Dust collector parts and components are vital to ensure that industrial dust collectors operate at peak efficiency. Though dust collection systems are engineered to filter, collect, and separate harmful particulates and dust from the air in factories, processing plants, and production facilities, they are only as effective as the parts necessary to run smoothly. Several parts can help improve performance and extend the life of a dust collector.
For optimal performance, optimum efficiency, and longevity of a dust collector, parts and components should be monitored regularly and replaced when needed. To ensure your system runs smoothly and as designed, here are 6 essential dust collector parts to keep an eye on:
Filters are the key performance indicator of every dust collection system. In baghouse systems, filter bags for pulse-jet and shaker-type dust collectors have an average service life of approximately 1 to 3 years. A filter bag’s lifespan will depend on the type and amount of emissions generated at the facility. Bag materials consist of common fabrics such as cotton, polyester, and polypropylene, as well as high-performance media like aramid (Nomex), acrylic, polyimide (P-84), PPS (Ryton), fiberglass, and PTFE (Teflon). No matter the application, filter bags should be monitored regularly for leaks or premature damage caused by tears in the fabric or singe marks and holes from sparks or embers.
Cartridges and Pleated Bags
Lifespans for cartridges and pleated bag style dust collection systems, both horizontal mount and vertical mount styles, can vary considerably with the facility. It’s recommended that cartridge filters undergo routine maintenance and change-outs regularly for the system to operate at optimum efficiency. Filter media options for replacement include nanofiber and spun-bonded polyester, cellulose-polyester blends, flame retardant, carbon impregnated, hydro-oleophobic, and PTFE membrane. Depending on your environment, because the time between filter replacements can vary by facility, regular monitoring will gauge the approximate lifespan of a cartridge filter for a given system.
Types of Valves
Solenoid valves, pulse valves, and diaphragm valves are integral components designed to control the baghouse cleaning mechanisms. The valves regulate airflow through the filters to facilitate cleaning operations. For example, pulse jet solenoid valves create shock waves that remove dust from filter bags. Properly maintained valves ensure the efficiency and effectiveness of a dust collection system. Faulty valves waste large amounts of compressed air, resulting in poor bag cleaning, and are costly when left undetected. Valves must be regularly monitored, repaired, or replaced as needed.
Bag Cages, Venturis, Bag Cups, and Clamps
As the name suggests, dust collector cages provide the required support and shape to the dust collector bags. Cages prevent the bags from collapsing. In time, the cages are prone to wear, and assemblies can break. Replacement bag cages and cups, along with clamps, are important dust bag hardware needed for routine maintenance and repair of dust collector systems. Bag cages are designed to different diameters and lengths and are generally manufactured with carbon steel, galvanized, 304 or 316 stainless steel, with epoxy or other coatings. Clamps, bag cups or hubs, and venturis needed to aid in speeding up the air being pulsed through a bag should be checked regularly when inspecting bag cages and replaced when needed.
Hopper Level Instruments and Flow Aids
Point level instruments and flow aids assist in discharging dust from the dust collector hopper. Flow aids can help solve bridging and stubborn hopper flow problems. A variety of solutions are available. Consider the addition of electric or pneumatic vibrators, sonic horns, air sweeps, and fluidizing air pads to help increase flow.
Differential Pressure Sensors
Differential pressure sensors are visual gauges used not only for measuring pressure in dust collectors but are vital to ensure accurate readings of a dust collector. The gauge readings are a first step that will guide operation and maintenance decisions. However, the sensors are prone to dust buildup, and even small amounts in the lines can cause irreparable damage. Therefore, differential pressure sensors should be cleaned and replaced at manufacturer suggested intervals to avoid downtime. Do not wait until failure.
To inquire about how to keep your dust collector equipment running smoothly and the dust collector parts needed, please contact us at CPE Filters today.