FACTAIR NEWS
Safe-Air Trolleys
Factair is proud to launch its new range of Safe-Air Trolleys, which incorporate CO and CO2 reduction systems as standard.
The SAT450 is the ideal breathing-air purification system for those working in areas where there is a risk of higher than normal levels of carbon monoxide or carbon dioxide being ingested into the compressed-air system.
The unit incorporates a compressed-air filtration and drying system which delivers a smooth, controlled, uninterrupted supply of breathing quality air far exceeding the requirements of BS EN12021. For heavier duty applications the SAT450HD is available which also includes an additional 1 micron pre-filter.
Built to last the SAT450 is mounted within a tough polyurethane housing. With virtually no ferrous components the unit incorporates stainless and aluminium components making it suitable to be used in tough and arduous environments. The stainless steel wheeled frame allows the unit to be easily manoeuvred into position
At the rear of the unit there are 2 CEJN breathing-air outlet couplings, the pressure being delivered to the user from these outlets can be adjusted via the regulator inside the unit.
Operation
The compressed-air supply is connected to the input connection on the side of the Safe-Air Trolley, air is then passed through a 1 micron pre-filter (SAT450HD only) and a 0.01 micron combined oil mist coalescing and carbon filter further reducing oil carryover to less than 0.003ppm. The air is then delivered to a pneumatically controlled pressure swing dryer incorporating a desiccant media capable of both drying the air to a pressure dewpoint of -40°C and significantly reducing the levels of carbon dioxide. Purge air from this system is exhausted from the cabinet via silencers at the rear of the unit. The dried air is now passed through a hopcalite catalyst filter which oxidises excess levels of carbon monoxide back to safe levels of carbon dioxide.
The system provides a safe reliable source of breathing quality air in excess of all international breathing standards with the additional confidence of protection against surplus levels of carbon monoxide and carbon dioxide.
F4000 & F4001 Safe-Air Testers
Factair, the market leader in breathing-air quality testing instruments, is pleased to announce they have launched latest generation of instruments.
The new F4000 and F4001 units incorporate a built in memory to allow test results to be recorded and then downloaded to a PC via a USB memory stick. Mounted within robust PELI cases the F4000 and F4001 testers weigh less and are more compact than the previous generation of instruments. With an easy to use touch screen menu, the correct oil test time can be selected from the built in memory which features over 360 different compressor oils.
The F4000 has an electronic flowmeter and has been designed for systems up to 10 bar as well as high pressure systems when used in conjunction with the F3002 regulator. The F4001 is designed specifically for high pressure cylinders and charging compressors. An optional digital dewpoint meter to measure water content is available for both the F4000 and F4001.
Ventilating Totley Tunnel
Factair recently completed its largest ever ventilation project at Totley Tunnel. Factair was working for ameyCOLAS which was completing a track and formation renewal contract on both roads from Grindleford station towards Totley.
At 3.5 miles in length, Totley Tunnel is the longest mainline railway tunnel, that runs its entire distance under land, in the United Kingdom. The tunnel is located on the outskirts of Sheffield and was completed in 1893. During its construction a natural cavern was discovered near the centre of the tunnel which is several hundred square feet in area and it was decided to incorporate this into the design and a large ventilation shaft was installed up to the surface at this point. This part of the tunnel is now fittingly described as “The Cathedral”.
With 4 additional ventilation shafts at the Totley end of the tunnel Factair’s engineers soon realised this was going to be a challenging project to ensure the entire work site was adequately ventilated. Factair’s engineers calculated that at any one time there was up to 12 Megawatts of diesel engines powering the equipment operating within the tunnel. When you consider the dust and fumes being generated from the work undertaken, not to mention the frequently moving plant equipment within a confined space, you can appreciate these are places where you certainly need to keep your wits about you.
Unusually prevailing conditions in the area meant air tended to be drawn in from both ends of the tunnel and ventilated out through “The Cathedral” ventilation shaft. As the length of the renewal work on one of the roads extended beyond “The Cathedral” Factair had to ensure air did not become stalled within the tunnel when its forced ventilation counterbalanced the incoming natural ventilation.
Normally Factair would temporarily install ventilation systems adjacent to the portal which would blow from one end of the tunnel all the way through to the other. The system would have sufficient power to keep the whole column of air within the tunnel moving at a minimum of 80 metres per minute, thereby ensuring the air within the tunnel was continually being replaced and limiting the build up of dust and fumes. This arrangement has a number of advantages over fans deployed locally within a tunnel. Firstly it avoids the possibility of the fumes and dust only being shifted along the tunnel but not out of it. Secondly it ensures there are no additional obstructions within the tunnel, keeping the workspace clear for the movement of plant and personnel.
