We all know that getting the oil change in our car regularly is important to the car being able to get you around when you need it.  However, your dust collector needs regular maintenance too.  The dust collector system consists of hoods, ductwork, air-material separators (cyclones, baghouse, cartridge collectors, wet scrubbers, etc.), explosion protection equipment, airlocks, instrumentation, and exhaust fans. 

All of these items should be checked at least once a year to make sure they are operating correctly.  The following points briefly describe what each piece of equipment needs:

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1. Hoods

• Visual inspection to make sure they haven’t been damaged during the year.
• Measure airflow velocity to make sure they are collecting the design airflow.
• If a local damper is located by hood for balancing, make sure it is operable and in the correct position.

2. Ductwork

• Visual inspection to make sure no holes have developed.
• Measure air velocity through ductwork to make sure designed airflow is correct.
• If possible, visual inspection of duct internal to make sure dust isn’t building up.

3. Air Material Separators

• Measure pressure drop across the separator to see if it is within parameters.
• Inspect cleaning process (baghouses and cartridge collectors) that they are operating properly (timing, valves opening, air pressure, etc.). See operations and maintenance manual.  Often time, listening to the system will let you know if it is operating correctly.
• Monitor recycle line pressure and overflow in wet scrubbers.
• Visual inspection of vessel walls to be sure there are no holes.

4. Explosion Protection Equipment

• NFPA requires yearly inspection, following the manufactures manual is very important so the explosion protection equipment will protect the facility, equipment, and workers as it was designed.
• Some explosion protection equipment such as chemical suppression should be done by factory trained personnel.

5. Airlocks

• Rotary valves
  • Should be checked to see they are still spinning
  • Bearings should be greased and temperature measured to make sure they aren’t overheating
  • On explosive applications the rotor clearance should be measured to make sure it still complies with NFPA 69.
• Pneumatic valves (slide gates, double flap valves, etc.)
  • Valves should be tested to make sure they are still operating as designed.
  • Air pressure should be measured, to be sure it is still within design parameters.
• Motorized valves (rotary valve, double flap valves, etc.)
  • Bearings should be greased
  • Bearing temperature should be measured to be sure they aren’t overheating
• Trickle valves
  • The sleeve should be inspected to be sure it is still sealing
  • During operation confirm that material is still draining and material hasn’t bridged above it.

6. Instrumentation

• Level gages, pressure gages, VFDs, pH meters, zero speed switches, etc. all have different maintenance requirements.
• Follow the manual of the specific model for maintenance and inspection.

7. Exhaust Fans

• The fan housing should be inspected to make sure no holes are present.
• The voltage and amps should be measured to make sure it is operating at its design condition.
• The bearings should be greased and temperature checked to be sure they aren’t overheating.
• The fan’s vibration should be checked along with checking to see if any abnormal noise is emanating from the fan.

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To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com.

To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

 

Click below and watch our video to identify five signs that may diagnose a sluggish system so that you can return your system to full efficiency.

 

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 4 of 4)

Surrounding areas

As mentioned above, the area surrounding the dust collector significantly affects where the dust collector can be installed.  Location of utilities such as electricity and compressed (plant) air all affect the dust collector location.  Baghouses and cartridge collectors usually require compressed air for cleaning, wet scrubbers often require makeup water and a drain to either local or plant water treatment facilities. 

Dust Collector Interference

The dust collector may interfere with surrounding equipment and operations, such as cranes and vehicle traffic.  Dust collectors are often tall pieces of equipment requiring large head room when indoors.  And the noise and explosion protection could affect personnel space such as break rooms, rally points, foot and vehicle traffic, etc.

So when looking for a space to install your dust collector make sure you take into account all the different factors such as explosion protection, utilities, operations, and workers safety and comfort. And install the dust collector as close as possible when conforming to the above requirements.

To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com. 

 

 

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 3 of 4)

Distance from Process

Ideally installing the dust collector should be located next to the dust generation.  However, this isn’t always possible.  There are space constraints, safety and noise concerns and process requirements that all affect the placement of the dust collector.  However, based on this, you should place the dust collector as close as possible to the process.  This decreases cost with less ductwork required.  You will also want to use as straight as possible runs of ductwork .  Short, straight ductwork will keep the pressure drop of the system low allowing you to install a smaller quieter blower.  It also helps prevent dust build up in the ductwork which can cause operational issues and be a fire/explosion hazard.

