Energy-Conserving Suction of Aerosols & Smoke at a Dörries Scharmann Machining Center

(PresseBox) ( Nordrach, )
The Alstom Power Service company in Berlin is active in service, maintenance & repair of turbines for power generation. At a Dörries Scharmann machining center, a lot of emulsion mist and smoke escaping through the not 100% capsuled machine cover is produced during the turning/milling processes due to the large size of the parts. It was LTA's task to prevent just that. An LTA air filter type AC 3061 was installed which extracts the generated aerosols and the smoke with an effective suction output of max. 7,400 m³/h. At the same time, the cleaned exhaust air of the filter is used to place an air curtain over the ports at the machine which prevents remaining smoke from escaping to the environment. The particles entering the air flow are precisely directed to the exhaust ports of the filter and cleaned there.

Please read the comments by the project manager at Messrs. Alstom Berlin on the LTA solution:

1.) Which were the decisive arguments in favor of LTA?

- LTA offered a solution which prevents heat from being extracted from the hall. The cleaned air is fed back.

- The air curtain solution is highly compact as no large cover for sealing the ports at the machine must be installed.

- Big effect with relatively little effort. Other offers were based on the extraction of large air volumes which also prevented aerosols from escaping, which on the other side, however, required an anormous - not so say expensive - effort. While the cooling effect would have had affected the geometry of the machine with other solutions offered, LTA avoided this thanks to the low suction output.

2.) How was the cooperation between Alston and LTA from the tendering phase right up to the completion of the project?

Consultation at LTA was highly competent. Project engineering and technical preparation during the planning phase were elaborate and with great attention to detail also in respect of the 3D drawings. In this way, problems could be revealed and made clearly visible which was followed by efficient problem solution. The execution and completion of the project was well accompanied by LTA providing efficient support.

3.) How does Alstom benefit from the project and in how far has the exhaust air problem improved for Alstom?

Within the Alstom group, great attention is attached to the working conditions for employees. Using an EHS (Environment, Health and Safety) Roadmap, the requirements of which usually exceed the legal regulations by far, strict specifications in this regard were imposed. This project is a showcase for the rest of the Alstom corporate group.

The results obtained concerning the air quality outside the machine are very good. Another effect is the improved climate inside the machining area.

The scope of delivery of LTA for this project comprised the cleanable air filter system type AC 3061 including attachments and accessory, external operating panel and console, one nozzle plate for optimized filtering coverage, the complete pipework, the related return containers as well as the assembly and commissioning of the complete system.

The advantage of this system is the high separation degree of the electrostatic filter as well as the use of regenerative filter elements. Thanks to the use of regenerative filter elements, the filters may be cleaned as often as required which eliminates the high disposal and purchase costs for replacement filters. In excess of this, an energy-efficient and energy-saving operation becomes possible due to the low pressure loss of the electrostatic filter. With just 4.8kW, a standard blower output of 16.800m³/h is achieved.
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