52nd North Carolina Industrial Ventilation

Conference

Have you ever heard this from

plant operations?

Monitoring & Maintenance of “The new local exhaust

Ventilation Systems, ventilation system we started up
Part
P t I (MM
(MM--1-1) a month ago doesn’t work!
Engineering didn’t design it
NC Industrial Ventilation Conference
Raleigh, NC – April 2010 right!”

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Tips to Prevent this Problem

at Your Site
Where Do You Start?
 Broadly, are system problems due to
 Where do you start?  Original design?
 Why IVS fail  System modified without redesign?
 Poor operating
p g practice?
p (ie,, adjusting
(ie j g blast
 Common failure modes for gates)
 Hoods  Little or no system monitoring &
 Ducts maintenance?
 Fans  Getting started
 Define the problem areas & symptoms
 Collectors – Tuesday
 Gather visual and measurement data on
 Ventilation System Measurements system
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Defining the Problem Data Gathering - Qualitative

 Observable Symptoms?  Original system design work as intended?

 Qualitative (visible, olfactory, etc.)
 Quantitative symptoms (air samples)
 Operator complaints
 Specific locations affected?
 Reasons, frequency of equipment entry?
 One hood/enclosure?
 Multiple hoods/enclosures?
 Nowhere near a hood/enclosure?
 Design basis for each hood/enclosure
 System layout and schematic
 System Baseline airflows and static pressures
 System IH Evaluation at startup
 Problem area data today?

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Data Gathering – Qualitative, 2 Data Gathering – Qualitative, 3

 Operating practices?
 System modification without redesign?  Designated system owner
 Site have a Change Management System with  Operators (line and IVS) trained
IVS knowledgeable people part of the  Blast gates locked or adjusted whenever anyone
process?? wants
 Compare original schematic to as installed  Monitoring & Maintenance?
 Visual clues if no documentation  System Baseline Documentation available as
reference for M&M
 Problem area data today  Installed monitoring devices or routine system
wide data gathering
 Breakdown or predictive maintenance
 Recent maintenance on system
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Data Gathering - Quantitative Data Gathering – Quantitative, 2

 Hoods/enclosures  Ducts & Fans

 Duct layout – diameters, lengths, types of transitions
 Measure area of opening at junctions
 Measure
M average face
f velocity
l it across  D t conveying
Duct i velocity
l it and d static
t ti pressures
opening  Fan shaft speed, motor amps

 Process at hood cause interference?

 Air cleaning device
 Differential pressure
 External air currents?
 Operating at base condition?

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Causes of IVS Failures Causes of IVS Failures

Sudden Failure Modes – major airflow reduction Gradual Failure Modes

 Broken fan belt  Dust buildup in elbows

 Water in baghouse  Dust erodes holes in ducts
Increasing filter differential
cleaning compressed air 
pressure
 Bag sucked into duct  Bag cleaning system
Moisture sensitive dust
Baghouse dust removal


 Slipping fan belts
system backs up into  Dust visible in exhaust
baghouse  Duct gaskets or access door seals
leaking audibly
 Explosion vent opens

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Causes of IVS Failures – Gradual Failure Causes of IVS Failures – where in the system?
Collector High Differential Pressure Branch versus System failure?

 High bag differential

pressure due to Branches - Localized impact
improper bag  Dusting at some hoods
conditioning (seeding)  Poor suction some hoods, harder suction at
at startup of new bags other
th h hoods
d
 Filter and fan not obviously affected
 Scrubber venturi
plugging another
example
System-wide
System-
 No or low airflow

 Similar effects seen at all branches

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Causes of IVS Failures Causes of IVS Failures

Change - Add a duct branch/hood Change – Remove a duct branch/hood

ID D, Q, V, VP/
inches CFM fpm 100’

A 8 1500 4200 3.4

A
B 8 3000 8400 13

B C 8 4500 16800 350

C
Impossible conveying velocity
Rough Rule of Thumb: Don’t blank a branch like these. It starves
requirements that fans cannot
Downstream duct diameter2 ~ sum of airflow and velocity downstream causing
deliver. Only option with this
squares of upstream duct diameters dust dropout.
duct is branch ON/OFF
82+82 = 128 ~ 112 or 121 procedure – good luck! Unless duct changed, bleed air equivalent
112+82 = 185 ~ 142 or 196, ~ 132 or 169 on removed branch.
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No Documented Proof of Causes of IVS Failures - Changes to

Performance Calculated System Resistance :

