35+ Years of industrial filtration experience
Essential Dust Collector Maintenance Tips for Peak Performance
Dust collectors are key to maintaining good air quality in industrial work environments by effectively removing airborne contaminants. After a dust collection system is installed, there is typically very little upkeep required, although the exact maintenance frequency depends on how heavy the application is.
A dust collection system will continually perform well as long as it's maintained regularly. To guarantee that your dust collectors are operating effectively - it is vital to remain updated on maintenance, including regularly changing filters, paying attention to overfilled dust bins, and monitoring airflow and system pressure.
1. Create a Maintenance Plan
It's important to have a preventative maintenance plan in place to guarantee that the dust collection systems components are working properly and, if not, replacing any damaged or broken elements, and taking corrective action if the operation process is unlike design conditions.
We recommend keeping a record of daily, weekly, monthly, and yearly inspection logs as directed in the manufacturer's manual.
2. Compressed Air Pressure
One of the most critical aspects of maintaining dust collectors is compressed air. There are a few factors that ensure compressed air is up to standard:
• High-quality air pressure is key to ensuring the best clean.
• If the pressure is too low, cartridges are not adequately cleaned, resulting in saturation.
• If compressed air pressure is too high, cartridges will be used and replaced more frequently.
• The power of the compressor needs to be strong enough to supply air at a constant pressure throughout maximum production and when operators require high levels of compressed air.
3. Dust Collector Filter Media
Inspect the clean-air side of the dust collector for leaks and the bag filter for tears.
The filter media is the most important element because it collects and controls the dust. If pressure drop within a collector becomes high it may be due to excessive dust buildup or blinding of filters.
Our dust collector replacement filters feature a pleated design that provides more surface area than traditional baghouse bag filters. Because of their design, cartridge filters allow air to flow through them easily while capturing dust particles more efficiently. When you shop with us, you can buy with confidence. If your expectations aren't met, we will replace your filter at no cost!
4. Don't Forget to Empty the Hopper
Hoppers may be used to direct collected dust to storage containers or transport systems, but they aren't meant for storage.
It's important to check the empty dustbin regularly to prevent bridging. Bridging traps dust in the hopper and can raise the pressure drop in the dust collector.
5. Look for Emissions
Keep an eye out for particulates that are discharged from the exhaust stack. Visible emissions suggest a tear in a seal or filter.
If you notice emissions leaking it's imperative to find the tear as they create health risks, property and equipment damage, and possible fines. It's recommended to integrate a broken bag detector that alerts staff of bag failure or leaks.
6. Don't Exceed Pressure Drop
When filter bags accumulate dust, some particulate becomes ingrained into the filter media and increases the appropriate pressure drop. The airstream that filters through this dust collects the fine particulate using high-efficiency. High differential pressures can cause filter media to bleed, impeding the dust collector's ability to capture dust and allowing it to escape into the surrounding environment.
• When airflow reaches a differential pressure of 120 to 150daP or above max. specifications it's time to change the filter.
• Differential pressure is the amount of static resistance across filters when operating a positive or negative pressure dust collector.
• A pressure drop is generally measured in inches of water column, or wc, and indicates the amount of dust collected on filter media and the condition of filters.
7. Choose the Proper Exhaust Fan
An exhaust fan is used to quickly send ventilation air from the hood or point of pick-up through the ductwork and dust collector filter and out of the exhaust stack. To determine which exhaust fan meets SCFM requirements, calculate the pressure drop by gauging the static resistance of ductwork, the dust collector, and hoods or pick-up points.
8. Structual Quality
The quality of a dust collector's structure can affect performance and maintenance, and reduce equipment life. It's important to inspect welds, joints, and flange seals. All leaks should be sealed mechanically or with silicone caulking.
In a positive pressure system, dust will blow out of the collector, creating a potential risk to employees.
In a negative pressure system, a tear in a seal or weld will allow ambient air to enter the collector bringing in moisture and contaminants.
Signs to check for:
• Make sure all fasteners are in place and tightly fastened.
• Check the structure for excessive corrosion and signs of weakness.
• Replace and re-weld any components that have cracked welds such as bolts, cross bracing, or gussets.
• Closely evaluate the filter's external walls for corrosion or bowing.
• Repair holes in the dust collector walls or hopper.
9. Check That the Cleaning System Is Functioning
Reverse air, pulses, and shakers are all used to loosen up dust from filter media. If the system that your dust collector uses is not properly functioning, dust will continue to build resulting in an increased pressure drop and a decreased volume of ventilation air.
If the situation escalates, airstream velocities will reduce, causing a dropout of dust in the ducts, which can interrupt the entire system.
