A major paper mill located in Virginia was updating and revamping their power plant as well as adding a new boiler and associated equipment.
The current sampling panel was not working properly, in fact it had never worked properly due to insufficient flow through the sample coolers.
While all this construction was going on the paper mill decided to upgrade the existing sample cooler panels as well as install the proper ones for the new plant.
The samples to be cooled were from the high pressure boilers, feed water, condensate, superheaters, and steam lines.
Some of the tests were for Silica, Dissolved Oxygen, and all other related tests for the water treatment.
We designed panels with multiple sample coolers on each panel.
Each sample cooler panel had a common inlet and discharge for the cooling water.

Panel showing common inlet and discharge

Each sample cooler was constructed with Stainless Steel internals and externals. Each cooling coil had 20' of Stainless Steel tubing and each shell was extended for a greater cooling area.

Stainless steel sample cooler internals

Discharge showing stainless steel braided hose to header

Each sample cooler was valved to be independent with valves, and each connection was attached utilizing Stainless braided hose with Teflon internals and/or Stainless steel unions.
Space was a concern so the coolers were staggered on the panel for a smaller footprint.

Inlet with valves and stainless steel braided hose

This accommodated the site requirements for size without restricting the cooling capacity of the sample coolers.
The Stainless Steel drip pan at the bottom of the panel will be used to catch and send to drain all samples not actually being used in the process.

Stainless steel drip pan

Top view of the sample cooler panel

Here are the panels to be put in place for the new facility as well as the upgrade of the existing sample cooler panel.

C&D Dust Control System

A Delaware Construction, Demolition (C&D) transfer station was experiencing extreme dust issues while dumping, moving, and reloading the C&D waste. Not only was it leaving the building to surrounding areas it was also a hazardous work environment for the employees working in the building.
The catch is that the dust has to be knocked down without soaking the floor.
We designed a system that would do just that.
By using nozzles set on specific centers and a regulated pressure we were able to obtain just the right droplet size.
The system also has the capacity to be expanded as the C&D waste intake becomes greater.
The current unit has the ability to operate 3 zones. One at a time, or all three together.
A side advantage is that during the sweltering summer months the building temperature actually drops about 10 degrees which is an added bonus for the workers.
Bottom line is; Happier employees due to better work conditions, higher productivity, and happy neighbors.

Inlet Water Filters

This particular building is 400' long x 100' deep x 50' high

The inlet water for the dust control system passes through 2- 10 micron filters before it reached the pump. This extends pump life and protects the nozzles.

Building view with overhead nozzles

The control panel is wired into a low water cut off valve so if there is a water loss for any reason the dust control pump shuts down.

3 Zone Manifold

Low Water Cut Off Switch

Full Nozzle Flow @ 500 PSI

Nozzles on 5' Centers