INSTALLATIONS
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and engineering quality safeguards against the risk of MDF dust ending up in the canal.” Having considered all of Crystal Doors’ extraction requirements, including further planned investments in new production equipment, DCS submitted designs and costs for a comprehensive installation project which would need to be implemented to a very strict deadline, over a long weekend shutdown. “Our design and project management team had planned the work to the last nut and bolt, and our installation engineers worked with military precision to meet the deadline,” comments Melvyn Bathgate. “Production at Crystal Doors finished at the end of the late shift on the Thursday night and we were committed to commissioning the new system for production to start up again at 6.30am the following Tuesday. The Schuko filter was delivered to site in pre-constructed sections then builtup in advance, on adjacent ground, ready to swing into place on the Friday morning.” The old filter unit has been replaced with an ATEX-Certified Schuko ECOVAR VALIDUS modular chain filter, with a flow-optimised
cascade system of 5 x 30kW fans, capable of extracting up to 80,000m3/hr from four separate lines. Dust-laden air extracted from the factory is drawn through anti-static, polyester needle-felt DCS installed a Schuko ECOVAR VALIDUS modular filter unit with 80,000m3/hr extraction capacity
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tubular filter bags, and waste dust is continuously removed from the filter media by a pulse jet cleaning train, with secondary removal of any remaining deposits by a pneumaticmechanical shaking system. The waste dust falls into the lower hopper section of the unit and is then discharged, pressure-free, by means of a rotary valve, to a screw conveyor which in turn feeds a bucket elevator; finally delivering the waste into a large storage silo. The installation also includes four ATEX-approved CARZ backpressure flap valves; one in each of the four main ducts. In the event of a dust explosion, the valves prevent the effects of a pressure wave and flames travelling from the filter, back along ductwork, and into the factory. DCS has also provided additional fire safety and air quality monitoring at Crystal Doors: a four-zone spark detection system will trigger a fast acting water extinguisher if a spark is detected in either of the four main ducts, and the integrity of the system’s cleaning efficiency is constantly monitored by a particulate emission measuring system which has sensors fitted to each of the four return air ducts. As well as delivering clean warm air to the factory to maintain optimum temperature for vinyl application, one of the return air outlets replenishes air extracted from the spray booth; ensuring a
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Richard Hagan checks air quality readings of cleaned air being returned to the factory
warm, dust-free atmosphere for a quality finish and quick drying times. Key to achieving the energyefficiency targets projected by DCS is the installation of an Ecogate greenBOX MASTER SRL 200. With the capacity to control and interrogate up to 200 motorised gates, and up to four variable speed drives, the MASTER SRL 200 is the most sophisticated control unit in the Ecogate technology range. The system auto-starts when the first machine is powered up, constantly optimises fan speeds throughout a three-shift production schedule, and auto-stops when all machines are shut down. Setup, monitoring and service functions are all accessible via the colour touch screen, and stored machine activity data can be downloaded to a removable flash drive. Furthermore, all control functions, activity logging and data storage can be securely accessed from any authorised internet-connected PC. The MASTER SRL also maintains minimal airflow to ensure a balanced system, programs filter cleaning cycles, and generates status indicators for system errors.
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