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  • Stationary Vacuum Systems

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    2Stationary Vacuum Systems

  • About Stationary Vacuum SystemsSubstantial savings can be realized by installing a Dustontrol system.Following are some example installations; All grinders and fi nishing tools in an FRP production facility are

    equipped with suction casings and connected to a central extraction system. Capture of the dust at source contributes to an improved working environment, higher productivity - shorter clean-up, cleaner process and improved product quality.

    Cleaning of saws, mills, lathes and other process machines with a centralized system. More effi cient production, cleaner machines, faster production, effi cient lubrication use and a higher return on prompt scrap through more eff ective collection. Your people spend less time on tasks that do not add to the bottom lne

    Extraction of chips and lube directly at the source: Cleaner parts thoughout the production process, and a cleaner environment on the shop fl oor. Cleaner machines mean better functioning lube systems,

    better function means cooler running tools. Cooler tools mean better parts and longer tool life.

    Fume extraction with extraction integrated welding guns.Reduced exposure to fume, healthier welders, higher productivity.

    Vacuum cleaning systems and air cleaning equipment in bakeries reduces airborne fl our dust that is dangerous to health and can cause asthma: Th e health and safety regulations are met and at the same time the workplace environment and overall effi ciency is improved. Fewer health problems from employees will aff ect insurance rates positively.

    Extraction/vacuum systems in pharmaceutical production for source extration in the process and for cleaning of production machinery and areas. To eliminate hazardous dusts generated during pharmaceutical production is a must from a health perspective as well as a product quality issue.

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    Stationary Vacuum Systems

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    1. Complete Extraction System.2. Vacuum Producer.3. Filter Unit.

    4. Pre-Separators.5. Installed Tubing System.6. Work Place Equipment.

    7. Cleaning Accessories and Suction Casings.8. Main System Control.

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  • 1 IntroductionTo attain the desired effi ciency and benefi ts with an extraction system, the system must be complete; from the suction casing to the vacuum producer to the control system. All the components of the system are equally important in implementing its functionality.

    2 Vacuum ProducersTh e vacuum producer is the heart of the system. Here the vacuum is created that drives the system. In Dustcontrol extraction systems, the vacuum level is gene rally from 640 kPa.Our normal source extraction and vacuum cleaning systems use turbo-pumps. Th is device has an ideally suited characteristic capacity for this type of system. Vacuum level increases as more resistance is pre sented, an important quality in minimizing the possibility of blockages in the tubing system. For applications involving fume and light dust, such as paper, radial blowers are used. Th ese have larger air-fl ows and operate at a lower, relatively constant vacuum level.Our turbopumps and radial blowers have very high quality built-in silencing, see technical speci fi cations.

    3 Filter UnitsAn extraction system should always be equipped with a fi lter unit. Dustcontrol fi lter units separate coarse material in the cyclone body of the unit and fi ne dust in an internal arrangement of conical pleated cartridge fi lters. Pleated fi lters have very high fi lter areas in relation to their physical size. Th e fi lter units therefore have high capacity while maintaining compact overall dimensions. Filters are cleaned with reverse pulse which results in very eff ective cleaning, long fi lter life and low maintenance.Normally the fi lter units are equipped with a plastic sack for collection of the extracted material but other types of discharge arrangements can also be installed.

    4 Pre-SeparatorsPre-separators can be used in all applications where the extracted material is coarse or voluminous. Th ese can be placed in the actual workplace for separate handling or recovery of the extracted material, or centrally.Pre-separators separate material from the air fl ow using cyclonic action or with inertial separation. Inertial separators are generally confi gured as containers with the inlet and outlet in the same wall of the container. When the air fl ow changes direction abruptly, separation occurs for the particles with higher relative mass. When pre-separation is used to accommodate higher material volumes it is also important to consider the type of material discharge to be used. Dustcontrol off ers a range of diff erent standard options including; screw compaction, airlocks or container collection.

    5 Tubing SystemTh e tubing system transports the material from the point of collection to the central unit. Dust is generally abrasive, some more than others,

    The Complete System therefore the standard material thickness of the tubing system is 1.5 mm. Applications with fume and light dust use reinforced spiral duct. Stainless tubing systems and extra abrasion resistant fi ttings are available.Dustcontrol has a very compre hensive assortment of tubing fi ttings and installation hardware. Th is gives greater fl exibility in design and installation of our tubing systems. Our mechanical jointing system makes alterations and additions very easy to carry out. Cones, branch pipes and bends are manufactured in EPDM- and NBR- rubber. Th e components are hard-wearing and sound deadening.

    6 Work Place EquipmentAn extraction system is sized for only those outlets which are to be used simultaneously. Th is is in order to maximize effi ciency and minimize the size of the central unit. All outlets must have some type of closure, either a fl ap valve or shutter. Th ese can be manually actuated, such as fl ap valves or manual shutter valves, or automatically controlled for actuation only when extraction is required.Th e Flexpipe can be used for fume extraction, high fl exibility and small diameter allow it to be placed very close to the fume source.Overhead suspension arrangements such as swing-arms and hose reels can increase the usefulness of the system, increase ergonomics and minimize potential trip hazards from hose left on the fl oor.When large volumes of material are to be introduced into the system, stainless fl oor funnels can be used from which the material is then extracted.

    7 AccessoriesA hose must have many qualities, the foremost for the operator however is fl exibility. It should also be tough enough to withstand the abrasion created when transporting the extracted material. Hose selection should include consideration of abrasion, chemical and heat resistance as well as conductivity to static electricity. Dustcontrol has a comprehensive assortment of hose types, diameters and hose connections.Cleaning tools, suction casings and special nozzles are those compo-nents that are actually used to cap ture the dust. Th e design and eff ective ness of these will determine the effi ciency and acceptance of the entire system. Th is demands a varied and comp lete assortment of specially designed products. Dustcontrol has that. If a standard pro-duct does not exist, we have the capacity to design and manufacture it.

    8 Control SystemsMotor starters and System Control Panels control the operation of the system, both operation of the vacuum producers and cleaning of the fi lter. A variety of other control functions can be installed as required. Even with a rather basic control system, intelligent features can be included to clear coarse material in the main tubing runs or control vacuum production and therefore energy consumption according to actual requirements.

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  • Planning and Design of Extraction SystemsTh e following points must be considered and a clear defi nition must be developed before design of the system can be undertaken.

    Determine the function of the system source extraction, cleaning or pneumatic transportation. In many cases it can be wise to equip the system for diff erent functions apart from the main function of the system, for example; cleaning.

    Choose the outlet confi guration. Determine for each outlet the type of extraction equipment required as well as the type of closure ( automatic or manual ). To determine this, a detailed study of the types of activities in each work place must be undertaken.Determine the number of outlets in simultaneous use. Th e system will be designed for a maximum number of users at any point in time. In larger systems, the number of simultaneous users in diff erent parts of the system should be determined.

    Decide the routing of the tubing runs and location of the central unit. Consider the degree of diffi culty for installation; ceiling height, wall and roof perforations, moving equipment into place, etc.

    Consider the type of material to be extracted, the degree of abrasion, risk for explosion and risk for clogging, etc.

    Determine the volume of material to be collected per unit time. Select the type of pre-separator and type of material handling for collected material. Material discharge etc, must be determined according to the customer requirement.

    Select the type of control system to be used, for example; programmable start stop or work place start - stop.

    Determine electrical and compressed air supply requirements for the system. Indicate location of the requirement and assign responsibility for the supply and installation.

    Tube SizingTh e tube dimensions are selected on the basis of maintaining the correct tran