one of the oldest occupational hazards. The health risks of silica were identified as early as 1700. Silicosis, the incurable lung disease caused by inhaling silica dust, causes hundreds of deaths every year. Other health effects also include liver and immune system diseases. OSHA concluded that the current silica exposure limits were too high after studying the research. So, they needed to set a new silica exposure limit to protect workers.
Some silica exposure still comes from well-known occupations like stone cutting, mining, and drilling. Abrasive blasting with sand is especially dangerous. However, newer industries have created new sources of exposure. One example of this is hydraulic fracturing, or fracking, for oil and gas. Another example is the popularity of natural and manufactured stone countertops. All of these industries must achieve compliance with OSHA’s new silica law to keep workers safe.
How does silica hurt you?
Silica is one of the most common elements on earth. It makes up a major part of sand, rocks, and all products made from those things, like concrete.
The major health risks of silica happen when one inhales it into the lungs. Silica that is small enough to be inhaled is called “respirable crystalline silica” in formal OSHA language. Drilling or grinding creates fine silica dust, and sand is already a form of crystalline silica that can become airborne, especially during blasting or fracking operations.
Developing Silicosis
Silicosis is a disease that causes the biggest concern with silica. The American Lung Association warns about the permanent lung damage that happens with this disease.
Silicosis happens when silica dust damages the lining of the tiny air sacs in the lungs. This injury causes scarring and makes it harder for the air sacs to get oxygen into your body.
Acute silicosis can occur within weeks or months of very heavy exposure. In this case, the lungs respond to the injury by swelling up and filling with fluid. This can be very dangerous and make it very hard to breathe.
Chronic silicosis is the most common kind. The swelling and scarring of the lungs happen over years. Symptoms include coughing, chest pain, and sometimes tiredness and weight loss. The scarring can progress to a condition called progressive massive fibrosis, where the lungs become stiff and full of scar tissue. When the disease is severe, people may need oxygen support to be able to breathe. Silicosis can cause death.
The health risks of silica include other deadly conditions. Silica is a known carcinogen, meaning it causes lung cancer. It also makes you more likely to get lung diseases like emphysema, tuberculosis or bronchitis. NIOSH, the research arm of OSHA, reviewed all of the studies on silica exposure and wrote a detailed report on it.
How can the health risks of silica be controlled?
OSHA recommends that the first line of defense is replacing silica with safer materials. This isn’t always an option. Replacement products may be expensive or just not available. Silica is common, cheap, and stable, which makes it hard to replace.
The second line of defense, and usually the best option when possible, is using engineering controls. A popular engineering control is a dust collector. A dust collection system removes silica dust from the work area and safely captures it for reuse or disposal. Just venting the dust out of the work area means that it ends up somewhere else, and that can be a problem.
A dust collector filters silica dust from the air. The dust drops into a hopper for safe handling. The air can be returned to the work area. The system can clean a large area and keep an entire facility free of silica dust.
Dust collectors can also be installed on equipment such as sand trucks or conveyors to control silica dust when moving sand around. This is important in fracking applications.
In situations like construction or drilling, the best solution may be a NIOSH-certified respirator. Because respirators are uncomfortable and difficult to fit correctly, they are not the ideal solution. Sometimes, though, they are the only option. If you must wear a respirator to protect you from the health risks of silica, make sure it is NIOSH-certified for the job you’re doing, and make sure it fits correctly.
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by Imperial Systems | Jan 19, 2017 | Uncategorized
The CMAXX for managing weld smoke on display at FABTECH 2017. This install is showing an ambient filtration method.
Managing weld smoke risks means dealing with very small particle sizes, toxic metals, and the combustibility of metal dust. Weld smoke is different from other types of dust, requiring a system design to deal with it. A CMAXX dust and fume collection system will meet any metalworking or weld smoke control needs.
Managing Weld Smoke for Health
One of the risks of weld smoke is hexavalent chromium. That’s because this compound can cause skin sores and lung damage, and cancer of the lungs, kidneys, and other organs. Many metals have chromium alloy to make them corrosion resistant.
Most of the particles in welding fumes come from the welding wire, but some of them come from the welded material. Some of them can cause allergic reactions and an immune response called “metal fume fever.” Lead and manganese can damage the brain. Further, others like hexavalent chromium and nickel, are carcinogens and can increase your risk of cancer.
Welding fume particles are extremely small. Most are smaller than one micron. This means they are small enough to get inside human cells and cause damage. This also means that welding fumes are lighter than air, especially when heated. So, a system for managing weld smoke and collecting these fumes requires a design to handle very small particles.
Managing Fire And Explosion Risk
Welding produces metal dust and gases that may be combustible. Some metals, such as aluminum, are very explosive in dust form. Almost all metal dusts have the potential to explode. Handling welding fumes means using appropriate fire suppression and prevention measures.