For Totley Tunnel Factair had to provide a system which could be varied to suit the changing natural conditions, this resulted in 18 of its 1.2 metre diameter electric fans being installed in the Cess adjacent to the Grindleford portal, delivering a maximum total airflow of 1.5 million cubic metres per hour! In addition a self contained 1.8 metre diameter engine driven fan was located in “The Cathedral” which produced an additional 180,000 cubic metres per hour. During the blockade the electric driven fans were run in varying numbers, to maintain a safe working environment, whilst also ensuring air speeds did not become too high and cause a significant wind chill in the cold winter conditions. The diesel driven fan was used to assist the induction of air into “The Cathedral” past the 4 previous ventilation shafts. As the work progressed through the tunnel and beyond “The Cathedral” the airflow was managed to ensure that the natural airflow from the Totley end continued to ventilate those working in this area.
During the blockade Factair’s engineers remained on site to ensure the equipment operated continuously and to regularly test air quality, wherever there was a worksite within the tunnel. The pollutants tested included carbon monoxide, carbon dioxide, nitrogen monoxide, nitrogen dioxide, airborne dust particles, volatile organic compounds, acetylene, hydrogen sulphide as well as the oxygen level; also the key members of staff such as machine operators, machine controllers and COSSs were individually issued gas detectors which monitored the main pollutants. This element of the service is vital and is designed so that at no point do those within the tunnel ever have to leave the worksite unnecessarily unless pollution levels have risen above those stipulated in EH40. The readings during the blockade are then compiled into a formal report which provides a useful health and safety record.
For the dustiest applications such as controlling auto-ballasters or for staff with existing respiratory problems such as asthma, Factair also provided battery powered air fed helmets. These self contained units deliver filtered breathing-air to the face of the user and feature an integral hard hat, hearing protection and eye protection to EN397.
With this comprehensive ventilation system Factair was able to ensured ameyCOLAS was able to complete the renewal work within the tunnel without any disruption due to problems with the atmospheric conditions. Should you have a tunnel renewal project, where you suspect fumes and pollution could be a problem, then Factair is on hand to recommend a solution and provide a no obligation site survey and quotation. To contact the company call 01473 746400.
Providing a safe atmosphere during the Blea Moor Tunnel Renewal Project
Never more so than when the site is a railway tunnel in the remote North Yorkshire moors, far out of reach of any mobile phone signal!
Factair recently helped First Engineering with a track and formation renewal project in Blea Moor Tunnel. With locomotives, diggers, dozers, generators and engine powered tools, totalling up to 6,600 kW of combined engine power, all being used within such a confined space, the atmosphere would have quickly become hazardous to health. To prevent this Factair supplied a ventilation system capable of ventilating the entire 1.5 mile long tunnel.
The renewal project was planned as a 5-day (120-hour) blockade during which Factair deployed 12 of its modular fans as a system delivering a total airflow of 324 m3/s. The immense power of these fans meant they could be deployed adjacent to the portal, at one end of the tunnel, leaving both roads free for traffic with no additional equipment being required in the already busy tunnel. This was no mean feat considering Factair kept the entire column of air, which has a volume of 120,000m3 and weighs almost 143 tonnes, moving between 1.5 and 3.5 metres per second for the entire blockade!
The ventilation system was supported by Factair’s engineers who performed regular atmospheric monitoring within the tunnel to check levels were within the workplace exposure limits stipulated by EH40.
For those working in particularly dusty situations, such as controlling whacker plates or auto ballasters, Factair supplied battery powered air fed respirators, which provided the users with head, ear, eye and breathing protection in one integral unit. Datalogging personal gas detectors were also supplied to key workers such as COSSs and machine drivers.
These measures helped ensure that First Engineering was able to proceed with the renewal work in a safe atmospheric environment, free from obstructions or interruptions.
At the end of the blockade Factair presented Ian Kilpatrick from First Engineering with a detailed report on the atmospheric conditions within the tunnel. This provided a useful record confirming the effective strategy and supporting the duty of care that has been delivered by First Engineering to both its employees and subcontractors during a successful renewal project! Case Study PDF
Civil engineering in railway tunnels can be a hazardous undertaking.
When you consider the dust and fumes being generated from the work undertaken, not to mention the frequently moving plant equipment within a confined space, you can appreciate these are places where you certainly need to keep your wits about you.
Hazards can come in many forms including exhaust fumes from diggers, bulldozers and locomotives; ballast dust from stone being removed or replaced; brake dust; fumes from welding, cutting and grinding.