Baseline  Dust plugs ducts, elbows first - more resistance

Performance Criteria:
•Airflow: + 10 % design  Baghouse filter media blinds - poor startup seeding
•Pressure: + 20% baseline  Bags bridge in filter - dust removal failure or filter design
•All duct branches incorrect for particulate collected
 A
Access door
d left
l ft open – bypass
b duct
d t network
t k
Turnover document -
 Fan belts wear and slip
engineering to operations along
with air monitoring results  Balancing orifices or blast gates removed/changed
 Unauthorized changes to system
 Design not robust enough to minimize duct plugging
 Proof of performance not measured or documented
ISOMETRIC VIEW
- OPERATOR FRIENDLY
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Causes of IVS Failures – Lack of IVS Operating Skills

Management Support
Needed
 Lack of management ownership and support  5 functional levels of increasing skill
General Awareness
 No one accountable for system operation 

 User
 No trained personnel on site
 Operator
p
 C
Cannott gett d
downtime
ti tto clean/maintain
l / i t i system
t
 Troubleshooter
 No system in place to ensure changes done by  Change Reviewer
competent resources
 Site complexity and risk assessment determines
 Breakdown rather than predictive maintenance –
Working Harder, Not Smarter job description and number of people trained at
each level

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Summary

IV Systems degrade and stop performing

Hood/Enclosure Failure

without maintenance due to



Physical reasons
Management reasons Modes
 Predictive M&M is “Before the Fact” control of
exposures
 Staff for success, but keep looking for the best
value
 Best to work with Baselined IVS

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Key Principle for Open Hoods

Open Faced Hoods Flow Rate as Distance from Hood

OBJECTIVE: CAPTURE
 Dust source between
person and hood
 Protection is general air
movement into hood
 Low air velocity must pull
dust into hood
X times
ti 2  Q times
ti 4
 Airflow requirement
increases with distance
 Welding hoods, simple (move hood away and performance drops)
“elephant trunk” hoods

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Capture Velocities – factors to

Capture Velocities decide upper or lower end of range

Dispersion Example Capture Velocity,

Lower End of Range Upper End of Range
Conditions ft/min
 Room air currents minimal  Disturbing room air
Release with practically Evaporation from tanks; 50 -100 or favorable to capture currents
no velocity into quiet air degreasing, etc.
 Contaminants of low  Contaminants of high
Released at low velocityy Spray
p y booths;; intermittent 100 - 200
toxicity or of nuisance toxicity
into moderately still air container filling; welding;
plating; pickling value only
Active generation into Spray painting in shallow 200 – 500  Intermittent, low  High production, heavy
zone of rapid air motion booths; barrel filling; conveyor production use
loading  Large hood-large air mass  Small hood-local
Released at high initial Grinding; abrasive blasting; 500 - 2000 in motion control only
velocity into zone of very tumbling
rapid air motion
Table 6-1: From American Conference of Governmental Industrial Hygienists (ACGIH®), Industrial Ventilation: A Table 6-1: From American Conference of Governmental Industrial Hygienists (ACGIH®), Industrial Ventilation: A
Manual of Recommended Practice for Design, 26th Edition. Copyright 2007. Reprinted with permission. Manual of Recommended Practice for Design, 26th Edition. Copyright 2007. Reprinted with permission.

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Hood Shape and Distance Hood Calculations - Math

Determine Required Airflow Review

 Continuity Equation:
Q = VxA = V1xA1 = V2xA2
Q-ft3/min, V-ft/min, A-ft2

 Duct Area:
A = pi x radius2 = pi x (diameter/2)2
A=3.14x(D/2)2x(1 ft/12in)2 = pi x D2/576

 Velocity-Velocity Pressure:
V = 1096x(VP/df)1/2 = 4005x(VP)1/2 (sea level)
Fig. 6-11: From American Conference of Governmental Industrial
or VP = (V/4005)2 (VP-inches water column)
Hygienists (ACGIH®), Industrial Ventilation: A Manual of
Recommended Practice, 26th Edition. Copyright 2007. Reprinted
with permission."

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Calculate Hood Face Velocity Hood Face Velocity Solution

 Find Vduct
Vd = 4005x(1.1)1/2 = 4200 ft/min
 Find Aduct

Ad = pi x (4)2/576 = 0.087 sq.ft.

 Find Ahood

Ah = 4”x10”x(1 ft/12”)2 = 0.278 sq.ft.

