An important first step when establishing a maintenance plan for your dust collector system is the creation of a dust collector maintenance checklist. As with any system, routine maintenance is an important component to ensure dust collectors keep running at peak efficiency. Evaluating the performance of dust collectors makes certain systems function as designed at all times. A maintenance checklist can direct facility managers and maintenance staff to perform periodic inspections when required.
Why Do You Need a Dust Collector Maintenance Checklist?
The checklist should encompass the entire system. Industrial dust collectors can serve different functions and come in different designs. Shaker, reverse-air, plenum-pulse-jet, and pulse-jet are common baghouse system designs with each requiring a checklist unique to the design. However, depending on the part, recommended inspections should be scheduled at specific intervals—daily, weekly, monthly, quarterly, six months, or annually. By scheduling routine dust collection maintenance procedures using a checklist, the system should operate efficiently for years.
Without scheduling dust collector maintenance regularly, a system will begin to perform sluggishly, which could lead to costly repairs to the dust collector and also for equipment damaged by dust accumulation. Repairs mean system downtime and loss of production. Above all, an improperly functioning system can pose health risks to every person in the building—workers, managers, owners, visitors, and so forth.
General signs that a dust collector needs maintenance would be abnormal drops in differential pressure, indicative of a filter issue. If particulate emissions are visually present there’s a good chance that a seal has failed or a filter bag is torn. Where there is dust accumulation around the hoods and pickups could indicate issues with the ductwork or fans. If materials are escaping from the exhaust stack, it could be a sign of a broken bag or that the dust load has increased beyond capacity. Visual rust or holes in the system are a clear sign of material erosion or environmental corrosion occurring. All of these issues can be easily avoided by staying current on basic maintenance.
Below are some dust collector maintenance items to check and when, depending on the system design:
- Record your differential pressure
- Monitor gas flow and dust collection pick-up point(s) for adequate flow and dust removal
- Check discharge system—the airlock, rotary gate, hopper high limit switch, and so forth—should be monitored to remove dust as needed
- Visual and audible inspection of baghouse to check for normal or abnormal conditions
- Visual inspection of exhaust stack outlet
- Monitor control panel pilot lights or meters
- Check pulse-jet baghouse compressed air is functioning
Check or inspect:
- The discharge system moving parts
- Dampers are in operation
- Solenoids are operating
- Diaphragm valves are firing
- Compressed airlines, including filters, are clean and free of moisture
- Hopper discharge device working
- Visible stack emissions
- Fan drive components
- Spot check the condition of bag-seating
- Inspect for bag leaks, fabric wear, or holes.
- For reverse-air and shaker bags, check tension
- Check shaker baghouse moving parts
- Record compressed air pressure
- Clean compressed air filter
- Check for corrosion and blade wear on fan
- Ensure the hopper is empty
- Inspect for deterioration of door seals
- Inspect the access doors for leaks
- Check all hoses and clamps.
- Inspect baghouse housing for corrosion
- Check gas flow rate
- Blow out differential pressure gauge lines
- Thoroughly check bags for wear
- Inspect ductwork for dust accumulation
- Ensure damper valves are properly seating
- Inspect gaskets on all doors
- Calibrate opacity monitor
- Record the pulse duration and pulse delay
- Check for general wear and tear
- Inspect bolts, welds, inlet baffle plate, and look for signs of corrosion or paint flaking on support steel
- Inspect ductwork for dust buildup
- Check hopper for wear
- Perform dye test for leaks
- Replace worn parts on the cleaning system
- Replace diaphragm internal components
A plan that includes a dust collector maintenance checklist benefits operators in meaningful ways and can be created with little effort. Checklists help define what items need to be inspected when to ensure routine maintenance is on a schedule and that the maintenance is performed in a systematic manner.
By following the steps that should be carried out at specific intervals and checking off the tasks when completed, you can help maintain your dust collector and keep it running efficiently. To learn more about dust collector maintenance, please contact the experts at CPE Filters today!