A leading Metal Castings’ manufacturer based in the UK were experiencing reliability problems with Dust/Particulate Devices consistently across all their manufacturing sites. Site operatives were
losing confidence in the dust readings on their Bag Filter Plants.
Furthermore, the control unit, as part of the emissions monitoring system, was difficult to
operate and more importantly was not able to generate suitable reporting files needed
to meet the local regulatory requirements. As they could not get a satisfactory response from their existing service provider, they decided to contact CEM Solutions (UK) Ltd for assistance, after a referral from an independent stack test house.
The Challenge
After initial discussion with the customer to establish the current issues, understand their challenges and establish their expectations, we arranged for a service visit to carry out a Site Inspection. We carried out a visual appraisal of all the devices and shared our findings. Essentially, the dust/particulate measuring devices were poorly installed, some of their locations were compromising the performance of the devices and additionally, wiring issues were identified which needed to be addressed.
As the site runs continuously, our challenge was to ensure timely restoration of the existing dust
measuring devices prior to scheduling the more thorough installation improvements that were required, all without affecting the overall process operation.
The Solution
After servicing and calibrating the existing serviceable dust/particulate probes, we agreed on an
Improvement Plan for the Dust Emission Monitoring System as a whole, including:
- Replacement of the faulty Dust/ Particulate devices with Dr Foedisch PFM Particulate Filter
Monitoring probes to restore a reliable measurement. - Installation of new wiring to improve the robustness of the complete system.
- Upgrade their unreliable control unit with our CEMWare Data Acquisition and Handling System
(DAHS) giving them local audible and visual alarms. - Implementation of a Service Contract to maintain and calibrate all the devices regularly to ensure optimal performance is achieved.
The Result
CEM Solutions (UK) Ltd worked closely with the customer to prioritise the work which needed to be
completed. Within a short space of time the performance of the Dust Monitoring System improved
considerably. This enabled a renewed confidence in the devices and data handling was no longer a
negative experience. With its user-friendly interface, operators can now use the data generated with
confidence, running reports as and when required.
- Having exceeded initial expectations in 2018, the customer asked us to help them to improve their other sites in the UK.
- We now have Service Contracts for all the UK Sites looking after their Dust Monitoring Systems and ensuring maximum performance from their Bag filter Plants.
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