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Diagnostics
In industrial facilities, there is often a need to upgrade or repair baghouse filters. In some cases, the systems require extensive repairs, while sometimes it is sufficient to restore the regeneration and control system. In any case, before starting work on restoring the equipment, it is necessary to address several important questions:
- What is the condition of the metal structures of the baghouse in terms of corrosion wear? If the equipment has been operating in a chemically aggressive environment, hidden defects may be present.
- Under what technological parameters was the equipment operated? It is important to determine whether there were any deviations from the original technological parameters (dust load, humidity, temperature, chemical aggressiveness).
- Under what modes and conditions was the dust collection system operated? It is essential to clarify the details of equipment operation with the personnel.
Inspection of Equipment
Main Causes of Repair
1. Incorrect Calculation or Selection of Equipment
The primary reason for poor equipment performance is the mismatch between the filter's parameters and the operating conditions, specifically, a small filtration area combined with a high initial dust load. This issue often stems from the understandable desire of customers to reduce capital costs, but it results in a problem that cannot be solved with minimal expenses.
2. Burnout of Components Due to Excessive Operating Temperatures
This common problem is related to the lack of effective monitoring of the temperature parameters of the technological process. When sleeves burn out, most of them fall through the panels (holes) and jam the discharge devices. If the housing has not deformed due to temperature exposure, restoring it is relatively straightforward. Typically, in such situations, it is enough to restore the filter panel, cages, and bags. An exception is units made of thin sheet metal (2 mm or less), which are susceptible to significant deformation under temperature stress.
The primary reason for poor equipment performance is the mismatch between the filter's parameters and the operating conditions, specifically, a small filtration area combined with a high initial dust load. This issue often stems from the understandable desire of customers to reduce capital costs, but it results in a problem that cannot be solved with minimal expenses.
2. Burnout of Components Due to Excessive Operating Temperatures
This common problem is related to the lack of effective monitoring of the temperature parameters of the technological process. When sleeves burn out, most of them fall through the panels (holes) and jam the discharge devices. If the housing has not deformed due to temperature exposure, restoring it is relatively straightforward. Typically, in such situations, it is enough to restore the filter panel, cages, and bags. An exception is units made of thin sheet metal (2 mm or less), which are susceptible to significant deformation under temperature stress.
BLIZZARD Bag Filter RS (round bags)
3. Incorrect Selection of Filter Fabric
This issue often indicates a lack of complete information about the characteristics and properties of the dust-laden air mixture in the technical specifications, or an incorrect selection of filter material by the equipment supplier.
4. Compressed Air Deficiency
This is one of the most common problems leading to the rapid wear of filter elements. It manifests as the presence of condensate in the regeneration system. During the regeneration pulse, this moisture reaches the sleeves and, combined with the incoming gas (and its chemical composition), can lead to chemical reactions (hydrolysis, low-concentration acids) that quickly damage the filter fabric's structure.
5. Ineffective Regeneration System
Problems with blow pipes are less common than the previously mentioned issues but still occur frequently enough to be noted. This is an issue for dust collector manufacturers, as many do not use blow nozzles or Venturi tubes to direct and distribute the compressed air flow over the inner surface of the sleeve. When using blow nozzles, it is crucial to ensure the nozzle is aligned with the center of the bag. Failing to meet this requirement can render the regeneration process ineffective.
Increasingly, the issue of poor maintenance of dust collection systems is becoming evident. Incompetent maintenance personnel can quickly turn well-functioning equipment into a unit requiring restoration.
Restoration, maintenance, and baghouse filter changes should be carried out by qualified specialists.
This issue often indicates a lack of complete information about the characteristics and properties of the dust-laden air mixture in the technical specifications, or an incorrect selection of filter material by the equipment supplier.
4. Compressed Air Deficiency
This is one of the most common problems leading to the rapid wear of filter elements. It manifests as the presence of condensate in the regeneration system. During the regeneration pulse, this moisture reaches the sleeves and, combined with the incoming gas (and its chemical composition), can lead to chemical reactions (hydrolysis, low-concentration acids) that quickly damage the filter fabric's structure.
5. Ineffective Regeneration System
Problems with blow pipes are less common than the previously mentioned issues but still occur frequently enough to be noted. This is an issue for dust collector manufacturers, as many do not use blow nozzles or Venturi tubes to direct and distribute the compressed air flow over the inner surface of the sleeve. When using blow nozzles, it is crucial to ensure the nozzle is aligned with the center of the bag. Failing to meet this requirement can render the regeneration process ineffective.
Increasingly, the issue of poor maintenance of dust collection systems is becoming evident. Incompetent maintenance personnel can quickly turn well-functioning equipment into a unit requiring restoration.
Restoration, maintenance, and baghouse filter changes should be carried out by qualified specialists.
Types of Repair
Repair of dust collectors can be divided into the following main tasks:
- Replacement of Filter Bags: Damaged or worn elements are replaced with new ones. This restores filtration efficiency and reduces pressure loss. Baghouse filter replacement is usually performed when the bags are significantly worn out or have large tears and damage.