To help in managing this problem Factair has developed the most extensive range of temporary ventilation and monitoring equipment on the market. Factair has been supplying tunnel ventilation and air quality monitoring services to the rail industry for over 13 years. In that time it has developed a comprehensive fleet of ventilation fans, which can be deployed in a variety of configurations, this is supported by a sophisticated range of instruments to monitor the air quality in the tunnel and respiratory protective equipment for individuals working in the dustiest applications.
Factair works closely with its clients, beginning with a site survey, progressing through to developing a risk assessment and method statement. Factair utilises sophisticated flow management software to establish the required airflow within the tunnel, allowing for obstructions such as locomotives and the air loss from ventilation shafts. This ensures that the ventilation scheme will be able to cater for the work being undertaken within the tunnel and the pollution from the vehicles operating within it. This is a vital part of the service and is designed so that at no point do those within the tunnel have to leave the worksite because pollution levels have risen above those stipulated in EH40.
Factair recently ventilated and monitored the atmospheric conditions within Abottscliffe and Shakespeare tunnels for Balfour Beatty Rail Infrastructure Services Ltd. Balfour had a contract to renew the ballast stone and track within both tunnels. The tunnels were ventilated using the modular fan system which ensured there was no equipment on track to obstruct the movement of plant, locomotives or personnel. This was especially useful for the Shakespeare Tunnel project where each road has an individual tunnel portal but there are large cross-passages situated inside joining each tunnel. As a result access for plant equipment was at a premium and Factair designed a stacked system of fans which moves air high in the tunnel as well as at ground level successfully ventilated the tunnels whilst allowing for the airflow losses through the cross-passages.
When it comes to ventilating a railway tunnel there still is no substitute for horsepower and Factair has the most powerful temporary ventilation fans on the market. Factair’s latest modular series fans each produce over 97,000 cubic metres an hour with a typical contract being supplied with in excess of half a million cubic metres an hour of air!
Wherever possible Factair deploys its fans adjacent to the tunnel portal in a number and formation sufficient to keep the whole column of air within the tunnel moving at a minimum of 80 metres per minute. This arrangement has a number of advantages over fans deployed locally within a tunnel. Firstly it avoids the possibility of the fumes and dust only being shifted along the tunnel but not out of it. Secondly it ensures there are no additional obstructions within the tunnel, keeping the workspace clear for the movement of plant and personnel.
During the possession Factair’s engineers remain on site to ensure the equipment is operating continuously and regularly test air quality wherever there is a worksite within the tunnel. The pollutants tested as standard are carbon monoxide, carbon dioxide, nitrogen monoxide, nitrogen dioxide, airborne dust particles, volatile organic compounds, acetylene, hydrogen sulphide as well as the oxygen level.
During the site survey the best location for deployment of the fans is identified and wherever possible this will be in accordance with the prevailing wind conditions. Factair’s fans, however, can be reversed in air flow direction without any re-deployment, should prevailing wind conditions change, which is always a possibility in the British Isles!
Also during the possession key members of staff such as Machine Operators, Machine Controllers and COSSs are individually issued gas detectors which monitor the main pollutants and also continuously datalog the readings. These results are compiled together with readings taken by Factair’s engineers and supplied to the client as an environmental report at the end of the contact. This provides a useful health and safety record for the client.
For the dustiest applications such as controlling auto-ballasters or for staff with existing respiratory problems such as asthma, Factair also provides battery powered air fed hoods. These self contained units deliver filtered breathing-air to the face of the user and feature an integral hard hat, hearing protection and eye protection.
Should you have a tunnel renewal project, where you suspect fumes and pollution could be a problem, then Factair is on hand to recommend a solution and provide a no obligation site survey and quotation. To contact them call 01473 746400. Case Study PDF
Factair, UK market leader in breathing-air quality testing instruments, has launched the F3004 Medic-Air Tester.
The F3004 was designed to establish air quality for medical and surgical air systems in accordance with the recently revised European Pharmacopoeia Convention.
The convention now permits two levels of acceptable water levels either 60 ppm or 870 ppm dependent upon the type of system. The F3004 can be programmed to check for both levels.
Additionally, with the ongoing introduction of specialist compressor oils the F3004 has a fully programmable test facility when used in conjunction with Factair’s oil test data provided on over 300 different compressor oils which ensures oil determination down to 0.1 mg/m3.
The detection parameters of the convention are met or exceeded during the test by using Draeger detector tubes. These establish levels of carbon monoxide, carbon dioxide, water vapour, oil, nitrous fumes, sulphur dioxide and hydrogen sulphide, present in the sample. An in-built electronic sensor with digital read out measures oxygen content together with digitally displayed system pressures and temperatures.
