COMPOSITE MANUFACTURER
solves current problem with a dust collector

Spaulding Composites Co., Inc. produces composites and high pressure laminates for markets including power generation, electrical distribution, cryogenics, aerospace, health imaging and water purification. The company's material and glass bonded ceramic divisions also produce high pressure laminates including glass/epoxy, paper/phenolic, canvas/phenolic and carbon/epoxy. ISO 9002 certified, Spaulding has had a long-standing, airborne dust concern which was at least partially solved by the addition of three bag house dust collectors in the 1970's. While this system was originally sufficient to draw from all areas exhibiting airborne dust, the need for more up-to-date machine tools, particularly a Fadal vertical machining center, would obviously create a problem which could not be solved with the existing dust collectors.

The fully enclosed Fadal machine would create enormous quantities of fiberglass dust which should be drawn directly from inside the machine tool and, if possible, be strong enough to collect from two CNC machines as the company was planning to add another machining center. Spaulding asked Clean Aire Technology to review the dust problems associated with the new machine tools. Realizing that a high efficiency cyclone dust collector with afterfilter bags is better suited for separating or filtering large particles, such as fiberglass, than a filter-type dust collector alone, the consultant suggested a Sternvent model CYA2407 high efficiency 7.5 hp cyclone dust collector with two capture arms,  silencer, and a 383 square foot afterfilter to allow recirculation of the filtered air. The cyclone would be installed inside the plant in reasonable proximity to the first new machining center and estimated to gather five pounds of fiberglass dust per shift. More than double that amount would probably be collected when the two machine tools are installed and operating on their own multi-shift schedule.

The operation of the first Fadal machine has been clearly enhanced by the Sternvent dust collector which will have the capacity for doubling its dust capacity with only another stretch of piping to the proposed new machine. According to Michael Harmon, manufacturing engineer at Spaulding, "The dust collector is a good fit next to the Fadal machine and fits in well with other equipment which do turning, milling, punching, progressive dies and more. It allows the new production machinery to run at full capacity without added airborne dust capacity."

Sternvent specializes in small to medium size industrial dust collectors which include high efficiency cyclones, compact shaker units with manual or motorized shaker, Jet-Pulse bag and cartridge units and oil mist collectors used in the woodworking, metalworking and chemical industries. Equipment is available with basic modifications such as special filter media, alternative blower, special height dust containers and special constructions such as stainless steel.

Sternvent Co., Inc.

GAUGE PRESSURE SWITCH
provides cost savings to open storage tank operators by performing multiple tasks

The Problem

Fluid tank operators can utilize a float and gauge combination, or a transmitter to obtain a continuous reading of open storage tank levels. While a simple gauge may be less costly and good for providing a local reading, a much more expensive transmitter is often necessary in order to monitor levels from a remote location such as a plant's automated control room. In addition, a separate control is required to signal when the fluid level is near-empty or near-full.

Combining the local and remote readout functions of a gauge and a transmitter, with the capacity of a switch in a single control can yield significant cost reductions for multiple open storage tank operators.

The Solution

United Electric Controls' One Series gauge pressure switch is ideal for measuring and maintaining levels in open storage tanks and vented reactor vessels. The pressure generated by the 'head' or height of fluid above the instrument (value 'x' on diagram), is converted to a digital readout displayed on the electronic device. For maximum accuracy the instrument is located as closely as possible to the bottom of the tank, as any height of fluid between the instrument and the bottom of the tank cannot be measured (value 'y' on diagram). The measurement readout can be expressed in psi or water column measurement units. In addition to the local indicator, the One Series' 4-20mA output also provides constant remote tank level readings when linked to a PLC or DCS.

Alarm and shutdown functions are also performed by the ONE Series to signal near-empty/near-full conditions using the integral switches. The ONE Series Dual control provides two set points for signaling both hi and low tank levels. In the absence of a PLC or DCS the switch acts as a stand-alone level controller by cycling a filling pump and/or opening a drain valve to maintain a certain level in the tank.

The Result

Ultimately, the ONE Series performs multiple tasks that would normally require a variety of mechanical and/or electronic devices. By using this control tank operators obtain: the alarm and shutdown functions of a traditional pressure switch, the local measurement indication of a gauge and the remote monitoring capacity of a transmitter all in one easy-to-use electronic device which presents a cost savings for open storage tank operators.

