ProEnergy’s turbine overhaul and repair facility installs custom dual downdraft tables for weld fume and dust collection
ProEnergy’s turbine overhaul and repair facility installs custom dual downdraft tables for weld fume and dust collection
ProEnergy’s 900,000 square foot corporate campus in Sedalia Missouri provides repair services and manufactures equipment for the power generation and oil & gas industries. After learning about the project Diversitech completed at Dresser Rand in Houston Texas, ProEnergy sought Diversitech’s expertise to develop a similar solution for the reconditioning of turbine blades. The downdraft tables were installed in the turbine services facility where operators repair and refurbish turbines by grinding, deburring and TIG welding various steel parts.
After reviewing ProEnergy’s project requirements, Diversitech’s application engineering department designed a custom downdraft table workstation to accommodate their welders and operators. The downdraft table includes a downdraft and backdraft suction to allow for weld fume and deburring dust to be removed higher from the table surface. The tables incorporate an 8600 CFM 15HP blower with 6 nanofiber filter cartridges to power the dual workstation system.
The downdraft table workstations were ergonomically designed so that operators could comfortably sit at the table with kick space for their legs. Explosion proof light kits were specified for each work cell along with sound attenuation media on the inner walls to reduce noise levels for workers. A blue cushion grid mat was also placed on the surface of the steel bar grating to prevent parts from getting damaged or scratched. 110v outlets were strategically installed on the table to provide power for hand deburring and finishing tools.
Shelving was installed on the sidewalls of the table to provide space for weld consumables and abrasive discs with weld wire and grinder holders. The downdraft tables also included a manual height adjustment feature, to allow for the unit to move up or down for various work pieces and operators.
Diversitech understood ProEngery’s unique application and indoor air quality issues, and designed a system that would fit the operator rather than providing a standard inflexible solution. Our application engineering team is ready to design a flexible cost-effective system for your air filtration application.
GE Aviation’s additive manufacturing facility installs a wet downdraft table to collect 3D printing dust
GE Aviation’s additive manufacturing facility installs a wet downdraft table to collect 3D printing dust
GE Aviation’s additive manufacturing facility in Cincinnati Ohio is focused on producing 3D printed parts for use in advanced turbofan jet engines. One of the parts produced is a 3D printed fuel nozzle, a critical component of the LEAP jet engine. The plant uses a variety of different 3D printing machines including direct metal laser sintering (DMLS), Electron-beam melting (EBM), Selective Laser Melting (SLM) along with other types of 3D printing processes.
These parts are frequently produced from exotic metal alloys including, aluminum, titanium, magnesium, cobalt chrome and stainless steel. In order to prevent fires and combustible dust explosion hazards from 3D printing dust, GE Aviation required a solution that would protect their workforce from the dangers of explosive dust.
Following a site visit by Diversitech’s local representative, a wet downdraft table system was custom designed for their specific deburring and finishing application. The table was divided into 6 workstations, each with a work area of 32” deep by 42” wide with side and back walls and middle dividers to contain the airborne dust. The tables were ducted to two W5000 CFM wet dust collectors with dual silencers and hydrogen vent fans to exhaust flammable hydrogen gas produced as the metal dust oxidizes in the collector’s water reservoir.
The downdraft table was ergonomically designed so that operators could comfortably sit at the table with kick space for their legs. Explosion proof light kits were specified for each work cell along with sound attenuation media on the inner walls to reduce noise levels for workers. A blue cushion grid mat was also placed on the surface of the steel bar grating to prevent parts from getting damaged.
Diversitech’s application engineering department is capable of providing a tailored solution for your 3D printing finishing dust collection application and can custom design a downdraft table work area to meet your specific needs. Companies know that combustible metal dust is a serious workplace hazard and that employees and property need to be protected from the risk of dust fires and explosions. Diversitech has the experience and the team to design the right dust collection system to suit your specific needs.
GE Energy seeks aluminum dust collection systems
GE Energy seeks welding fume extraction and aluminum dust collection systems
GE Energy’s 750,000 sq ft manufacturing plant in Salem, Virginia is dedicated to manufacturing turbine components and control equipment for the industrial and power industries. GE required a solution to capture toxic hexavalent chromium fumes generated from their stainless steel welding process. The grinding and deburring of various steel and aluminum components created an airborne aluminum dust hazard which required the use of both dry and wet dust collection equipment to eliminate airborne particulate in the facility. GE’s dedication to workplace safety and a clean environment has ensured that welders and operators are protected from welding smoke and aluminum dust.
Diversitech’s local sales representative visited the facility, and met with the maintenance supervisor in charge of the project. Measurements were taken to determine the correct size of the equipment for the project and all applications were analyzed by Diversitech’s applications engineering group to propose the optimal solutions for GE’s hexavalent chromium and aluminum dust collection requirements.
After careful analysis of GE’s steel grinding and deburring areas, Diversitech proposed four 5′ x 10′ downdraft tables equipped with electronic height adjustment system, able to support 2000 lbs of weight (1000 lbs table and 1000 lbs part). This system allowed operators to work at the best working height depending on the part size and operator height. The table also included a start/stop floor sensor mat to ensure energy efficient usage as the table shuts off when the operator moves away. The Optiflow grating option permitted operators to channel airflow only onto areas where they were working for better suction and a minihelic gauge provides a visual indication for when it is time to clean or replace filter cartridges. The downdraft also included dual high efficiency 99.99% @ .3 micron HEPA after-filters to eliminate all particulate from the air stream.