 Calculate Vhood

Vh = Vd x (Ad/Ah)
= 4200 x (0.087/0.278) = 1315 ft/min

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Calculate Hood SP Calculate Hood SP

1. Find duct VP

2
2. Find entry loss coefficient for shape

3. Find acceleration loss

Included angle = 90o

4. Calculate Hood SP
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Hood Entry Losses – Shapes Hood Entry Losses - Transitions

Fig. 9-a: From American Conference of Governmental Industrial Hygienists (ACGIH®), Industrial Ventilation: A
Fig. 9-a: From American Conference of Governmental Industrial Hygienists (ACGIH®), Industrial Ventilation: A
Manual of Recommended Practice for Design, 26th Edition. Copyright 2007. Reprinted with permission.
Manual of Recommended Practice for Design, 26th Edition. Copyright 2007. Reprinted with permission.

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Using Hood Static Pressure (SP

(SPh) for
Calculate Hood SP Monitoring

1. Duct VP = 1.1”w.c. (diagram)  Every hood has a specific SPh based on its shape
and the airflow through it.
2. Entry loss = 0.25 x VP  SPh values can be found in Industrial Ventilation,
3
3. Acceleration loss = 1 x VP A Recommended Practice
4. Hood SP  SPh values can be measured in the field at
startup
= acceleration loss + entry loss  Local SPh indication (Magnehelic or manometer)
= 1VP+0.25VP=VP(1+0.25) provides operator warning of IVS problems
=1.1x1.25 = 1.4”w.c.
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52nd North Carolina Industrial Ventilation
Conference

Uniform Velocity Profile Techniques to

Open Enclosures Get Equal Air Path Lengths

OBJECTIVE: CONTAIN Bag dump open face Internal

enclosure baffle
 Person in front of cabinet, dust
inside cabinet
 Protection: low velocity inward
air
i movementt
 Avoid giving particle escape
velocity from process or manual
handling procedure Air inlet from
back – equal air
 Bag dumps, super sack dumps, path lengths also
possible – decide
dump cabinets Air inlet from top – unequal air paths => Baffle moves air inlet to back wall – equal
poor face velocity profile (arrow length) air path lengths & velocities based on layout

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Uniform Velocity Profile

Slots
Hood opening: 60” x 60”
3 slots, 2”x 36”
Duct diameter 12”
12
Rectangular to round duct
transition 120 degrees
Sealed Enclosures
 Contaminant totally surrounded by
enclosure
 Protection: negative pressure and
inward air movement
 Low air velocity at access openings
 A id enclosure
Avoid l positive
i i pressure -
dusting
 Examples: belt conveyor housings,
bins, Loss In Weight bins
 Need air bleed to maintain duct
conveying velocity

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Air Bleeds – Maintain Duct Conveying Biggest Hood & Enclosure Failure
Velocity with Sealed Enclosures Cause: Room Air Currents

Good Air Bleed

Design

High velocity
HVAC diffusers

How does air get Pedestal fans

into the duct? Open windows
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Face Velocity Impact: Other Hood/Enclosure Failure

Unauthorized Changes Modes

 Open hood moved out of position

 Excessive particle momentum
 Face velocity too low to stop high energy particles
 Process design steps to slow particles
 Poor face velocity profile
 Unequal air paths
 External air currents
 Changing hood airflow
 Physical changes to hood (ie, dust buildup inside, etc.)
 Connected IVS degrades
 No air bleed on sealed enclosure
 HVAC Supply insufficient
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Hood Maintenance Hood Maintenance, cont.

 Visual Checks  Things that can

 React to visible emissions to room change airflow:
 Check for hood modifications  Dirty screens
 First line of defense – monitor air  Deposited
flow contaminants in
plenum behind
 Install Hood Static Pressure gauges hood opening
with action limits (+ 20% Baseline)
 Bypassing thru
OR open access doors
 take routine Face Velocity
 Hood face
measurements modifications

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Duct & Fan Key Duct Design

Failure Modes Principles
 Round ducts preferred
 Smooth duct interior, not spiral wound
 Adequate conveying velocity - ALL BRANCHES – target +
10% design
 Elbow radius 2.5 R/D mitered or 2.0 R/D smooth is best
to minimize duct fouling
 Merge two dusty streams at angle appropriate for dust
properties
 Balance and Baseline systems to prove you got what you
paid for

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Conference

Design Principles - Duct Range of Minimum Duct Design

Sizing Velocities
Size Ducts for Conveying Velocity Range
Nature of Examples Minimum Design
Dust Control Systems: 3500 to 4500 fpm.