United Electric Controls (Canada) Ltd.

PLASTICS MANUFACTURER
improves absenteeism and IAQ with new HVAC retrofit

Hi-Tech Plastics has a loyal work force, but even the most dedicated employees were tested on 90°F-plus summer days when humid, sweltering outdoor air mixed with intense interior heat produced from injection molding plastics machinery used in producing high quality injection molded tool handles.

In fact, the 64,000-square-foot plant had even sent workers home on several unbearable afternoons when interior temperatures surpassed 100°F. Such work conditions and absenteeism typically result in reduced productivity and lower profits. "Other plants in this area had been faced with the same problems of absenteeism, lower productivity and worker morale on hot summer days," said Adam Xenides, project manager, Hi-Tech Plastics. "We wanted to create a facility that supported our core business and added value back to the company -- specifically through energy efficiency, customer satisfaction and operating cost per square foot."

Typically, HVAC engineers remedy this common production plant problem with a chiller, air handler and metal ductwork solution that involves high equipment costs and operating overheads. Mechanical engineer, Smiley El-Abd, P.E., sales/engineer, G.F. Morin Co., had a better idea. Hi-Tech already had a chiller cooling its 18 plastic injection molding machines ranging in size from 200 to 1800 tons in Plant 2. Since the chiller typically was used to only 60 percent capacity, Hi-Tech engineers and El-Abd targeted the remaining chiller capacity to spot cool workers at their 100-square-foot stations instead of cooling the entire plant.

While this method saved the costs of the purchase of a new dedicated chiller and piping to cool the plant, it was Hi-Tech and El-Abd's innovations that made the project successful as well as energy efficient.

Metal ductwork was impractical not only due to high installation and material costs, but also because the metal building roof was already at its total bearing capacity. Instead, fabric duct by FabricAirŪ, which is 90 percent lighter than metal duct, made the project possible because it didn't affect the roof load.

Another factor making metal duct an impossible solution in this project is its immovability. Like many plastics manufacturers, Hi-Tech sometimes moves an injection molding machine into a different location throughout its production line, which may require the disassembling of duct lines. The two lines of fabric duct -- a 292-foot-long (64-inch-diameter) and 256-foot-long (52-inch-diameter) run, can easily be unzipped, capped off and relocated using the in-house plant maintenance staff rather than sheet metal contractors.

The air distribution design doesn't attempt to cool the entire plant, but instead spot cools each operator station with several hundred in-duct, high velocity nozzles each with a 7 to 21-cfm throw of approximately 12 feet.

Using Hi-Tech's existing 200-ton chiller, El-Abd used a pressure independent valve by Flow Control Industries, on the plastic machinery chilled water supply lines to harness and control the excess capacity. Sizing the cooling load of plastic injection molding machines is usually calculated to include the worst case scenario of every machine in production. In typical operating schedules, however, only 60 percent of the machinery is drawing from the chilled water, which is supplied through a pressurized manifold. "What's sent into the air conditioning coil is based on not exceeding the chiller's maximum demand," explained El-Abd. "With a valve that's not pressure independent it's possible to overload or create it's possible to overload or create safety failures on the chiller."

In the event Hi-Tech Plastics ever expands its production line, modular features of the Multi-Stack Chiller allows another 50 tons to be added.

The excess chiller capacity supplies one Rapid Series 4000 make-up air handler with 100 percent modulating outdoor air. Because of the roof's load bearing capacity and the lack of floor space in the plant, the 64,000 air handler was installed outside. The aesthetic 8X8X8 wooden plenum that CT/HX built is covered with aluminum sheeting that feeds the two massive fabric duct trunk lines. Return air is taken from the ceiling area and mixed with cooler outside air before entering the cooling cycle again. Instead of stale indoor air quality that's typically associated with plastics manufacturing plants, workers now breathe a healthy mix of approximately 5.5 air exchangers/hr in occupied zones. Workers are experiencing more comfort as well as an indoor air quality.

FabricAir Inc.

Canadian Industrial Equipment News September 2003

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