Smaller Fans

Smaller fans usually mean lower horsepower motors.  This translates into lower operating cost for the fan.  And shorter ductwork requires less cleaning, thereby less time for maintenance on the whole system.  If long distances are required, look at using local pre-filters to lower dust loading going through ductwork.  This will help solve some of the issues such as dust buildup in the ductwork.

To learn more about dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com or click on the button below to get our whitepaper: Top 5 Reasons to Use a Cyclone as a Pre-filter.

 

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 2 of 4)

Space Constraints in New Facility

In new facilities, the installation of dust collectors is often pretty easy.  Many times the building is designed around the equipment.  This doesn’t mean that compact equipment isn’t beneficial.    This can help lower ceilings, prevent the need for installation on the roof.  When placing a dust collector in new facilities, it would best to place them as near to the system as you can while conforming to all the NFPA and other specs.

Space Constraints in Existing Facility

Existing facilities pose much more issues than new facilities.  Often times existing facilities are constrained for space.  They have added / expanded lines in a building that weren’t built for its current use.  New regulations could require a new dust collector, larger dust collector, or modification to the dust collector (including explosion protection).  All of this could require finding room for a new dust collector or moving the existing one.

Noises from Dust Collector and Fan

If the dust collector is not going to be mounted indoors, it needs to fit under the existing ceiling.  Low profile units are often required.  It might be easier to use low profile point of use dust collectors than to find a place to install a large dust collector for multiple processes.  It is often beneficial to locate the dust collector as close to the processes it is collecting dust from.  This lowers the cost of the system by minimizing ductwork which in turn minimizes the fan size and HP.  When installing the dust collector you should remember to take into account noise from the dust collector and the fan.  Fan silencers and noise blankets may be required if the equipment is too loud.  And as discussed above, enough space should be available for installing all the explosion protection required.

Protect Dust Collection Equipment from Weather

If the dust collector is not going to be mounted indoors, height is usually not an issue.  Some facilities do have outdoor height restrictions.  Sometimes it’s the local city and sometimes it is to keep a low profile with the neighbors.  The dust collection equipment must also be protected from the local weather.  Equipment in the Midwest often requires freeze protection, while the Gulf Coast need to withstand high winds.  When locating the dust collector outside you should install it as close as possible to the process, so as to minimize ductwork and power requirement.

Conform with NFPA

Many customers when installing equipment have to deal with local ordinances on the appearances of the outside of the facility.  Other times, the company wants the facility to be aesthetically pleasing, and / or they want their neighbors to be comfortable with the appearances so as to minimize any issues in the future.  And as mentioned before, the dust collector should conform with NFPA when installed on an explosive application.

To learn more about compact dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com or click on the button below to get our whitepaper: 5 Ways to Save Costs by Using Small Dust-Collection Cyclones.

 

OSHA is issuing citations and fines to companies with unsafe combustible dust hazards, using their general duty clause and NFPA 652: Standard on the Fundamentals of Combustible Dust as a guideline. Any industrial facility that creates dusts or uses powders was mandated by NFPA 652 to complete a Dust Hazard Analysis by September, 2020 to identify the presence of combustible dusts and establish a plan for eliminating or mitigating potential risks associated with these dusts in their facilities. The DHA is essentially the framework around which NFPA 652 is built, and the starting point for getting a facility into compliance with the standard as a whole.

Dust Hazard Analysis (DHA) Complexity

The complexity of performing a DHA varies with the complexity of the facilities and processes being analyzed.  For instance, a small wood cabinet making shop with a limited number of dust generating machines will present a less daunting task than a large scale manufacturing facility that use powdered raw materials and performs cutting and grinding of its finished product. It should also be noted that performing a DHA should not be viewed as a “one and done” procedure that is completed and forgotten. As new processes or raw materials that have the potential for impacting a facility’s combustible dust profile are introduced in the facility, the DHA needs to be modified to incorporate these changes accordingly.

