Dust collector system maintenance is an essential component of ensuring your industrial or manufacturing operations run smoothly. Regular maintenance performed with accuracy can result in significant cost savings and reduced downtime.
That’s because when your dust collectors are working at optimal capacity and are regularly maintained, they introduce efficiencies in your processes that are both qualitative and numerically quantifiable.
In this article, we explore what steps you need to follow to carry out your industrial dust collector maintenance. From recording your pressure to lubricating fan bearings, we’ve got you covered.
Dust collector maintenance checklist
There are several steps that are involved in dust collector maintenance. Each of these plays a very important role in your industrial operations because they can lead to significant cost reductions, better health and well-being of your team members, reduced downtime and more.
Despite the fact that dust extraction systems are designed bespoke to each application and the same rules do not apply to all systems, the steps mentioned below are some of the key components to effective and efficient dust extraction at your organisation.
Let’s take a closer look.
Step 1: Record differential pressure
This type of pressure is a measurement that records the difference in pressure between the dirty and clean parts of your dust collector. High pressure signals that your filters are creating high resistance, which is an indicator that the dust filters are clogged up. low pressure indicates low resistance this could be an indication that the filter media has a hole and could be allowing dust to pass into the clean side of the filter unit
Wondering about how often you should change the dust filter? As a rule of thumb, differential pressure of around 5” WG signals that your filters need to be replaced. Also, if the pressure drops significantly, it could be a sign of a leaking filter with a hole in it. Alternatively, it could be a leaking gasket. This results in contaminated air entering through and bypassing the filters, which is a situation you want to avoid. This task should be performed once daily.
Step 2: Check drums and hopper
A dust waste bin that’s overflowing is not only a messy situation to deal with. It’s also a potential safety hazard as the dust inside could be ignited and cause a fire. The longer you leave your drum (Bin) uncleaned, the higher the chance of damaging the dust collector. As such, it’s essential to empty your drums (Waste bins) before the dust reaches the top.
Often, as a way of addressing this situation in organisations with multiple dust filters, a dust level sensor is installed to help monitor the dust levels and enable you to carry out preventive maintenance to reduce unforeseen damage to equipment and costly downtime.
Dust collector hoppers should be checked regularly to ensure no waste is settling within the hopper. A high volume of material in the hopper can plug the dusty inlet(s) and create air turbulence. Furthermore, it can disrupt airflows and cause dust to re-enter the facility. In short, this can result in impeding performance and abrading filters.
Step 3: Inspect valves and hoses
Some dust filters receive pulses of compressed air and these are controlled through diaphragm and solenoid valves. However, a high volume of compressed air can result in dirty and clogged filters. These valves should be checked regularly.
For starters, you want to ensure that they work at the same time when emitting the pulses. Secondly, you will want to ensure that valves can open and close at the full spectrum while also making sure that all necessary hoses are attached and inspected for leaks.
Other type of dust extractors have a shaker system fitted to clean the filter media, these work by agitating the filter media allowing the dust to drop in to the waste collect bin, you should ensure this is working correctly
Step 4: Examine door seals and gaskets
The fourth step involves examining door seals and gaskets. Unfortunately, due to wear and tear, gaskets around the edges of a door can become worn out or cracked, resulting in the inability of the door to seal closed properly and affecting the efficiency of your dust collector. As such, you want to check all the gaskets and inspect them for damage, replacing them where necessary.
Step 5: Check compressed air pressure
Compressed air pressure should be at optimal capacity so that your filters can get cleaned effectively. However, high pressure could damage your filters. Therefore, you want to ensure that settings are as they are specified in your owner’s manual.
Step 6: Inspect rotary airlocks
Rotary Airlock rubber seals should be inspected and replaced when worn out. The typical time frame for doing this is doing so once a year. Another element you should pay attention to is inspecting and replacing the shaft bearings. Often, through wear and tear, these get damaged and need replacement.
Step 7: Lubricate fan bearings
Make sure to lubricate your bearings according to the manufacturer’s manual and ensure this task is a regular part of your maintenance schedule.
Step 8: Check for visible emissions
The exhaust stack and filter unit should be checked for visible signs of dust discharge. This can signal that a seal is broken or a bag is worn out or torn. Immediate attention is required in such cases where visible emissions are present.
Step 9: Test regularly for leaks
As an ongoing diagnostic measure, leak testing helps ensure that your filters are not failing prematurely. If you identify any increase in emissions, you may be dealing with damaged bags that cause performance issues.
Step 10: Inspect the ductwork
Failure to inspect the duct can result in blockages within the system because dust does not reach the collection system and settles in the duct. With ducts being an essential component of the extraction system, they should be kept clear for optimal efficiency. This task requires regular inspection for dust accumulation to ensure that the right pressure and velocities are maintained.
Conclusion
When it comes to questions such as how do you maintain a dust collector or how do you clean a dust filter bag, it’s important to note that this will critically depend on the dust extractor assets that you have installed at your organisation.
With Ducting Express at your side for effective dust collector maintenance services, you never have to worry about questions such as how long do dust collectors last. That’s because dust collectors can last as long as they are compliant and kept in good condition,if maintained correctly this will ensure your get the most of your dust extractor
Meanwhile, in terms of how often you should clean extractor filters, the answer lies in checking the owner’s manual as every extractor filter will have its own regulations. However, with regular inspections of these filters or if you notice signs of dust build-up more frequently, then daily or weekly cleaning should be the norm. Of course, this will highly depend on your operating environment and the amount of dust that is filtered.
Through our powerful and professional service, we help keep air quality at your facility as clean and safe as possible for the well-being and stability of both your team and your organisation as a whole. Get in touch with us today!