Weld-Master Smoke Removal System

Weld-Master

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Smoke Removal System

The Weld-Master ventilation system by XeteX saves more fuel and provides cleaner breathing air in a welding plant than conventional "Mixed Air" heaters. Welding facilities installed with each method of smoke removal are illustrated to show the difference in performance.

Problem

Conventional "Mixed/Diluted-Air" welding smoke removal units typically filter or exhaust polluted air. When filters are used, the cleaned air is recirculated into the room. When exhausters are used, some type of fuel-fired make-up air units blow in heated air to keep the plant warm. Each of these smoke removal units have their advantages and disadvantages but both provide mediocre air quality; they only mix or dilute the smoky air generated by the welders with some clean supply air which results in less smoky air throughout the plant. Operating costs for "Mixed/Diluted-Air" units are very high and plant air is never really clean.

Solution

Weld-Master ventilation systems in contrast use "Separated/Displacement Air" to provide exceptionally clean breathing air at much lower operating costs. Nature's way of moving heated air to the ceiling by natural convection without blowing air around is used.

Fresh, pure air accumulates above the plant floor providing a "Man-high" layer of very clean air to breathe. Welding smoke flows up to the ceiling directly by natural draft, where it is exhausted. Warmer, dirty air flowing to the ceiling is kept separated from the clean, slightly cooler air staying near the floor. Workers are warmed by radiant heat and breathe only clean, uncontaminated fresh air. Plant operating costs are slashed because the amount of air to be heated and blown around is reduced ... as much as half. Only enough ventilation air to maintain a 6-7 foot high level of clean air is required since all the concentrated, polluted air is exhausted from the ceiling; never to be recirculated.

The key to the Weld-Master ventilation system is the air distribution device. These air distribution devices are called Air-Master Vents. They slowly let the clean air enter the room near the floor to prevent it from mixing with the smoky air.

Air-Master Vents are sized to deliver the amount of clean air necessary. Enough clean air must be supplied to maintain a "Lake" of unpolluted, breathable air up to 7 feet high and still provide a source of air to carry the welding fumes to the ceiling. The CFM or quantity of clean air required depends on how much polluted smoke must be carried away. OSHA has set the maximum pollutant level based on a Time Weighted Average (TWA) of 5 as a minimum guideline. Based on the number of welders, type of welding machines, intensity of use and some basic building information, the minimum quantity of clean air can be calculated.

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