Dust Hazard Analysis (DHA) Preparation

Preparation for a Dust Hazard Analysis can also be incorporated into a more comprehensive review of a facility’s dust collection system that examines overall system design, efficiency, and safety. Aerodyne Environmental’s Dust Efficiency Clinic offers dust collection system evaluation services that do just that. An Aerodyne dust collection specialist will review a facility’s equipment, installation, controls, and protective devices with an eye toward improving overall system performance, decreasing maintenance costs, prolonging equipment life, and improving safety and regulatory compliance.

Dust Hazard Analysis (DHA) Report

At the end of the system review, a report is generated that summarizes the existing state of the dust collection system and offers targeted suggestions for areas that can be improved. This valuable service offers facility and plant managers outside expertise in boosting the performance and safety of their systems, and is a logical first step in preparation for a DHA.

To learn more about Aerodyne’s Dust Efficiency Clinic consulting services, call Dan Navicky at (440) 543-7400 or tollfree at (800) 358-7546, or email dc@dustcollectorhq.com.

 

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 1 of 4)

Explosive dust

One of the most important factors to take into account is the explosibility of the dust.  If the dust is explosive you will have to make sure the location of the dust collector conforms with the appropriate NFPA specification.

The NFPA specifications require dust collectors to be located outdoors if they have explosive dust, unless specific explosion venting or mitigation equipment is being used.  Even if your dust collector is located outdoors, it should still have venting, because you don’t want your collector to create shrapnel during and incident.

Explosive Vent

One of the most common and least expensive explosion protection methods is the installation of explosion vents on the dust collector.  The explosion vent directs the pressure wave out of the vessel through an area, thereby controlling the explosion.  This protects the dust collector from the worst of the damage.

When using explosion vents, it does matter if your dust collector is indoors out outside.  When located indoors, the explosion is required to be vented outside.  The vent is connected to ductwork to an opening in an outside wall or roof.  When this is used, the dust collector should usually be within 5 feet of the wall.

When the dust collector is outdoors it should be orientated so that the explosion vents are directed away from the building and any other equipment.  The vents should also be directed away from any walkways, roadways, and areas where employees would be. (Ex. Rally points, picnic tables, etc.)

Flameless Vent

A flameless vent can be used instead, which allows the dust collector to be installed inside without venting it outdoors.  The flameless vent directs and vents the explosion as a standard vent, but it has metal fins mounted on the vent so the explosive wave travels past the fins.  The metals fins rapidly cool the wave, stopping the flame, so only a hot pressure wave is left.  Enough room must be left around the flameless vent so that adjacent equipment isn’t damaged.  The vent area should not be an area where workers are or a walkway.

Chemical Suppression

Chemical suppression is another technology that is used to protect dust collectors from explosions.  The technology uses non-explosive chemicals to flood the dust collector and prevent an explosion.  Sensors located in the dust collector and the ductwork measure the temperature and pressure to monitor for an explosion.  When they detect an explosion the chemical suppression system is activated.

Chemical suppression systems require yearly maintenance to make sure the system is still protected.  So the sensors and chemical canisters need to be accessible for the maintenance checkups.  This means platforms or open spaces for portable lifts should be located around the equipment.

To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com. 

Click below and watch our Webinar that offers a thorough explanation of the changes in NFPA 68 and how they may affect your existing system design.

 

The most basic reason to install dust collectors is because the EPA, OSHA or other regulatory agency requires you to.  However there are other reasons to install a dust collector even if you aren’t required to.