Contaminant Velocity, fpm
Aerosol or other small particle Control Systems:
 Vapors, All vapors, gases, smoke Any desired velocity
2500 to 3500 fpm. gases, (economic optimum
Q smoke
k velocity
l it usually)
ll )
A   ( D 2 / 4 )(1 / 144 )   D 2 / 576  where : 1000 - 2000
V
A  cross - sectional area of duct (ft 2 ) Fumes Welding 2000 – 2500
D  duct diameter (inches) Very fine Fine rubber dust, Bakelite molding
3000 – 4000
powder dust, jute lint, cotton dust,
light dust
shavings (light,) soap dust, leather
Q  airflow (ft 3 / min) shavings
V  air veloci ty in duct (ft/min) Table 3-1: From American Conference of Governmental Industrial Hygienists (ACGIH®), Industrial
Ventilation: A Manual of Recommended Practice, 25th Edition. Copyright 2004. Reprinted with permission.

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Range of Minimum Duct Design Duct Conveying Velocity Changes with

Velocities Diameter
Nature of Examples Minimum transport
contaminant velocity, fpm Find V & VP
Q=VA=VAAA=VBAB, VB=VA(AA/AB)
Average Grinding dust, buffing lint (dry), wool 3500 - 4000
industrial jute, coffee beans, shoe dust, granite Remember duct area A=Pi D2/4
dust dust, general material handling, brick
dust, clay dust, foundry (general,)
limestone dust VB=VA(DA/DB)2 = 1000(8/4)2
Heavy dusts Sawdust (heavy & wet,) metal turnings, 4000-4500 = 4000 fpm
foundry tumbling barrels and shake-out,
sand blast dust, wood blocks, hog V = 4005(VP)1/2, VP=(V/4005)2
waste, brass turnings, cast iron boring
dust, lead dust
VPA = (1000/4005)2 = 0.062” w.c.
Heavy or Lead dusts with small chips, moist > 4500
moist cement dust, asbestos chunks from
transite pipe cutting machines, buffing VPB = (4000/4005)2 = 0.998” w.c.
lint (sticky,) quick lime dust
Table 3-1: From American Conference of Governmental Industrial Hygienists (ACGIH®), Industrial
Ventilation: A Manual of Recommended Practice, 25th Edition. Copyright 2004. Reprinted with permission.
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Pressure Loss – Maintenance Saver –

Overcoming Straight Duct Friction Long Radius Elbows

Smaller ducts have greater

resistance per length. They
create high system pressure
drop on the governing leg of
the system.

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Branch Entries:
Merge angle based on contaminant characteristics
Branch Entries:
Do not use T-
T-Connection

30 degree
15 degree
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Pressure Loss – Branch Entries Balancing Airflows

Between Branches

Very sticky

Mildly sticky
Note: 11” S.P. to fan,
7” just to get to bag
Dry, free flow
house inlet

NO, don’t do this!!!!

1. w/o balancing devices, airflow takes path of least resistance
2. Change in one branch affects entire system balance
Fig. 9-f: From American Conference of Governmental Industrial Hygienists (ACGIH®), Industrial Ventilation: A
Manual of Recommended Practice for Design, 26th Edition. Copyright 2007. Reprinted with permission.
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Which Method to Balance Systems Is At a glance, duct design

Used at Your Site? principles met?
 Balance by Design
KEY PRINCIPLES
 Size ducts to restrict flow or
add flow 1. Size duct for
conveying 4
 Adds 10-20% more airflow to velocity in all
system branches 1
 Balance
l by
b Blast
l Gate 2. M i t i
Maintain 3
conveying
 Adjustable (both advantage velocity
and disadvantage) through merge
 Balance by Fixed Orifice of two dusty air
streams 2
 Pre-calculate orifice size
based on actual duct
construction – most accurate Good, Bad, & Ugly all in one photo!
balance

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Duct Maintenance Maintenance Access

 Visual  Fittings & elbows should be flanged (or have quick
 Damage-dents, holes? disconnect couplings) at both ends.
 Open duct access doors?
 For frequently removed section or complex sections -
 Local gauges with action
limits match mark adjoining duct sections for efficient re-
 R ti monitoring
Routine it i assembly
assembly.
 Duct network static pressures  Provide quick opening access door in large diameter
 Strategic airflows ductwork (18” dia. and above).
 Take Troubleshooting action  Consider permanent platforms for hard to reach duct
> + 20% Baseline static section requiring frequent cleanout.
pressure

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Monitoring - Test Ports Fan Failure Modes - Fan

Drive System
Belts lose or worn?
 Remote sensing of duct Pulleys aligned?
static pressure saves Bearings lubed?
climbing ladders
Vibration?
 Use single piece of tubing
 Need to wait for reading
to equalize
 Check for plugging if
reading doesn’t change

Courtesy Dwyer Co.

