HomeMy WebLinkAboutTEST & BALANCE REPORT 1
Southeast Building Solutions, Inc.
Ventilation Solutions for Industry
TEST & BALANCE REPORT
Fort Pierce, FL
Maverick Boat Group
PLANT 2
NEW VENTILATION SYSTEM
April 26, 2019
104 Meco Lane; Oak Ridge, TN 37830 Phone (888) 716-8808
2
April 26, 2019
Maverick Boat Group
St. Lucie Blvd
Ft Pierce, FL
Attn: John Sampson & Jim Leffew
Dear John & Jim,
Here are your results for the Styrene Test & Balance performed at Maverick Plant 2 in Fort Pierce, FL , on April 9
& 10, 2019.
Balance & Test Summary:
Gary Mayfield arrived at the plant on Tuesday 4-9-19 and walked thru the lamination area with John
Sampson to review overall general conditions for balance and testing. The plant was in full production.
There were three work areas, the gel coat booth zone and the Lamination Booth work zone and a grinding
booth. Normal lamination production shift starts at 6:00am. Production schedules run Monday thru
Friday. We used a Rosco Mini-V Fogger to check and set air flow patterns and an Alnor CompuFlow
Model 8585-Anemometer to check air velocities.
Lamination Area:
I walked thru the new lamination areas and adjusted and balanced the air flow in both work zones and
made sure we had good air flow into the work zone prior to testing. We also fogged inside the Gel Coat
Booths. We noted the part placements and work positions as well as safe work practice within the new
work zones were complied with. It is very critical for these parts to be positioned where the fresh air is
set. It is also critical for all employees to be aware of others around the work zones, as well as avoiding
possible overspray from resin spray from chop application. We used the fogger to spot check the air flows
and overspray containment in those spray areas. We made air adjustments to air patterns around the work
zones. The air distribution patterns were re-adjusted to better limit fume exposure around the parts. It is
very important to keep all filter media clean to keep capture efficiency (high) at best ventilation capacity
possible during all lamination production. We recommended that filters be checked every day. Look for
spray to penetrate thru media, if there is residue getting through to the back side then it is time to replace
the media. We recommend the media used be the same specification or equal. It is our recommendation;
for best operation and performance, the exhaust filter plenums existing 24x24 pre-cut filter media will
require new filters as needed, depending on loading. Before leaving for the day, I was provided with a list
of personnel to test on Wednesday.
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Grinding Booth:
I walked thru the new grinding booth and adjusted and balanced the air flow in both work zones and made
sure we had good air flow into the work zone prior to testing. We also fogged inside and outside the
grinding booth. We noted the work positions as well as safe work practice within the work zones were
being complied with but part placement could have been better for airflow. We discussed this with
Russel and he is aware of where the best work areas are. It is very critical for these parts to be positioned
where the fresh air is set. We used the fogger to spot check the air flows and containment of grinding
booth. The air distribution patterns were re-adjusted to control dust exposure around the parts, when
properly placed within the booth.
Observations:
1) We inspected the exhaust air systems. There will be a difference in loading on the chop zone lamination
filter banks. For example, the filter bank directly behind the chopper will load (get dirty) faster than the
filter bank just behind roll-out zone. If filter media is not maintained, it will allow buildup. This will
negatively impact system performance. Filters should be changed at appropriate intervals to allow proper
system operation This was discussed with John, Derrick, Tony and Shawna.
2) We adjusted settings for units in both areas. These units should not be adjusted without contacting
Ventilation Solutions. Any adjustments to the replacement air units will require additional heating system
adjustment to burner profile and pressure settings. This will cause problems with heating.
Maverick testing notes;
Styrene Testing:
Here are a few notes from the testing done on 4-10-19. Arrived on site at 5:55 am. We started hanging
the pumps at 6:00am. Pumps were placed on 1 Gun Operators, 1 Hull Build, 1 Stringer Build, 1
Deck/Spraycore Build and 1 Background reading in the small parts lam area. We noted workers working
outside of the workzone several times during the day, these workers are subject to higher exposures to
Styrene. These concerns were discussed with Maverick Management. This was corrected several times
by telling the workers to follow proper part placement and work practices to ensure they are not exposing
themselves to more styrene than is necessary for their work. Our background reading for the small parts
area was less than 1 PPM. Testing concluded at 2:00 pm and pumps were removed from test subjects and
samples sealed for laboratory.
Dust Testing:
An Alnor CompuFlow Model 8585-Anemometer was used to check air velocities at intakes and supply
grilles. The testing was conducted utilizing sampling pumps using the NIOSH 0500 method and NIOSH
0600 method for dust sampling. Pumps were placed both in the chamber area and inside the grinding
booth space. Results are as follows below.
