Industry: Machinery manufacturing

Comprehensive gas safety monitoring solution for machinery manufacturing

Industry Pain Points

The machinery manufacturing industry covers vehicle assembly plants, heavy machinery, precision machining, molds, and welding assembly. The gas risk characteristics are a combination of "process dust + VOC spraying + localized open flames": ① **Welding workshop**: argon arc/CO2 welding fumes (including NOx + CO + manganese + chromium, etc.), with employees densely exposed for long periods, causing respiratory damage; ② **Spraying/coating line**: VOCs (toluene/xylene/butyl acetate) + curing oven LEL. In recent years, a certain automobile OEM has invested tens of millions of yuan in VOC rectification in its spraying workshop; ③ **Casting workshop**: high-temperature CO + SO2 (coke combustion) + dust (metal dust has an explosion lower limit); ④ **Heat treatment workshop**: carburizing/nitriding/quenching — CO (protective gas) + NH3 (nitriding) + CH4 (carrier gas); ⑤ **Machining cutting fluid**: long-term use of water-based cutting fluid produces bacteria → endotoxin + odor; ⑥ **Environmental regulation**: HJ 1093 emission standards + LDAR legal requirements + boundary odor control + park supervision. The machinery manufacturing industry is the second largest source of VOC emissions (accounting for 12% of the national total), and is subject to strict regulation.

Solution Overview

Youri'an's mechanical manufacturing solutions cover five major processes: welding, spraying, casting, heat treatment, and assembly: ① **Welding workshop**: Distributed CO + NOx + fume + local exhaust air status joint measurement, linked with mobile welding fume purifiers; ② **Spraying/Coating line**: VOC PID online monitoring + curing oven LEL × 25% interlock gas cut-off + baking oven flue RTO (regenerative thermal oxidizer) inlet/outlet concentration (monitoring RTO treatment efficiency ≥ 95%); ③ **Casting workshop**: CO + SO2 + dust + high-temperature protection probe (temperature resistance 80°C); ④ **Heat treatment workshop**: CO + NH3 + CH4 multi-component + furnace door interlock; ⑤ **Machining and cutting fluid workshop**: endotoxin + VOC + air volume monitoring; ⑥ **Factory boundary + chimney emissions (environmental compliance)**: HJ 1093 Continuous Emissions Monitoring System (CEMS) (VOC + particulate matter + NOx + SO2) + four factory boundary odor monitoring stations, with data directly connected to the environmental protection bureau's regulatory platform.

## Key Monitoring Nodes (By Process)

### Welding Workshop
– CO 0-200 ppm + NOx（NO + NO2）
– PM2.5 + PM10 (welding fume)
– Distributed probes: 1 probe per welding position + linkage with the air volume of a mobile welding fume extractor

### Spraying / Coating Line
– **Spray Booth**: VOC PID 0-1000 ppm (toluene / xylene / butyl acetate) + LEL
– **Leveling / Drying**: VOC + Temperature
– **Curing oven**: LEL × 25% high alarm → shut off main gas valve; CO incomplete combustion + O2 combustion monitoring
– **RTO regenerative thermal oxidizer**: inlet + outlet VOC concentration (calculated treatment efficiency = 100% × (inlet – outlet) / inlet, ≥ 95% compliance)
– **Workshop main exhaust outlet**: Continuous Emission Monitoring System (CEMS) for flue gas (VOC + particulate matter + NOx + SO2)

### Foundry workshop
– Cupola / Furnace: CO + SO2 (coke combustion)
– Pouring / Sand Removal: Dust (explosive metal dust → explosion-proof grade Ex d IIIB / IIIC) + CO
– Sand processing: dust + VOC (resin sand)

### Heat treatment workshop
– Carburizing / Nitriding / Quenching Furnaces: Multi-component detection of CO, NH3, and CH4
– Furnace door interlock: CO + LEL detection must meet the standard before opening the door
– Atmosphere furnace: H2 + CO + N2 flow rate + concentration monitoring

### Machining / Assembly (Low Risk)
– Cutting fluid mist + endotoxin
– Local VOC (cleaning agent usage)

## Key Technical Specifications

– Explosion-proof: Ex d IIB T4 (spray coating / baking oven) + Ex d IIIC (cast metal dust)
– Protection: IP65 (high dust in workshop + cutting fluid splash)
– Range: VOC PID 0-1000 ppm (PPB level sensitivity) + LEL 0-100%
– Response time: T90 < 30 seconds (PID)
– Operating temperature: -20℃ ~ +60℃ (workshop) + 80℃ (high temperature casting)
– Communication: Modbus + Profinet (interface with workshop PLC / SCADA)
– CEMS flue gas online monitoring: certified by CCEP / CMC (issued by the Ministry of Environmental Protection)

## Implementation Key

1. **VOC + RTO treatment efficiency compliance**: The core of strict environmental management requires monitoring of both inlet and outlet concentrations to demonstrate a treatment efficiency of ≥ 95% (GB 16297 + HJ 733)
2. **LDAR statutory leak detection**: Conduct PID inspections on flange, valve, and pump sealing points four times a year. Any reading exceeding 500 ppm indicates a leak
3. **Integrated welding fume purification**: Increase in CO + NOx → Automatically increase the air volume of the welding fume purifier
4. **Casting dust explosion protection**: The lower explosion limit of metal dust accumulation is much lower than that of gas (aluminum powder 30g/m³), requiring independent explosion-proof IIIC level + anti-static grounding
5. **Data-linked environmental monitoring platform**: CEMS data is automatically reported to the local environmental protection bureau every minute, and in case of exceeding standards, an automatic SMS notification will be sent to the factory manager + a warning of potential fines

## Regulatory Basis

– HJ 1093-2020 "Continuous Monitoring System for Pollution Source Flue Gas"
– HJ 733-2014 "Control of Volatile Organic Compound (VOC) Emissions from Leaks and Open Liquid Surfaces"
– HJ 1131-2020 "Technical Guidelines for Leak Detection and Repair (LDAR) of Volatile Organic Compounds in Industrial Enterprises"
– GB 16297-1996 Integrated Emission Standard of Air Pollutants
– GB 50058 Electrical Apparatus for Explosive Gas Atmospheres
– GB 50493 Detection and Alarm Design
– GBZ 2.1 Limits (Welding Fume / Cutting Fluid Mist PC-TWA)

## Applicable Customers

Vehicle manufacturers (FAW / SAIC / BYD / Geely / Great Wall / Changan / NIO / Ideal / XPeng / Tesla China); components + molds (Huayu / Fuyao / Tuopu / Sanhua); construction machinery (XCMG / SANY / Zoomlion / LiuGong / Shantui); heavy machinery (Shanghai Blower Works / Harbin Electric / Shanghai Electric); shipbuilding (Waigaoqiao Shipbuilding / Jiangnan Shipbuilding / Hudong-Zhonghua); machining + mold SMEs (industrial clusters in Jiangsu, Zhejiang, Guangdong, and Shandong).

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