Smart Weld Fume LEV System for E+I - Vertiv

Vertiv are the largest manufacturer of electrical switchgear in UK and Ireland. Their own brand electrical busbar, Powerbar has been so successful the brand name has come into common usage to describe the category.

The company continues to innovate and have become the first in their sector to achieve the new BSI kitemark for BIM. BS 8541 which is a great advantage to their clients who can select and customise their products at an early design stage for faster build times and cost efficiency.

Vertiv differentiate themselves in that they produce all components needed for their products in-house. In their new plant in Letterkenny, they have developed a new production line for the manufacture of 15m modular steel frame buildings which required a bespoke welding fume extraction system.

BEAM were invited to quote for the new weld fume LEV system for the production line. Working with the client, BEAM LEV engineers developed a solution to meet the client’s brief;

• Long range LEV extract arms were needed to cover large-scale production bays.
• Ease of operation and ability to fold the LEV arms was required to facilitate overhead crane access.
• With energy efficiency a priority, Smart controls were needed.
• Full automatic start/stop and variable speed control of the extract fans was requested.

BEAM's proposal exceeded the client’s minimum requirements, and we were delighted to be selected for this prestigious client. The specification of our weld fume LEV system was as follows;

• Super long-reach 9m double articulated extract arms with bearing joints for user convenience.
• Gas-strut balanced extract arms with range of horizontal movement from 0m – 9m, and vertical reach up to 4m to accommodate the client’s large scale steel fabrication.
• Beam provided our unique Smart sockets whereby the welders are plugged in, and a start signal for the LEV extraction is generated when an arc is struck. This avoided the need for external wiring for current or optical sensors.
• Linked to a VSD and fast motor dampers, the system is “fully automatic” and provides LEV extraction to where and when it is needed with potential for up to 70% energy savings compared to industry norms.

• BEAM's unique Smart controls ensure that extraction is only provided where and when it is needed – matching the energy demand to actual requirement in real time.
• Operating costs are optimised.
• Fully automatic system which does not require any operator input.
• Heat loss is minimised.
• The Smart LEV system is a positive contributor to the whole building efficiency.

Ahead of the installation, the client had prepared the mounting steelwork for the arms which allowed BEAM installation engineers to complete the project ahead of the scheduled date. This was followed by the commissioning and demonstration and hand over to enable the system to go into production as quickly as possible.