The instrument is completely portable, operating from standard AA batteries, which provide a prolonged operating life. The unit is supplied with a ‘laptop’ style carrying case which protects the unit during transport and has individual pockets for storing chemical reagent tubes, inlet adaptors, tube tip cutter and documentation.
The F3004 will test systems between 1.5 bar and 10 bar and can be provided with an optional regulator and connecting hose to accept pressures up to 20 bar. Case Study PDF
Containerised Breathing-Air Solutions
As confined spaces go you don’t get much more confined than the inside of an aircraft wing, especially when the interior contains a fuel tank that needs to be regularly cleaned with highly volatile chemicals.
Those working in such confined environments, where the atmosphere is obviously too hazardous to breathe, require long duration breathing apparatus to ensure they can operate safely. This was the problem that faced the engineers of BAe Systems at the RAF Kinloss Nimrod aircraft base in Scotland.
Factair worked with them and developed a containerised breathing-air system that could supply up to 8 people simultaneously. To meet this requirement the container incorporates 2 rotary screw compressors in a duty/standby arrangement. The air supply from the compressors is passed through a filtration and drying system, which purifies the air to breathing standards. The air is then supplied via a pipework system to each aircraft hanger.
As the container is essentially a piece of life support equipment it was critical to incorporate a back-up system that, in the event of a power failure or machinery breakdown, continued to provide breathing-air to those working inside the fuel tanks. The unit contains a reserve of breathing-air stored in cylinders at high pressure. A separate compressor ensures that the reserve air supply is maintained and alarms in the container and hangers detect any faults and warn users to leave the hazardous area. It was also vital that the compressor air intakes are protected against possible contaminants such as carbon monoxide, carbon dioxide and LELs. A gas detection system is fitted in the intake, which is interlinked with the high-pressure reserve and alarm systems.
RAF Kinloss is a remote site and it was therefore important that the status of the system could be monitored remotely either by BAe Systems or Factair. A link was installed which allows the control system within the container to be interrogated via a modem connection. This allows routine servicing to be better scheduled, diagnostics to be undertaken, therefore optimising service visits.
Now the containerised system is installed BAe Systems have a state of the art unit that not only provides a highly reliable source of filtered breathing-air but also incorporates the latest in safety back-up and remote diagnostic features. Case Study PDF
Coates Rentair, the international compressed air rental specialists call on factair!
Coates Rentair, the international compressed air rental specialists, needed a mobile unit that could provide high-pressure compressed air, filtered to breathing quality standards (BS4275, EN132 and EN12021). The requirement was for a unit that could deliver 1700 l/min at a pressure of 350 bar. A task for which the Compair Reavell 4-stage, watercooled, reciprocating 5436 MkII Compressor is ideally suited.
Working in partnership Coates Rentair, Factair and Compair Reavell have developed the highly specialised F5436E. This unit needed to meet the stringent specification set by Coates Rentair whilst retaining the flexibility to work in a diverse range of applications including Naval dockyards, Nuclear Power Stations and the Petrochemical industry.
The F5436E are unique fully self contained site mobile systems carrying the Coates Rentair livery, each unit is totally enclosed, rather than open sided, with external pushbutton controls ready for immediate operation after simply connecting to an electrical supply.
Environmentally friendly, with energy efficient motor, condensate collection and filtration, on-board dryer and storage for 36,000 litres of breathing quality air, the units are designed for easy maintenance. Being fully encased and weatherproofed, added advantages include quiet running and a prolonged life expectancy. Pictured is the third unit which has just been delivered to Coates Rentair.
Top: Coates Rentair High Pressure Compressor
Bottom: Control Panel inside High Pressure Compressor
The petrochemical industry has many situations where the ambient atmosphere is hazardous to breathe.
One of the most common situations is the cleaning of residue from the bottom of tanks containing substances such as crude oil and styrene. The air in these tanks is highly hazardous to health and anyone working in this type of environment needs to be protected with suitable respiratory protection and clothing.
Cleaning of these tanks involves the shovelling of the residual oil sludge from the bottom of the tank. This work is both tiring and time consuming; anyone working in this environment needs an air supply system that is both comfortable to wear and provides a cool odour free source of air. In addition to the atmosphere being toxic these tanks have limited access and the oil residue makes movement inside the tanks both difficult and tiring.