- Repair of Bags: In some cases, temporary fixes can be made by applying patches to impaired areas. This can be useful as a temporary measure until full replacement, especially if the impairment is localized and minor.
- Rehabilitation of Cages: This involves straightening deformed cages or replacing damaged components that support the shape of the sleeves.
- Cleaning and Restoration: Accumulated dust and residues can be removed using vacuums, mechanical scrapers, or compressed air. Cleaning internal components, such as diffusers and ducts, is also important for restoring proper equipment operation and preventing sleeve wear.
- Replacement of Seals and Gaskets: Sealing elements that ensure system tightness may wear out and require replacement. Leaks can lead to contamination escapes and reduced operational efficiency.
How to Choose an Air Filter
Bag Replacement Process
The process of replacing filters includes several stages and may vary depending on the design, type of sleeves used, and their attachment. Here are the main steps typically undertaken:
1. Preparation for Baghouse Replacement Bags
The system must be shut down to ensure safety and to prevent pollutants from entering the working area. If the unit operates at high temperatures, allow the system to cool to a safe level to prevent burns or damage to the bags.
Workers should use appropriate PPE, such as respirators, gloves, safety goggles, and coveralls, to avoid contact with harmful particulates and chemicals.
2. Accessing the Section:
Depending on the design, filter replacement may involve opening side or top service hatches. These hatches are opened to provide access to the elements.
Ensure that there is no excessive dust in the work area to prevent its release into the environment or onto personnel.
1. Preparation for Baghouse Replacement Bags
The system must be shut down to ensure safety and to prevent pollutants from entering the working area. If the unit operates at high temperatures, allow the system to cool to a safe level to prevent burns or damage to the bags.
Workers should use appropriate PPE, such as respirators, gloves, safety goggles, and coveralls, to avoid contact with harmful particulates and chemicals.
2. Accessing the Section:
Depending on the design, filter replacement may involve opening side or top service hatches. These hatches are opened to provide access to the elements.
Ensure that there is no excessive dust in the work area to prevent its release into the environment or onto personnel.
Replacement
3. Removing Old Bags:
Filter elements are usually secured in cages with special clamps, rings, or other fasteners. These fasteners need to be loosened or removed. Old components are carefully removed from the cages. This process should be done slowly and cautiously to minimize airborne particles.
4. Cleaning and Inspection:
After the old sleeves are removed, the cages and internal parts are cleaned of accumulated contaminants. This can involve using vacuums or compressed air.
Cages and other internal components are inspected for damage or wear that may affect equipment operation. Faulty parts are replaced or fixed.
5. Installing New Bags:
New elements are placed into the cages. They should be installed carefully to avoid harm.
After installation, they are secured with the same clamps, rings, or fasteners used for the old elements.
6. Completion of the Process:
After replacement, hatches and access doors are closed and sealed.
The unit is restarted. It is recommended to perform a leak test and check the equipment's normal operation immediately after startup.
7. Disposal of Old Elements:
Old bags may contain harmful substances and should be disposed of according to local environmental regulations and standards.
These steps ensure proper and safe replacement of baghouse filters, maintaining their efficiency and longevity.
Filter elements are usually secured in cages with special clamps, rings, or other fasteners. These fasteners need to be loosened or removed. Old components are carefully removed from the cages. This process should be done slowly and cautiously to minimize airborne particles.
4. Cleaning and Inspection:
After the old sleeves are removed, the cages and internal parts are cleaned of accumulated contaminants. This can involve using vacuums or compressed air.
Cages and other internal components are inspected for damage or wear that may affect equipment operation. Faulty parts are replaced or fixed.
5. Installing New Bags:
New elements are placed into the cages. They should be installed carefully to avoid harm.
After installation, they are secured with the same clamps, rings, or fasteners used for the old elements.
6. Completion of the Process:
After replacement, hatches and access doors are closed and sealed.
The unit is restarted. It is recommended to perform a leak test and check the equipment's normal operation immediately after startup.
7. Disposal of Old Elements:
Old bags may contain harmful substances and should be disposed of according to local environmental regulations and standards.
These steps ensure proper and safe replacement of baghouse filters, maintaining their efficiency and longevity.
Post-Repair Tips
To improve air cleaning efficiency after a baghouse repair, consider the following tips:
- Use components made from materials suitable for the specific operating conditions (temperature, chemical environment).
- Conduct scheduled inspections and timely cleaning of filters and their components to prevent clogging.
- Optimize air blow systems or other regeneration mechanisms to effectively remove accumulated dust without causing damage.
- Install sensors to monitor pressure, temperature, and air flow to detect deviations in operation promptly.
- Train staff in proper operation and maintenance techniques to minimize errors and prevent harm.
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We always make extremely precise calculations and provide assistance in choosing the optimal cleaning systems, which usually takes 1 to 2 days.
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
CALCULATION AND SELECTION
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