Case Study: GS Hydro - Efficient Dust and Fume Extraction in Welding Operations
Introduction
GS Hydro is a market leader in the provision of fluid transfer products to the energy, OEM, marine, renewables and defence industries.
They have facilities worldwide, including a UK branch in Ossett, West Yorkshire which has been operational for 15 years. As part of recent improvement plans, GS Hydro needed to implement more stringent control measures for fume and dust. They partnered with dust extraction specialists, Dust Control Environmental Ltd. (DCE), for the provision of a tailored solution.
Project Requirements
GS Hydro faced challenges in controlling both welding fumes and process dust in their manufacturing facility. Primarily they needed to provide a compliant, safe and clean working environment for the work force.
They also needed to control the process dust generated by cutting and welding operations to prevent it from contaminating other areas. This dust was settling on stock, causing discoloration and ultimately compromising the quality of the final product.
How DCE Met the Requirements
DCE Limited designed, supplied and implemented extraction systems customised to GS Hydro's specific needs. Key elements of the scheme included:
Welding Arms: Each of the three welding bays was fitted with flexible, self-supporting welding arms, offering a 6-metre reach and providing a 12-metre radius of work coverage. These arms were fitted with flared hoods and damper controls to enhance functionality.
Ducting: Galvanised, clip-together ductwork was installed for the efficient channelling of dust and fumes to the externally installed dust collector.
Typhoon 4 Dust Extractor: This high performance, reverse jet cartridge filter dust collector from DCE will provide high-performance collection of dust and fumes from the welding arms. Its compact design minimised the space required for the installation.
The DCE dust control systems play a major part in a broader dust containment scheme, which features the addition of a sealed containment wall.
Benefits
The implementation of these advanced extraction systems achieved significant gains including:
· Controlled Fumes and Dust: Welding fumes and process dust are extracted directly at source, ensuring a compliant, safe, and clean workspace.
· Enhance Product Quality: Eliminating the risk of dust contamination preserves the appearance and quality of hydraulic parts, upholding GS Hydro’s high standards.
· Operational Efficiency: The Typhoon 4’s pulse jet cleaning system offers true 24/7 operation and serves to minimise maintenance costs by extending the filter media life. The tool-free filter media removal further streamlines maintenance processes.
· Sustainable Operations: A waste collection bin facilitates safe, efficient and contained disposal supporting sustainability goals.
· Environmental Responsibility: The comprehensive dust and fume containment measures spotlights GS Hydro’s dedication to workplace safety and environmental stewardship.
· Conclusion & Client Feedback
The collaboration between GS Hydro and DCE Limited exemplifies the importance of tailored engineering solutions in industrial settings. By addressing specific operational challenges, the implemented extraction systems meets GS Hydro's expectations.
Danny Smart, Project Sales & Operations Manager, GS Hydro commented, “We recently had the pleasure of contracting Dust Control Environmental Ltd to fit a dust extraction system in our workshop that is specially designed to handle welding fume gases. The system, which consists of high-efficiency fan assemblies, flexible welding arms, and a comprehensive ducting pack, has significantly improved the quality of air within our welding bays.
“The installation was trouble-free and dealt with in a professional manner, with the team demonstrating excellent expertise and attention to detail. The training and commissioning that was conducted ensured that our staff felt comfortable using the system.
“Overall, we are extremely satisfied with the quality of the product, the professionalism of the installation team, and the excellent standard of service provided by Dust Control Environmental Ltd. We would not hesitate to recommend their products to any company looking to improve their workshop environment.”
Find out more about DCE Dust Control Environmental Ltd on their member profile page here
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