To solve this problem Factair has developed a range of mobile breathing-air compressors. Because reliability is paramount, these units use the Gardner Denver rotary vane compressor and are powered by diesel engines. As the Gardner Denver rotary vane compressor does not require an air receiver the resulting breathing-air compressors are both compact and highly mobile. This enables the units to be positioned as close as practicable to the point of work reducing the amount of breathing-air hose that has to be used.
The units incorporate a sophisticated alarm and high pressure air cylinder reserve system which ensures that in the event of a mechanical failure the users operating in the confined space are ensured a continuous air supply.
These units have become the industry standard within the UK and are also widely distributed throughout Europe. The petrochemical industry has many situations where the ambient atmosphere is hazardous to breathe.
Top: Confined Space Entry with BA Equipment
Bottom: Final checks on a BA25DE mobile breathing air compressor prior to entering an oil storage tank.
Warrior compressor with standard tools
Have you ever wondered how the military service their armoured vehicles, as they can require maintenance or repair work in the most inhospitable places, far away from any service facilities?
Over recent years the armed forces have had to rapidly deploy to an increasing number of areas, such as Kosovo, lacking any equipment or facilities from which to maintain the military equipment. In addition to this the roads and infrastructure of these areas are often so limited or damaged that tyres and track need to be repaired more frequently.
In the past this work would have been completed the hard way with manual tools. To improve upon this method the British military therefore identified a requirement for a mobile compressor that could power a range of air tools to speed up and simplify the maintenance process.
In conjunction with the Ministry of Defence, Factair has since developed and supplied a range of mobile tool compressors that have been designed to fulfil various applications including track repair, tyre inflation and general maintenance. These units have been designed to meet stringent military requirements and have both a lightweight and rugged construction.
Powered by either petrol or diesel engines with a specially selected range of tools including tyre inflators, impact wrenches, track pad removal tools, needle scalers and grinders, each unit has been customised to suit its intended role. Case Study PDF
Air powered needle scaler at work on a Scimitor CVR T
Maintaining equipment and vehicles on sites and in storage yards can be a problem when you need power to drive air tools and equipment.
Often these sites have only limited facilities which are generally remote from your point of working. The terrain is also often rugged and presents a difficult challenge for moving large pieces of support equipment around.
To cater for this type of environment Factair has developed a range of compact engine driven compressors.
The range is built around the proven Gardner Denver rotary vane V02 and V04 compressors, which provide an efficient and reliable source of compressed air, ideal for powering small tools such as impact wrenches and pneumatic drills.
Because the VO2 and V04 do not require an air receiver the units are both lightweight and highly mobile, making them ideal for moving over rough terrain or through areas of restricted access. Power sources for the range include petrol, diesel and hydraulic motors. The latest generation of mobile engine driven rotary vane compressors incorporate a modular concept that allows options such as filters, aftercoolers, inboard wheel kit, site mobile pneumatic wheel kit, tool trays and even electric start engines to be fitted with ease.
Many hire companies have found that they can maximise the utilisation of their fleet by being able to customise each unit to suit individual applications.
The mobile engine driven rotary vane concept has proved so successful that a whole range of specialist units have been developed and are now the industry standard for the UK telecommunications and rail industries. Case Study PDF
Top: An engine driven unit being used to reapair tyre on plant machinery
Bottom: An engine driven unit being used to repair a mobile lighting tower.
Air Power for the Rail Industry
RailAir compressor being used for Stoneblowing. The rail industry has a problem of trying to ensure that track is both safe and well maintained whilst maximising the time the track is available on which to run trains. In the past trackside maintenance work such as track levelling, tightening fishbolts and rail baseplate coach screws would have been completed manually.
Factair has now introduced the custom designed RailAir compressor which provides a source of compressed air that can be placed on the trackside close to the point of work. The RailAir compressor has been so popular in the UK that it can be considered the industry standard mobile rail compressor.
As a result it is used for a wide variety of applications, some of the more unusual include powering air operated moles for running cables under track, air lights and driving air operated power packs at up to 700 bar.
The RailAir compressor uses a petrol engine driven CompAir rotary vane compressor to provide an output of 10.4 l/s (22.0 cfm) at 7 bar. One of the main advantages of using the CompAir compressor is that it does not require an air receiver allowing Factair to design a compact unit that is highly mobile. One of the most popular applications for the RailAir compressor is in track levelling work, particularly around switch toes and crossing areas. The original compacting technique known as tamping has been replaced by a ‘stoneblowing’ process, which generally lasts twice as long as tamping. To enable the compressor to be used in red zone working an automatic warning device is available.
Top: RailAir being used for Stoneblowing
Bottom: RailAir Compressor and Accessories
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