Baghouse dust collector 15 types of failure, causes and countermeasures summary.

Baghouse dust collector 15 types of failure, causes and countermeasures summary.

Under the current high pressure of environmental protection, many industries are facing severe tests, and enterprises are putting environmental protection in the important position of enterprise development. Baghouse dust collector is a highly efficient dust removal equipment to control air pollution, and is very widely used. Understand the common failures and solutions of baghouse dust collector, emergencies can also be easily dealt with.

In the process of dust removal system operation, users are more concerned about the service life and efficiency of dust collectors, but usually neglect the safety of dust collector bags and routine maintenance. With good routine maintenance and timely troubleshooting, baghouse dust collector equipment can work more stably and efficiently. The following are the parts of the bag filter that need to be checked routinely as well as common failures and troubleshooting methods.

 

Baghouse dust collector routine check points

 

1. Air duct: Check for corrosion, holes or any external breakage. Check for loose bolts, welded cracks and ash accumulation in any area (mainly flat ducts, reducers).
2. Solenoid/pulse valve: Check for proper operation: Listen to the sound of compressed air blowing.
3. Pressure reducing valve: whether the air is leaking. Pay attention to the debris inside the pressure reducing valve
4. Fan: Make sure the fan is firmly installed and level, and refuel regularly. Note that dust tends to accumulate on the blades.
5. Compressed air system: Check if the compressor is properly filled with lubricant. Check for cracks on the air pack and piping; note the pressure indication of the regulator (if installed). Check to see if the air compressor and air pack are drained.
6. Inspection doors: All inspection doors should be sealed firmly. Look for loose, cracked or worn seals. Replace as needed.
7. Inlet/Guide: Look for excessive wear or corrosion.
8. Airflow regulator and poppet: Check for proper operation of the oiler (if required).

Baghouse dust collector common failures and troubleshooting methods

1. High differential pressure of dust collector

• Main reasons and troubleshooting methods:

1. Incorrect differential pressure reading: clean the pressure measuring interface/check the air pipe for cracks/check the differential pressure gauge.
2. Incorrect setting of blowing system: increase the frequency of blowing/compressed air pressure is too low; increase the pressure/check the dryer, clean up (if needed)/check if there is any blockage in the pipeline.
3. Blowing valve malfunction: check the diaphragm valve/check the control solenoid valve.
4. Pulse controller malfunction: check whether the controller indicates each contact point/check the output of each terminal.
5. Filter bag blockage: condensation on the dust filter bag (see below); send the filter bag to the laboratory to analyze the cause. Filter bag dry cleaning treatment / or replace / reduce air volume / increase compressed air pressure / increase cleaning frequency / spray in neutral modulating powder to form a protective layer and porous loose primary cake.
6. Excess secondary dust: continuously empty the ash hopper/each row of filter bags/cartridge cleaning in random sequence, not sequential cleaning. Check the inlet baffle to ensure clean.

2. Fan motor current is small / small air volume

• Main reasons and exclusion methods :

1. High differential pressure of baghouse dust collector: See above.
2. Fan and motor pulley connected backwards: Check the drawing and reverse the pulley.
3. Ducts are blocked with ash: clean the ducts and check the gas flow rate.
4. Fan baffle closed: Open baffle and lock in open position.
5. Dust collector lift valve closed: Check the gas circuit and open the valve plate.
6. System static pressure is too high: Measure static pressure at both ends of fan and check design specifications, adjust as needed. For high flow rates check ducting to replace original poor design.
7. Fan not operating within design requirements: Check fan inlet structure to ensure smooth airflow. Inspect blades for wear and tear and repair or replace as needed.
8. Fan reverse rotation: reverse the wiring on the motor.

3. Dust escaping from the dust collection point

• Main reasons and methods of elimination:

1. Small air volume: See above.
2. Duct leakage: Repair the cracks so that dust will not bypass the dust collection point.
3. Incorrect duct balance: Adjust the branch duct dampers.
4. Unreasonable design of the suction hood: Close the open area around the dust collection point. Check that the flat suction ventilator has overcome the suction force. Check whether dust is taken out of the suction hood by the belt.

4. Chimney ashing

• Main causes and elimination methods:

1. Filter bag seepage: replace if the filter bag is torn or has a small hole. Check the installation of the spring ring to ensure tight.
2. Flower plate seepage: fill the gap or welding seam.
3. No sufficient dust cake: Reduce compressed air pressure; reduce dust cleaning frequency/spray in neutral modulating powder to produce primary dust cake.
4. Excessive air holes in the filter bag or cartridge: filter bag or cartridge for penetration test and consult the manufacturer.

