Smart Machine Technologies recently completed a custom explosion relief door project on a spray cooler for a global chemical manufacturer. The project faced several unique challenges that required innovative solutions.
A Global Chemical Manufacturer
The client is a global developer and manufacturer of oleochemical and oleochemical derivative products used in a wide range of industries. Headquartered in Tennessee they boast a multi-acre-acre site with a 16,000-square-foot technical center and an 8,000-square-foot pilot-scale manufacturing facility.
The two explosion relief doors on the spray cooler equipment used to dry the wet pharmaceutical powder had recently begun to leak. Servicing the 21-year-old doors was near-impossible as they were in operation 24/7. In early 2021, the leaks had reached a level where they had to shut down the production line.
The client turned to Smart Machine Technologies to help them solve this unique and time-pressing challenge.
The Challenge: Missing Blueprints and a Non-Standard Design
The average lifespan of an explosion relief door is anywhere from 20-25 years. When it comes to building an exact replacement, the challenge lies in getting accurate dimensional data. The original files, company names, and contacts often change hands several times since the installation date.
Such was the case for the two explosion relief doors on the client’s spray cooler equipment. Smart Machine Technologies needed to know who the original doors were sold to and their proper application.
Most explosion relief doors share a semi-standard design and are always customized to each project. However, these particular doors required a highly customized design that deviated significantly from the norm.
Making matters more complicated was the fact that it was impossible to physically measure the existing doors due to them being inaccessible while the production line was in operation.
In short, Smart Machine Technologies had their work cut out for them.
The Solution: Design an Exact Replacement
After much research, Smart Machine Technologies realized that they had originally supplied the Philadelphia Safety Device (PSD) explosion doors to the manufacturer of the spray cooler in 1997. This new information allowed them to locate the original drawings and build an exact 2-inch thick replacement instead of the standard 1” thick door.
Downtime for installation is always a concern for any manufacturer, as even a few days of lost production can lead to a substantial loss in revenue. Therefore any onsite work had to be done during routine maintenance of the production line.
Smart Machine Technologies worked closely with the company throughout the life of this project to develop a comprehensive solution and make their production line operations more reliable.
Results: On Time, On Budget, and a Happy Client
Thanks to the team at Smart Machine Technologies, the chemical company now has fully functional explosion relief doors—and a spare one. The extra door will help prevent lengthy downtime and result in significant cost savings in case anything goes wrong in the future.
The maintenance personnel at the company will also be receiving comprehensive training on how to properly maintain and service the doors to help keep them in good operating condition.
The client was very happy with their new explosion relief doors, which allowed them to restart the production line. After the successful installation, they contracted Smart Machine Technologies to work on another explosion relief door project for their manufacturing facility.
Explosion Relief Doors from Smart Machine Technologies
Smart Machine Technologies offers a wide range of custom explosion doors. Learn why more manufacturing companies choose Smart Machine Technologies to help solve their safety device challenges.
Contract
Food & Bev
Safety