When management hear of the plan to shut down the Baghouse system for routine maintenance, they begin to ask questions and usually get a little nervous. After all, when a Baghouse system is not operating, more than likely the plant is not either. No Baghouse, No Plant, No Production, No Income.
However, planned shutdowns of Baghouse systems are a necessary part of routine maintenance, therefore it is essential to plan well in advance in order to minimize downtime and maximize efficiency.
What tasks should be completed during your next planned shutdown? Usually the main task of a shutdown is to replace the baghouse filters, which have deteriorated over the course of normal operation. However, there are other items that should be inspected and tasks that need to be addressed in order to prevent future unplanned outages and issues.
Let’s examine some of these tasks in further detail.
Inspect and Review The Condition Of The Entire System
Rain, snow, and sun can cause corrosion of the baghouse and its components
Normal operation and constant exposure to the weather can result in various parts of a Baghouse system deteriorating and or being damaged. For example, exposure to rain, snow and sun can result in a breakdown of exterior components, water leakage and corrosion of the system. Thus, a planned outage is the perfect time to inspect and review the condition of the entire system and to replace or repair any necessary items.
Check for rust and other corrosion, especially near doors, hatches, and other ports. Insulate against cold or heat where necessary to prevent hot/cold spots that can cause condensation issues. Ensure all door and hatch gaskets are in good condition, and replace worn out ones immediately.
Holes in the ductwork lead to loss of vacuum (i.e. loss of suction). Additionally, holes allow for outside air to enter into the baghouse. Hot, cold or moist air can cause problems inside the unit such as corrosion, acid flashes or sticky dusts. Finally, holes in the structure allow dust to escape, where it can accumulate nearby, disperse to nearby working areas, or into the filtered gas steam and show up as increased emissions.
Inspect All Movable Parts
Diaphragms should be given regular maintenance and repair if needed
All movable parts should be fully inspected during a shutdown. These include fans, bearings, brushes, belts, gears, etc, to mention just a few. Constant operation can lead to these items being worn or damaged. Therefore, during the shutdown, these items should be repaired or replaced.
Poorly maintained diaphragm pulse valves have a dramatic effect on the efficiency and effectiveness of a pulse jet baghouse. Leaking diaphragms waste huge amounts of (often very expensive) compressed air. More seriously, worn out diaphragms decrease the effectiveness of the cleaning pulses, which results in poor bag cleaning. Inadequately cleaned bags create higher operating differential pressure, increasing operating costs and lowering suction throughout the system (product dropout and damage to vented equipment).
Keeping the diaphragm valves in good working condition is fairly simple and relatively inexpensive. Extra diaphragm repair kits should be kept on hand so malfunctioning valves can be repaired without delay.
Conduct A Leak Test
Even the most efficient and well-maintained dust collection systems will occasionally experience leaks, compromising their effectiveness and putting worker health at risk.This is why implementing effective leak detection strategies is crucial.
A planned shutdown is also a perfect opportunity to conduct a leak test of the entire system. This is to ensure the Baghouse system is operating to its optimum performance.
Conducting a dye test is not only for filter bags that have been in operation for an extended period of time. Newly installed ones can (and should) also undergo leak testing.
It is also a great time to test the system to see if it will continue to meet environmental standards as well as meet any future requirements.
All the stress and anxiety of a planned outage can be alleviated by contacting a professional before your next planned shutdown. Baghouse.com can provide expert advice, advance planning, review system and provide any necessary suggestions.