For the aluminum grinding area, Diversitech devised a wet type dust collection system to protect operators from airborne aluminum dust which can be flammable or explosive when presented with an ignition source. Two 5×5 tables were butted together to create a 5’x10’ ducted downdraft table connected to two 5000CFM wet collectors.
The wet downdraft table included a manual height adjustment system with a 10” range, operated with a manual crank shaft connected to 4 pistons on each table leg. The table also included a start/stop mat to allow seamless operation.
GE controls and power electronics also purchased 4 FRED 01-Ts for their stainless steel welding stations, and a FRED CV6 cartridge dust collector for a spot welding table. In order for GE to weld very large parts, Diversitech designed a 10’ x 10’ x 8’ galvanized welding booth with an eight cartridge environmental booth collector. The booth included fluorescent dust tight light kits, motions sensors and antiflash welding curtain to enclose the booth. Diversitech was able to offer a full line of turnkey air filtration solutions for GE’s welding fume and dust collection needs by custom engineering the correct equipment for their applications.
Héroux-Devtek streamlines capture of aerospace combustible dust
Héroux-Devtek streamlines capture of aerospace combustible dust
Héroux-Devtek is a tier-1 manufacturer of aerospace components with facilities in Montreal, Toronto, & Kitchener - Canada, and in Cleveland & Springfield, Ohio. The Landing Gear Division asked us to review their titanium and magnesium deburring workstations, and advise on how to reduce any risk of explosion or fire.
The challenge at hand was to safely capture the combustible dust emitted during component finishing, in a facility that was extremely limited by space. The small footprint excluded any typical wet dust collection equipment. Héroux-Devtek had been using several small dry downdraft tables, but there was a concern about the possibility of a filter cartridge fire.
Héroux-Devtek’s application clearly called for a customized Monsoon Wet Downdraft Table, so our engineers set out to learn more about how the operators would be interacting with the equipment
Their first priority was operator health and safety. The Monsoon’s wet filtration system immediately helps mitigate the risk of explosion or fire from combustible dust. We added an auto wash-down spray kit that actively rinses surfaces of the table that tend to accumulate dust, and included custom gauges on the inlet/outlet to alert the operator when the filter needs to be serviced.
Héroux-Devtek’s second priority was “ease of use”. We custom installed a thermal motion sensor that detects when an operator approaches the workstation, immediately switching on the machine. When the operator leaves the station, an automatic time delay runs the machine for 30 more seconds, so that all hazardous dust can be sequestered. We also installed a high-power, dust proof, vapor-proof, LED light kit for improved workstation visibility.
We learned that the client had installed improvised tool racks on their old downdraft tables. Understanding this need, we custom installed an air tools shelf, complete with compressed air distribution and an inline filter regulator lubricator. To accommodate left-handed and right-handed operators, we installed the tool rack on both sides of the table.
The Monsoon Wet Downdraft Table is fitted with high-strength, industrial swivel castors as standard, allowing the unit to be re-positioned with ease. To maintain the machine’s mobility with all of Héroux-Devtek’s customizations, we engineered the electrical control panel to run everything on a single input power plug.
The duct muffler silencer was fitted with a custom butterfly damper allowing the machine to either recirculate clean air into the facility or be connected to a central collection system.
Héroux-Devtek’s third priority was “ease of service”. The fact that the Monsoon’s water tree can removed and cleaned without the need for any tools was a significant advantage.
Diversitech’s versatile Monsoon downdraft table platform is compact and self-contained while also allowing for many customization’s to suite various aerospace combustible dust applications. Weather you have Aluminum, Titanium or Magnesium dust to collect, Diversitech’s Monsoon series provides an affordable wet solution while complying with all OSHA and NFPA standards.
Boeing Faces Problems with Deburring Dust Control
Boeing faces problems with deburring dust control
Boeing’s facility in Wichita, Kansas was facing problems dealing with dust control created during deburring and finishing of certain aluminum components. As a premier manufacturer of commercial and military aircraft, it was important to them to find a way to contain the aluminium dust.
The process of deburring aluminum removes sharp edges and excess material from the components being produced.
When we visited the facility, operators were deburring on tables with no ventilation and were forced to wear uncomfortable face masks to prevent dust inhalation.
After careful evaluation, we recommended a 2′ x 4′ downdraft table equipped with extended overhang, lexan side & back walls, and explosion proof motors. The extended overhang table was key to operator comfort, giving them the ability to sit comfortably with legs under the table for an entire shift. The lexan side & back walls were used to ensure good visibility through the facility, and the explosion proof motors were specified to reduce the hazard in the presence of aluminum dust.
After initially installing four of these 2’x4′ extended overhang tables, the staff at Boeing were so pleased with the improved air quality, dust control, and workstation comfort that they requested additional 3’x6′ and 3’x8′ custom downdraft tables for other deburring processes.