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Fan Design Principles Design Operating Point

 Match the fan performance curve with the system Pressure
 Oversizing for possible future need may be inefficient operating  System balance
point for current need calculations determine
 Consequence – major energy costs Fan fan requirement
 For
o long
o g term
te reliability
e ab ty  Fan Performance Tables
 Heavy duty industrial exhausters Operating locate the vendor’s fan
 Optimal shaft alignment and balance Point that can deliver
 Don’t exceed fan mfr’s maximum shaft speed recco. requirement
 Avoid fan performance degradation (system effects) due System
to poor fan inlet and discharge duct design

Flow
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Fan Laws Calculation – Fan Capable of

Change?
 N3   Performance of existing fan
•First Law: Airflow Q3  Q2   
 N2   12,546 ACFM @ 8” FSP
Fan shaft speed 875 RPM and 23.2 BHP.
2
N  
•Second Law: Static Pressure SP3  SP2   3 
 N2 
 Increase flow at the system hoods to
14,000 CFM without changing any of the
3
N 
•Third Law: Power PWR3  PWR2   3 
 N2  system duct. The Determine new
rough approximation:
 m3 
operating volume, pressure and
airflow    SP Pa horsepower if the change is made by only
 h 
PWR(kW ) 
2.268 a fan speed increase.
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Fan Laws Calculation Fan Laws Calculation

 Speed change
1. Calculate new fan shaft speed  N2=N1(Q2/Q1)=875(14000/12546)=976 RPM
 Static pressure change
( / )2= 9.95”
P2=P1(Q2/Q1)2 =8”(14000/12546)
2
2. Calculate new static pressure required 

 Brake horsepower change

 HP2=HP1(Q2/Q1)3=23.2(14000/12546)3
3. Calculate new brake horsepower  =32.2 BHP (versus 25 HP motor)
 fan motor upgrade to next size, 40 HP
 MCC & wiring upgrade size 2 size 3

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Effect of Fan Speed Change No Fan System Effects

Inlet duct System effects
No loss stack can add several
4 x (D+1”) - 5D or greater
inches Fan Static
(1.1)2=1.21
Pressure to
overcome poor
(1.1)3=1.33 inlet conditions

(1.1)

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Stack Weather Head

– Critical to Dispersion Fan Maintenance
 Visual
 Overheated bearings?
 Unusual noises or vibrations (belts aligned?, impeller
out of balance-erosion/buildup?)
 Air leaks on flexible connections?
 Routine Maintenance
 Lubricate shaft bearings – fan, motor
 Check mechanical components (belts, bearings, fan
impellor & housing clean)
 Check vibration isolators
Recommended “No Loss”  Vibration analysis
Stackhead – bird’s eye DON’T USE THESE!  Motor condition & electrical current draw
view!
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Useful Fan References Key Issues for Any Collector

 AMCA  Meeting environmental emission permit

 Publication 201 – Fans & Systems
 Publication 202 – Troubleshooting Fans
 ACGIH
 Industrial Ventilation, A Manual of Recommended
Practice for Design, 26th edition
 Industrial Ventilation, A Manual of Recommended
Practice for Operation and Maintenance, 1st edition
 Your Fan Manufacturer’s literature
requirements
 contaminant collection efficiency
 collected contaminant recycle or disposal
 Operating the collector within its design
differential pressure (DP) range
 DP high – acts like a damper & reduces airflow in
rest of system
 DP low –
 bypassing of collector and DC System?
 cause higher than desired airflow in DC System?

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SUMMARY –
Types of Collectors RELIABLE IVS PERFORMANCE

 Particulate Collectors  Vapor/Gas Collectors

Reliable Hood/Enclosure Exhaust Airflows
(dusts/mists/fumes)  Absorbers

 Interference by room air currents
 Fabric Filters or  Gas Scrubbers  Modifications that degrade performance
Baghouses
 Thermal & Catalytic  Keep duct conveying velocities within range
 Cyclones Air flow balanced between all branches
Particle Scrubbers
Oxidizers 
  Design systems with maintenance in mind
 Electrostatic Precipitators  Bio Filters  Fan inlets and exhausts – avoid fan system effects
 Mist Eliminators  Keep air cleaning device differential pressures within Base
Condition range

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