Considerations for the design of industrial ventilation systems

Good industrial ventilation system design includes a wide range of variables, from the type of dust and fumes produced, to the dynamics of the airflow that carries particulates and contaminants throughout the plant. So, for some HVAC systems It can be difficult to properly assess the condition of each of the components.

Industrial ventilation solutions are like technical socks, which are intended to incorporate moisture wicking components, such as cushioned fabrics, and are strategically placed to maximise the structural support of complete industrial ventilation systems according to the specific plant environment.

On the other hand, it is recommended that before starting up and taking over the first fume extraction system for the whole plant, it is important to take into account some considerations during the design of industrial ventilation systems:

1. Ensure that the welder's position in relation to fume creation is taken into account to ensure breathing space protection, which means that the design of industrial ventilation systems should avoid exhausting fumes as they pass near the operator or through the breathing zone.

Note that a fully functional smoke collector with an integrated cabinet, motor blower and particulate containment unit is an indication of a smart design that will be easier to install to achieve its purpose.

2. Design air-to-fabric ratios for cartridge filters, following the rule of thumb, a 3 to 1 ratio of air to fabric. This may seem like a higher cost up front, but smaller filters will wear out at a faster rate, whereas cartridge filters should last up to twelve months depending on the application.
3. Choose an industrial ventilation system design that can automatically monitor filter performance as a way to automate worker tasks when tracking maintenance.

This action will allow the filter to start and stop automatically during operation, while the welder or machine operator is working. Some of the more advanced systems have applications for remote monitoring.

4. The design of industrial ventilation systems must be safe, which requires the inclusion of spark arresters and explosion vent controls, as they reduce the risk of explosion and fire. It is especially important if paper filters are used and where multiple metals are processed.
   Another important safety feature in a dust collector is to use a fire extinguishing system that activates instantly in case particles are accidentally ignited during welding or other operations. The best collectors offer a system that can detect both the presence of smoke and heat. 
5. Avoid having open plant doors and windows dominate the system. Do not consider open plant doors and large windows in the design, they can overwhelm the fume extraction processes, even a light breeze (around 500 feet per minute) can drastically change air circulation patterns.
6. Ensure that the design of industrial ventilation systems processes fumes properly. On average, human welders keep the arc active for 30 per cent of their shift, but that number increases to 90 per cent with robotic systems. Make sure the system is designed to process fume properly.

When evaluating the design of industrial ventilation systems, we should look for those that start and stop instantly while a welder or machine operator is working. The best control systems continuously monitor collector performance, including blower and filter differential pressure.

In addition, they have built-in diagnostic features and track maintenance history to help maintenance and engineering staff create a safer environment and maximise picker performance.

Keeping a check on rising operational costs is an ongoing challenge for everyone in business and filters are one of those costs. Which is why it is necessary for dust collectors to have high quality filter media to help keep a plant cleaner and safer for employees. 

If you want to know 5 ways welding fumes damage the profitability of metal processing plants and understand how good design of industrial ventilation systems can minimize these risks, we invite you to subscribe to the Technology for Industry Newsletter, The newsletter will inform you about new solutions available on the market to optimise your plant operations.