5. Fan wear serious

• Main causes and troubleshooting methods :

1. Fan handling excessive dust: See above.
2. Fan is not appropriate: determine whether the fan is suitable for the working conditions; consult the manufacturer.
3. Fan speed is too high: consult the manufacturer.

6. Fan vibration serious

•  Main causes and methods of elimination:

1. Dust accumulation in the wheel leaves: wheel leaves cleaning dust, check whether the fan is handling excessive dust. Check the installation position of the fan / drain the condensate or moisture / keep the fan dry.
2. Fan impeller is not suitable for working conditions: Consult the manufacturer.
3. Belt pulley is not flat across: belt pulley for power balance.
4. Bearing wear: Replace.

7. The amount of compressed air is too high

• Main causes and elimination methods:

1. Ash cleaning cycle is too frequent: delay the ash cleaning cycle (if possible).
2. Blowing time is too long: reduce the duration (except after the initial shock, all other air volume is wasted; usually the blowing setting is 0.1 seconds).
3. High pressure: Check diaphragm and spring (see analysis on valve malfunction).
4. Air line leakage: make bubble test and repair.

8. Compressed air pressure is low

• Main causes and troubleshooting methods :

1. Compressed air consumption is too high: see above.
2. Resistance in the air pipe: Check whether the air pipe is blocked.
3. Desiccant blockage: Replace desiccant or bypass the desiccant if the working condition allows.
4. Compressor wear: Consult the manufacturer or check the compressor maintenance manual.

9. Air volume is too high

• Main causes and elimination methods:

1. Duct leakage: Caulk the cracks.
2. Insufficient static pressure: Close the air valve. Reduce fan speed.

10. Compressed air consumption is low

• Main causes and troubleshooting methods:

1. Pulse valve does not work: Check the pulse valve according to the aforementioned method.
2. Controller failure: Check the terminal output according to the aforementioned method.

11. Premature failure of filter bag – decomposition

• Main reasons and methods of elimination:

1. The filter media is not suitable for the working condition: Analyze the gas chemistry and consult the filter bag or cartridge manufacturer.
2. The filter media is not suitable for the gas composition: treat the gas before entering the baghouse dust collector; or replace the filter bag or cartridge.
3. Operating at acid dew point temperature: Increase gas temperature.

12. High filter bag failure rate – excessive wear

• Main causes and elimination methods:

1. Wear out of uniform flow guide baffle: replace uniform flow baffle.
2. Too much dust: install primary dust collector.
3. Ash cleaning cycle is too frequent: extend the cycle time.
4. Inlet airflow is not properly equalized by the filter bag or cartridge: Consult the manufacturer.
5. Dust in clean air chamber/splash: Clean inside splash and filter bag or cartridge; do fluorescent test to find leaks.
6. Burrs/corrosion on cage (if used): remove smooth burrs; replace if needed. If corrosion, consider using anti-corrosion coating of the cage.

13. filter bag failure rate is high – burning

• Main causes and methods of elimination :

1. Laminar distribution of hot and cold gas: use baffle in duct to solve turbulent flow.
2. Spark into the dust collector: Install spark eliminator.
3. Thermocouple failure: Replace and identify the cause of failure.
4. Cooling device failure: Check the design specification and consult the manufacturer.

14. Dampness in dust collector

• Main causes and elimination methods :

1. Insufficient heating: Input hot air into the system before starting to process airflow.
2. No clear blowing system after shutdown: Run fan for 15~20 minutes after system shutdown.
3. Shell temperature is lower than dew point temperature: Increase gas temperature/unit insulation insulation/reduce moisture in the system to lower dew point temperature.
4. Outside air enters the dust collector: check the shell for leaks and worn door seals.
5. Insulation worn with colder objects inside: eliminate direct metal for lining.
6. Water vapor inside compressed air: check automatic drain/install secondary cooler or dryer.
7. Process working condition becomes poor: spray in modulating powder.

15. Material bridging in the ash hopper

• Main causes and elimination methods :

1. Moisture in dust collector: See above.
2. The design of the ash hopper hinders material movement: Install acoustic horn or vibrator to promote material movement.
3. Dust buildup in the dust hopper: Discharge dust continuously; do not store dust in the hopper.
4. Conveyor opening too small: use wide flared slotted blades; feeder/star discharge valve does not work or is undersized.

 

The above are some of the failure phenomena that can easily occur in the operation of baghouse dust collector. Do a good job of daily maintenance, timely detection and solve the hidden problems, to ensure the stable operation of the baghouse dust collector, you can effectively improve the dust removal efficiency. Environmental protection storm again, your business to do a good job of environmental protection measures?