Installation of a Spark Arrestor (or Spark Trap) in a maintenance weld shop.
Suppressing sparks to keep them from getting into the collector can help prevent explosions from welding smoke dust. Spark Arrestors are certainly important in keeping most sparks from getting to the collector. Also, an explosion isolation valve can prevent a fire from traveling back through the ductwork. Chemical control systems can suppress or extinguish a flame, but only certain chemicals are approved for fires involving metal dust.
Filters can also be important for fire suppression in a welding smoke system. Filters with a fire-retardant coating will resist burning and help control deflagration. Some collector designs have filters that help isolate an explosion and keep it from causing damage inside the workplace. DeltaMAXX filters with a fire-retardant coating will prevent a fire from occurring inside a dust collector.
Handling Weld Smoke
Figuring out what type of fume extraction system to use in your facility is an important decision for managing the risks from weld smoke. Our systems engineers will consult with you to help you determine the best way to manage your weld smoke risk.
Shadow portable weld fume collector at FABTECH 2017. Designed for managing weld smoke
If there are not very many welders and they don’t always work at the same place, portable collectors can be a solution. They can be useful for handling point-of-source capture. An ambient system design moves a volume of air out of a large area and through filters.
For managing weld smoke, portable collectors are easy to move around, but they are not as powerful as larger collectors. Central collectors are the most efficient for large areas, but if they are inside they take up floor space. We recommend locating the collector outside for safe explosion venting.
One of the biggest advantages of an ambient system that recirculates the air back into the facility is energy cost savings. When heated or air-conditioned air is vented outside, the energy used is lost. Many businesses find that a fume collection system can pay for itself within two years with the money saved in energy costs.
CMAXX dust and fume collectors have proven themselves in the welding and metalworking fields. Our newest product, the SHADOW portable collector, gives you even more options for managing weld smoke. DeltaMAXX nanofiber filters are the best available material for capturing metal fumes. At Imperial Systems Inc., we are committed to helping you control your weld smoke risks.
(as seen in The Fabricator Magazine)
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by Imperial Systems | Jan 12, 2017 | Uncategorized
You know we manufacture our DeltaMAXX™ filters for our own dust collectors. If you’re looking for replacement dust collector filters and you own a collector made by another manufacturer, you should know that some of our top-selling filters are replacements for the other guys’ OEM filters!
Why People Buy DeltaMAXX Replacement Dust Collector Filters Instead of OEM
Basically, a cartridge filter is a cartridge filter. There’s nothing magical or special that makes one company’s filters superior. As with any product, there are different levels of quality. Choosing a manufacturer who makes a quality product instead of junk is always going to be important.
So let’s assume that most of the big-name OEM companies, like Donaldson Torit, Robovent, and Camfil Farr, make a quality filter. You own one of their collectors, and you’re putting their filters in it. Why would you think about switching?
Here are three good reasons:
- Isn’t that always the best reason? Our replacement dust collector filters are guaranteed to perform as well as, or better than, your OEM filters. And almost everyone who comes to us for replacements finds that our prices are better.
- NO GIMMICKS. We don’t play games with filter gimmicks. Drug companies that keep releasing “new and improved” versions of the same medication so they can keep their patents. Some OEMs try to do the same thing. Weird new shapes, cool-looking inserts, special new gaskets. Do you really need any of them? Probably not.
- Getting a good price doesn’t help if the filters aren’t as good. That’s why our guarantee promises you that while we’re beating your OEM’s price, you’re not sacrificing filter quality.
If you’re looking for replacement dust collector filters, it’s worth your time to get a quote from us. We make replacement dust collector filters for almost all manufacturers, including:
- Donaldson Torit
- Camfil Farr
Filters come in many shapes and sizes. These are a few of those replacement options
- Robovent
- Clean Air America
- TDC
- Lincoln Electric
- Mac
- Chemco
- Nordson
- Environmental
- Micro-Air
- Many others… just call us and ask!
How to Get a Quote On Replacement Filters
It’s easy to get a quote from us on filters made by most other manufacturers. Our specialized cross-matching system will match the part number you usually order with the right filter.
Don’t have a part number? We can still help you. Call us or send an email, and we’ll talk you through the measurements we need to get you a match.
Replace dust collector filters for Donaldson Torit round and oval cartridge filters
Have filter problems?
Sometimes the wrong kind of filter won’t work for some applications. For example, if you have moisture damaging your filters, you may need a spunbond material that can resist water. If you’ve experienced a fire in your dust collector, it’s definitely worth investing in some fire-retardant filters. If your regular 80/20 filters are getting plugged up with dust after only a few months, you might want to try a nanofiber filter that will collect smaller particles.
Whatever problem you might be having, we can help. Talk to a filter expert right now on Live Chat (during normal business hours) or fill out a contact form!
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