HomeMy WebLinkAboutMaverick Boats Phase 2 Expansion - GEL & GRINDING BOOTH PERMIT 2107-0635 - Test & Balance Report 03-17-22 1
Southeast Building Solutions, Inc.
Ventilation Solutions for Industry
TEST & BALANCE REPORT
Fort Pierce, FL
Maverick Boat Group
PLANT 2
NEW EXPANSION VENTILATION
March 17, 2022
104 Meco Lane, Oak Ridge, TN 37830 Phone (888) 716-8808
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March 17, 2022
Maverick Boat Group
4551 St. Lucie Blvd
Ft Pierce, FL
Dear David,
Here are your results for the Gel Coat Booth Balance performed at Maverick Plant 2 in Fort Pierce, FL , on March
1, 2022.
Balance & Test Summary:
Adam Brown arrived at the plant on Tuesday 3-1-22 to review overall general conditions for balance and
testing of new Plant Ventilation. The plant was not yet in production. 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.
Gel Coat Booths:
Gel Coat booths were adjusted and balanced according to design. We also fogged inside and outside the
gel coat booth. We used the fogger to spot-check the air flows and containment of gel coat booth. The
air distribution patterns were re-adjusted to control exposure around the parts, when properly placed
within the booth. This process was done for both the large boat spray booth and the small parts booths.
Air Flow Testing:
The large booth is configured with 6 banks of filters (4 Bays of 10 filters and 2 Bay of 6 for a
total of 52 Filters) down each side of the booth, and readings were averaged across each bank to give a
good representation of the airflow for the banks.
RH Bank Readings:
251 FPM, 289 FPM, 267 FPM, 261 FPM, 292 FPM, 271 FPM
LH Bank Readings:
241 FPM, 269 FPM, 257 FPM, 252 FPM, 261 FPM, 253 FPM
This booth was designed for an intake velocity of 250-300 FPM Avg velocity per filter, so these numbers
are within design for proper ventilation of the booth.
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The booth is supplied make up air via 12- 20” x 20” HVAFS supply grilles. The velocities of these grilles
were measured and averaged per grille and returned the following readings per grille
Supply Readings:
921 FPM, 935 FPM, 940 FPM, 940 FPM, 945 FPM, 935 FPM, 928 FPM, 938 FPM, 930 FPM, 943 FPM,
945 FPM, 948 FPM
These grilles were designed for a velocity of 900-950 FPM, and all are within design range.
Exhaust of the booth is calculated at 72,000 CFM, and the supply as read is approx. 30,000 CFM which
would leave the booth approx. 42,000 CFM negative to allow for no fumes to escape the booth and
additional supply provided by filtered door intakes.
Negativity was measured via a door opening and was read at 850 FPM Avg. Which shows that even if
the man door is opened during booth operation the booth remains negative enough to contain spray and
fumes from entering the plant.
Lamination Areas:
The new lamination areas were adjusted and balanced the air flow in work zones and made sure we had
good air flow into the work zone prior to testing. 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 of resin 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 through 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. All exhaust intakes read within
design velocities of 300-400 FPM.
Grinding Booths:
The new grinding booths were adjusted and balanced the air flow in thework zones and made sure we had
good air flow into the work zone prior to testing. We also fogged inside and outside the grinding booths.
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 part, when properly placed within the booth.
Booth 1
Supply Readings:
680 FPM, 675 FPM, 669 FPM, 681 FPM, 685 FPM, 682 FPM, 681 FPM, 672 FPM, 677 FPM, 682 FPM
Booth 2
Supply Readings:
683 FPM, 676 FPM, 678 FPM, 682 FPM, 683 FPM, 679 FPM, 675 FPM, 676 FPM, 672 FPM, 681 FPM
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Booth 3
Supply Readings:
615 FPM, 620 FPM, 611 FPM, 605 FPM, 620 FPM, 618 FPM, 613 FPM, 611 FPM, 618 FPM, 615 FPM
These grilles were designed for a velocity of 612-680 FPM, and all are within design range.
Negativity was measured via strip door opening and was read at 490 FPM Avg. Which shows that during
booth operation the booth remains negative enough to contain dust from entering the plant.
Observations:
1) We inspected the exhaust air systems. There will be a difference in loading on the filters due to slightly
higher intake velocities on plenums near duct drops. 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 management.
2) We adjusted settings for units in both exhaust and supply air. 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.
Dust Analysis:
We received the results of the dust test of Maverick’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 .in your existing grinding booths
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If you take the dimension of the filter chamber of the booths the calculations would be as follows:
Filter Chamber - (Partial Enclosure)
36” x 12’H x 55’ 5” = 1995 ft3 = 56.5 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 56.5 m3 = 3333.5 g of dust required to meet Minimum Explosive Concentration.
3333.5g = 7.35 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
1638.5 g = 613. 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].
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.
Suggestions:
1) It is our opinion that Maverick is operating a safe work environment for its employees, based on readings,
the ventilation systems are performing as designed and operating correctly.
If there are any questions about these results, please call Ventilation Solutions.
Best Regards,
Gary Mayfield
Eng/Tech Manager
Ventilation Solutions