Regular maintenance plays a crucial role in guaranteeing that an industrial dust collector works properly. A dust extraction system is designed to gather, separate and filter pollutants and metal residue in industrial facilities, such as processing, manufacturing, and production plants. When maintained properly, a dust collector removes 99% of dust particles from the surroundings.
For industrial dust collectors to work, operators and management should set up a daily, monthly or annual maintenance schedule. A few routine checks of the dust cleaning machine will go a long way toward ensuring proper functioning.
9 Maintenance Tips for Dust Collecting Machines
For optimal performance and maximum life span of the dust extraction system, here are nine industrial dust collector maintenance tips:
1. Differential Pressure Check
Monitoring differential pressure regularly ensures that the industrial dust collector is working smoothly. Depending on the type of dust collecting machine, the differential pressure may vary. In the long run, however, the dust collector will attain a consistent state of activity with a predictable pressure drop.
Monitoring differential pressure on a daily basis will identify early discrepancies that could cause certain problems in performance or output. It may also indicate that modifications are required in the system, or that it is an ideal opportunity to perform a maintenance check. Differential pressure sensors can be used to read the difference in pressure at various points in the dust collector. However, these sensors should also be replaced regularly.
2. Empty Hoppers and Filters
Hoppers are used in dust extraction systems to collect the particles that have been filtered out. For optimal use and to ensure the proper functioning of a dust collector, these hoppers should be replaced every few months. An excessive amount of material in the hopper can block the dusty gas inlet, create turbulence, cause dust re-entrainment, reduce the efficiency of performance, and wear out filters. It can also create a fire hazard.
3. Filter Inspection
Assessing the filters in a baghouse is very important. Dust cakes form in many dust collectors that have felted packs. This is an indication that the collector is working properly. The clean side of the air duct must be checked for evidence of breaks or leaks caused by wear and tear on the filter packs. If a residue cake is hard and doesn’t clean off easily, there could be moisture in the baghouse from low-quality compacted air. Or it may be a sign of an upstream issue, for example, a high moisture content in the process gas.
4. Changing Bags Regularly
Baghouse filters should be changed at regular intervals, according to the recommendations of the manufacturer. Intermittent filter changeouts minimize downtime and maximize performance. It’s best to purchase the filters or bags from the original supplier, or at least a trusted reseller, to guarantee their quality and ensure that they are similar to the ones used before.
5. Emissions Check
Check for emissions from the fumes stack. Noticeable levels of emissions release are an indication that a seal is broken or a sack is torn. Outflows can result in health concerns, property damage, or fines enforced by the Environmental Protection Agency. Emissions leaks must be fixed immediately.
6. Reviewing Diaphragm Valves
Properly maintained diaphragm valves guarantee the viability of the dust extraction system. A torn diaphragm valve may stick open, releasing a large amount of compressed air. This is the greatest expense associated with a dust extractor machine. Diaphragm valves are accessible, and just the internal components must be replaced. You might want to keep a few replacement kits in your inventory in case of emergencies.
7. Normal Leak Testing
Leak testing can be a continuous task for system operators. Standard emissions testing is a predictive maintenance step that ensures that the filters have not failed suddenly. Increased emissions and performance issues can be caused by damaged bags or filters.
8. Ventilation Checks
Exhaust fans provide ventilation throughout the industrial dust collector. If the ventilation fans or ducts are not in good working order, they will impede the functioning of the dust collector. Fan belts must be checked on a quarterly basis, while amperage ought to be checked regularly. Signs that you might need to check your exhaust fans include unusual vibrations and/or squealing noises.
9. Maintenance Programs
Smaller companies with limited resources can have maintenance checks performed by a third-party service provider. This would save both time and money. Safety and maintenance programs should be carried out by experienced, skilled technicians who are familiar with industrial dust collectors. Regular servicing can minimize system downtime and expensive repairs.
If you work in a chemical, pharmaceutical, food processing, agribusiness, metalworking, or carpentry facility, the air you breathe on a daily basis may be polluted. Soil, dust, gases, and synthetic chemicals may be present invisibly around you. Inhaling these substances can lead to some serious health problems for everyone who works in the facility. An industrial dust collector helps combat this problem. It also helps businesses remain compliant with safety and health regulations mandated by the authorities.