Dust collection systems play a critical role in many industrial manufacturing environments. By capturing and containing nuisance dust, they contribute to a cleaner work environment and efficient production schedules.
Like any industrial process component, it’s important to keep the dust collection system well-maintained to maximize production goals. Here are 5 tips to help keep your processing running smoothly and minimize unplanned downtime at your facility.
Tip #1: Align maintenance checks with your operating schedule
Establishing a proactive maintenance schedule that includes daily, weekly, monthly, and annual tasks is important. Streamline tasks so that they become routine and manageable with the right schedule.
For most industrial systems, daily maintenance involves simple tasks, such as checking the differential pressure across the filters and monitoring the fan exhaust stream to ensure filters are working and installed properly. Maintenance tasks like emptying discharge bins, however, will depend on the system’s dust load. For some facilities, this may be a daily occurrence while for others it may be weekly. It’s also important to verify that the discharge container is suitable for the amount of dust you collect, otherwise this could lead to unplanned shut-down periods.
Pro Tip: Consult your equipment vendors for preventative maintenance guidelines specific to their equipment. This can help you identify common tasks and frequencies that can then be altered to fit your operation schedule.
Tip #2: Change filters based on differential pressure, not appearance.
Most end users believe that filters should be replaced when they appear dirty; when in fact, filters are supposed to be dirty. Pulse jet dust collection filters are designed to capture and trap dust particles, forming a “dust cake” on the media, and this in turn, improves the efficiency of the filter. When air can no longer easily pass through the dust cake, filters are pulsed clean, and the dust cake is dislodged. Residual dust particles help trap new particles and recreate the dust cake that enables filter performance.
Monitoring the differential pressure across the media will help you identify when filters actually need to be replaced. During normal operation, the differential pressure will repeatedly climb and fall. A consistently high pressure reading that doesn’t recover after a cleaning cycle or a sudden low pressure drop that does not increase, are both good indicators that filters should be replaced.
Pro Tip: System airflows may fluctuate based on the differential pressure across the filter media. Any sudden increase or decrease in capture velocity could also mean it’s time to replace filter elements.
Tip #3: Maintain discharge devices for optimal performance.
Dust collectors are designed to collect and filter dust; they are not intended to be used for long-term material storage. Below the filter elements, a hopper is configured to direct material into a disposal bin or discharge device. Ensuring material discharges out of the dust collector is critical to the performance of the dust collection system.
Dust that accumulates in the hopper can redeposit onto the filters, increasing the differential pressure and making it harder for the system to maintain the desired airflow. This buildup often leads to unexpected downtime and increased maintenance needs. Material handling devices will have their own preventative maintenance schedules and should be incorporated into an overall maintenance plan.
Pro Tip: When using mechanical discharge devices, such as rotary airlocks, it’s important to make sure that any downstream devices are also capable of supporting the material load. Blockages downstream of the airlock can easily create blockages upstream or inside of the dust collection system.
Tip #4: Know the required airflow for the system
Most industrial dust collection systems use a fan to pull air from the hood, through a series of ducts, to the final exhaust point. Fan selection is based on the required air volume and system static pressure. Just because a fan is turned on, doesn’t mean it’s pulling the correct volume of air.
Effective dust collection relies on achieving specific airflow levels that align with the system’s design requirements. Knowing what these requirements are and how to validate them are key to meeting performance expectations. System airflows should be validated and/or modified as part of a change management program.
Lower than expected airflow may reduce the amount of dust that is captured at the hood and result in increased housekeep measures. Conversely, higher than expected airflow may result in increased abrasion or wear-and-tear of system components. Maintaining an appropriate airflow will improve the system’s effectiveness and reduce maintenance demands over time.
Pro Tip: Use an airflow controller with a variable frequency drive to maintain design airflows in the duct prior to the dust collector. With this arrangement, a design pressure, and therefore airflow, is maintained in the ductwork despite changes in the filter differential pressure.
Tip #5: Automate preventative maintenance with smart technology
Dust collection systems have greatly improved and are now easier to monitor and maintain thanks to smart technology. Technology has turned routine maintenance tasks that previously required manual inspections and recordings into automated processes where sensors provide real-time data of critical system components. Monitoring of airflow, filter differential pressure, particle emissions and discharge devices can now be managed remotely with daily reports and alarm functions.
Using this technology, process owners are able to schedule maintenance work based on data trends that they can see. For example, early indication of filters reaching their end of life, will allow users to schedule filter changes at a convenient time, rather than reacting to a sudden filter breach and unexpected downtime. By detecting potential issues, maintenance teams can address system challenges before they become costly problems.
Pro Tip: New technology can also be applied to existing dust collection systems. There are many retrofit options that will allow you to monitor and maintain all of your dust collection needs.
Conclusion
Dust collection systems are an important component to many industrial manufacturing facilities. Aligning preventative maintenance tasks around daily operations and properly maintaining system components enables process owners to optimize production schedules and reduce unplanned downtime. With key maintenance tasks identified, an established and proactive schedule in place, and automated tools to record information, process owners can efficiently monitor and maintain their dust collection system for long-term performance.
