Commercial Vehicle Fume and Welding Fume: Port Facility Case Study 

 

The Client

A leading engineering and construction company were contracted to supply and built a new port facility on behalf of their client. The complex job included various kinds of LEV extraction systems for two straddle carrier workshops, a forklift truck workshop, a battery charging station, an electrical welding room workshop, a hot work area welding workshop and; two pit workshops.

 

The Challenge

With such a wide variety of different forms of LEV solutions required; the best way to approach the project was on an individual process basis. Auto Extract Systems were tasked with proposing and installing a comprehensive LEV (local exhaust ventilation) system in the workshops to safely capture and remove the dust and fumes emitted into the workplace’s air during the port’s operations. The LEV system was installed as part of a project to ensure the site meets stringent operational requirements to work strictly in accordance with HSG258: Controlling Airborne Contaminants at Work: A Guide to Local Exhaust Ventilation (LEV) guidance.

 

The Solution

Two Straddle Carrier Workshops

The straddle workshop’s solution included two, three-point, eight-metre-long double-hinged swinging articulated swing arms (fit the walls of building at a high level on the underside of crane track to enable reach to vehicle engines at a 10m height) that were complete with a five-metre-long x 150mm diameter, 400⁰C high-temperature exhaust extraction hose and with a commercial metal nozzle (clamp-on type) for connection to the vehicle. To keep the hose out of the way from hitting vehicle when not in use, the hose was installed with a spring balancer enabling it to retract back up to the arm.  The systems were connected to a common duct to a 4kW centrifugal fan capable of 9800m³/hr.

Forklift truck workshop

The forklift truck workshop’s solution included a seven-point, 4.5-metre-long double-hinged swinging articulated swing arms, complete with a five-metre-long x 125mm diameter 400⁰C high-temperature exhaust extraction hose and a commercial rubber nozzle and steel clamp-on nozzle for connection to the vehicle. To keep the hose out of the way from hitting vehicle when not in use, the hose was installed with a spring balancer enabling it to retract back up to the arm. The systems were connected to a common duct to a 4kW centrifugal fan capable of 9800m³/hr.

Battery Charging Station

The battery charging station consisted of two duct lengths, each 355mm in diameter and progressively increasing to 450mm in diameter. Each length was fitted with a series of equidistant grills and with volume control dampers (to enable the system to be fully balanced). The duct was connected to a 2.2kW fan to providing an air volume of up to 14,100m³/hr.

Electrical Welding Room Workshop

The (dirty) electrical room and (clean) electrical room for fume soldering operations consisted of two self-supporting welding fume hose extraction arms complete with a 100mm balancing damper. The extraction arms were connected to a common duct and to a 1.1kW fan that’s capable of 3100m³/hr (free-blowing).

Hot Work Area Welding Workshop

The hot work area welding workshop featured two boom hose extraction arms 4.8m long with a further 4m long ball-bearing jointed self-supporting fume extraction arm complete fume capture hood for removal of fumes at source. The boom extraction arm gave a total reach of 8.8m. The fan was connected to a common duct and ran to a 2.2kW fan which is capable of 5,800m³/hr

Two Pit Workshops

The installation of two, one-point extraction system that was located at a low level and extending the length of the pit, with a 150mm diameter spiral-wound galvanized steel duct. The ducting was be fit with a series of 400mm x 100mm extraction grills and a volume damper to allow the system to be balanced. The duct was run underneath the floor and rose alongside the wall at floor level. The fan was connected to a common duct and ran to a 1.1kW fan which is capable of 3,100m³/hr.

The Feedback

With such an array of LEV systems required at the new port facility, the building services engineer highly recommend Auto Extract Systems Ltd approach to problem-solving, stating: “With a large project like this, it was hard to find one solutions provider who could meet all our requirements in this building; I would recommend Auto Extract Systems to anyone!”