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Dust Analysis:
We received the results of the dust test of Frontline’s fiberglass dust performed by Fauske Laboratories.
Please find the attached testing results for MEC, Pmax, and MIE.
This sample resulted in a KST value that makes the dust a Class I.
While this dust can be an explosion hazard if it is under specific conditions only, these conditions are
addressed in the test results.
The dust control booth is designed as a dilution system. The booth region where grinding and trim operations
are producing material concentrations suspended in the air does not impose a deflagration hazard as part of
the booth ventilation design. [8.2.5]
1. There is no potential ignition source in the booth.
2. The booth has a bonding and grounding system.
3. The MEC of the dust will not be met if proper housekeeping procedures are followed in accordance
with NFPA 652 Sec. 8.4. This includes vacuum cleaning [8.4.2.2] and compressed air blow down
methods of cleaning. [8.4.2.6] It is highly important that the Facility must establish, record and
maintain housekeeping procedures where the fugitive emissions do not approach the MEC and the
housekeeping schedule does not allow settled dust accumulations to exceed the threshold
housekeeping dust accumulation limits.
Per NFPA 652 Sec A.5.2 – A Dust Explosion requires the following five conditions:
1. A combustible dust sufficiently small enough to burn rapidly and propagate flame.
2. A suspended cloud at a concentration greater than the minimum explosion concentration.
3. Confinement of the dust cloud by an enclosure or partial enclosure.
4. The atmosphere to support combustion.
5. An ignition source of adequate energy or temperature to ignite the dust cloud.
According to the test results from the test with the Kst, the MEC of the sample was 59 g/m3 or 59,000
mg/m3 .
Galson results on the highest value returned were 29 mg/m3.
If you take the dimension of the filter chamber of the booth the calculations would be as follows:
Filter Chamber - (Partial Enclosure)
36” x 12’H x 50’ 5” = 1815 ft3 = 51.4 m3
According to test results the Minimum Explosive Concentration (MEC) is 59 g/m3 so to reach that
concentration in the filter area we would need to be
59 g/m3 x 51.4 m3 = 3032.6 g of dust required to meet Minimum Explosive Concentration.
3032.6g = 6.68 lbs of dust that would need to be suspended in cloud form to be ignited by the 2.5 kJ
ignition sources or a 450° C (842° F) temperature that were used in the laboratory test.
Based on your results from Galson of 29 mg/m3 equates to an actual amount of
1490.6 g = 3.28 lbs of potential dust if proper housekeeping procedures are followed
These concentrations will be impossible to reach under proper operation and housekeeping of the booth.
Scheduled Housekeeping effectively with auditing and documentation in accordance with frequency and
accumulation goals established in [8.4.6.1].
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NFPA promotes awareness of the three following fundamental principles:
1. Controlling the fuel (Dust is diluted and kept below MEC)
2. Controlling the ignition sources (None Present) [8.5]
3. Limiting the spread of any combustion event. (Booth contains dust from migrating into other
areas of the plant.)
This means ensuring that you are reducing the number of factors from the dust explosion pentagon and
installing the proper equipment to reduce the effects of an explosion, if one should happen.
Please find attached a copy of analytical results from Galson Laboratories and Fauske & Associates.
Please continue to police the safe work practices in the designed work zones. If any additional testing or
rebalancing is required later, additional charges will apply. If there are any questions about these results,
please call Ventilation Solutions.
Styrene Analysis:
Please find attached a copy of analytical results from Galson Laboratories. There 2 results that were more
than 26 PPM which is well below the level so that workers do not have to wear respirators. Background
readings for the small parts zone were less than 1 PPM.
Please continue to police the safe work practices in the designed work zones. If any additional testing or
rebalancing is required later, additional charges will apply. If there are any questions about these results,
please call Ventilation Solutions.
Suggestions:
1) The review of the attached styrene testing results, it is our opinion that Maverick is operating a safe work
environment for its employees.
2) Policed worker practices throughout day.
Frequent filter inspection & Replacement
Keep work within Ventilated Work Zones
A 10% (+,-) variance can be applied to pumps sampling and analytical results. Please continue to police
the safe work practices and parts position in the designed work zones. If there are any questions about
these results, please call Ventilation Solutions.
Attachments:
1) SGS Galson Laboratory Report
2) Fauske Laboratories Report
Best Regards,
Gary Mayfield
Eng/Tech Manager
Ventilation Solutions