Background
The Marine Corps Logistics Base Albany project started as part of a broader Defense Logistics Agency initiative to upgrade dust collection systems in box shops at military facilities across the country. These shops produce wood crates and shipping containers, which means the dust collection challenge is straightforward — it is all wood dust — but still serious from both a performance and combustible dust safety standpoint. The existing equipment in these facilities was older, harder to maintain, and not performing as well as it should.
Baghouse.com reviewed the RFQ, put together a detailed proposal, and submitted a package built around relevant project experience, technical depth, and value. Based on the government’s evaluation criteria, Baghouse.com was selected for the Albany project.
The project at Albany became part of a larger relationship that also included similar box shop work at Barstow, Warner Robins, and Hill Air Force Base. It was part of a larger effort to bring older military woodworking facilities up to a more modern standard for dust collection performance, maintenance, and NFPA combustible dust safety.
Scope of Work
The Albany facility is a woodworking shop where personnel manufacture wood crates and shipping containers. That means the system needed to capture wood dust generated during cutting and handling operations while also addressing combustible dust risks that were not adequately covered by the older equipment.
Unlike some projects that begin with a pre-bid walkthrough, Baghouse.com developed its initial proposal using the information provided in the solicitation package. That included documents, photographs, and layouts from the government. Once the contract was awarded, we went to the site in person to walk the shop and update the engineering plan based on actual field conditions. From there, Baghouse.com prepared a full engineering submittal package that included:
- ⦿ Updated ductwork layouts
- ⦿ Duct sizing calculations
- ⦿ Airflow and velocity calculations
- ⦿ Collector and fan sizing
- ⦿ Combustible dust protection equipment layout
- ⦿ Custom controls
- ⦿ Civil coordination for a new concrete equipment pad
The safety package was a major part of the scope. The new system included provisions for:
- ⦿ Explosion isolation valves
- ⦿ Spark detection
- ⦿ A water extinguishing kit
- ⦿ Explosion venting on the baghouse
- ⦿ Explosion-rated airlocks
In addition to design and installation, the project also carried government-specific testing and turnover requirements, including a formal functional test procedure, on-site verification, and post-startup performance validation.
Solution
The final solution for Albany centered on replacing the old equipment with a modern pulse-jet baghouse and a high-performance, efficient fan. The goal was to give the wood shop a system that would perform better, be easier to maintain, and meet current expectations for combustible dust protection.
Baghouse.com designed the new system around the actual operating conditions in the shop and incorporated the required fire and explosion safety equipment from the start. A custom control package was also included to support proper system operation and integration. Because this was a wood dust application, NFPA compliance was a major part of the value of the upgrade.
Baghouse.com included a quarterly maintenance support commitment, with regular inspections and ongoing system checks. That gives the customer a path to keeping the system operating the way it was designed.
Installation Challenges
As with many government and military projects, the field conditions introduced a few surprises. One of the more important issues was electrical power. The site documentation indicated the system would be served by 460-volt power, but once Baghouse.com got into the field, it turned out the actual available power was 208 volts, which is less common for this kind of industrial dust collection equipment. The team had to adjust the design to accommodate that condition.
There were also the kinds of access issues that are common on military bases, including badge access and coordination for crews and subcontractors. In addition, the team had to deal with a site water supply issue tied to the extinguishing system. A valve outside Baghouse.com’s original scope was not functioning, which required bringing in another contractor and processing a contract modification to complete the connection properly.
A concrete pad also had to be poured for the installation, so Baghouse.com coordinated with a local subcontractor for that portion of the work.
From award to completion, the project took roughly eight to nine months, which included design updates, fabrication, site coordination, installation, testing, and final acceptance.
Outcome and Conclusion
The Albany project gave the Marine Corps Logistics Base a much stronger dust collection system for its wood shop operations. With the new pulse-jet baghouse and fan package in place, the facility should see better suction, better airflow, fewer dust-related maintenance issues, and a more reliable overall system. Just as important, the site now has the combustible dust protection features that were missing from the older setup.
The project also went through the kind of testing and validation process that government customers require. That included a 24-hour functional test with Baghouse.com personnel on site, followed by a 30-day operating period before final certification of compliance. That process has now been completed for Albany.
Baghouse.com will continue visiting the site quarterly to inspect the equipment and help keep it running correctly. This is part of the long-term value of the maintenance support tied to the installation.