1. Health and safety
   • Dust can cause health issues, even if the material isn’t a carcinogen or sub-micron. Dusty air can cause issues breathing, allergies, etc.  All of this can cause operators to be sick more often or want a new job.  This can cause increased operating expenses and less efficiency as you have to cover for absences or have to train a replacement.   Small local dust collectors can help clean the air around operators.
   • Some dust is explosive, and the regulatory agencies are requiring that you test the dust to make sure it isn’t. Even if they haven’t gotten around to it yet, a fire or explosion will cause property damage and possibly injury to employees.
2. Maintenance – Dust will get into mechanical equipment and cause increased wear on them. This increases the maintenance on the equipment, lower productivity and increase operational expenses.  Installing a local dust collector can minimize the dust getting to the surrounding equipment, thereby extending their life.  While there are many factors that affect when equipment needs maintenance, minimizing dust in the air will definitely help extend the time between maintenance.
3. Recycling of material – Local dust collection can help capture product / raw material dust before it is contaminated by other material. This dust can then be reused or recycled, thereby lowering the cost of your process.  Cyclonic dust collectors are especially good at collecting un-contaminated material since they have no filters to retain dusts and can be cleaned out.
4. Environmental responsibility – Local dust collection will help you keep fugitive dust from escaping the building and into the environment. While rain and wind often deposit dust back on the ground, the more dust escaping will cause the air to be dirtier. This could cause smell or dust clouds that neighbors will dislike.  Beyond being a good direct neighbor, you may just have a goal to be a better inhabitant on the earth.
5. Higher morale – A cleaner, healthier environment will help your employees be happier at work. If they aren’t irritated from dusty air, there is a better chance they will enjoy work better and be more productive.  This will allow you to produce more at a lower cost.  And the company will make more money allowing the employees to get better raises.

To learn more about which dust collector, please contact our experts at 440-543-7400 or click on the button below to get our Whitepaper: 4 Potential Dangers to Collectors! How Cyclone Pre-Filters Can Help!

 

 

The airflow in a dust collection system is extremely important, since the air collected at the hoods is removing the dust from the affected areas.  This air is then sent to the dust collector to remove the dust from it.  While it is always desirable to use the least amount of air as possible in your dust collection system, you must have enough air so that it is actually doing the job it is meant to.   If not enough air is going through the system, you will not capture all the dust from the pickup areas, thereby allowing dust to escape into the facility, cause health / nuisance issues and/or fire hazards.  If the airflow is too high, you could be picking up product/ raw materials, wasting energy and increasing maintenance issues.

There are many reasons that the airflow through a dust collection system can change.  A few of them include:

• Environmental changes – temperature, humidity, etc.
• Changes in the system – such as opening/ closing dampers, dust buildup in the ductwork, damage to the ductwork and/or hoods.
• Dust collection issues – such a plugged filters, old filters, holes in the filter, etc.
• Damage to the exhaust fan – such as bearings, damaged impellers, etc.

Unlike liquids, there is no easy and inexpensive way to monitor airflow in a dust collection system.  The most common way is to periodically manually measure the airflow by inserting a pitot tube in the ductwork and measuring the air velocity.  The airflow is then calculated.

One option to monitor your airflow is to install a cyclone pre-filter ahead of the filters.  A cyclone’s pressure drop increases as the airflow increases in them.  Usually the manufacturer of the cyclone can provide a curve, showing the relationship between the pressure drop and the airflow.  So if you monitor the pressure drop through the cyclone, you will notice if the airflow suddenly increases or decreases.  And if the pressure drop drifts too far from a certain pressure drop you will know to troubleshoot the system.

To learn more about the different types of Dust Collection methods,  please contact our experts at 440-543-7400 or click on the button below to get our whitepaper: Top 5 Questions To Ask When Considering A Cyclone Dust Collector.

 

 

Dry dust collectors and humidity don’t react well together.  Baghouses and cartridge collectors operate by having dirty (dusty) air enter the housing.  Multiple filters (bags or cartridges) are located in the housing.  The air travels through the filter and then exits the dust collector.  The filters are a mesh of fibers that allow air to travel through small holes, while dust is too large to pass.  The dust builds up a layer (dust cake), further limiting the subsequent dust’s ability to pass through while allowing the air to pass.  From time to time the dust collector will clean the filters by shaking them or using compressed air to expand them.  This causes the outer layer of the dust cake to fall off.

Humidity can cause problems in the process described above.  Humidity is a way to express the amount of water in the air, (the higher the humidity, the higher the amount of water in the air).  When high humidity air enters a dust collector with fabric filters, there is a chance that the water vapor will condense and create water droplets or the dust on the filters will absorb the water as the airflow passes through.  Many dusts change their physical properties when the water content increases.  Some become sticky, some become hard like concrete, etc.  When this happens to the dust cake, it affects the ability of the air to pass through and the ability of the dust to fall off during cleaning.

When dust becomes sticky, it will adhere to neighboring dust particles and not want to fall during cleaning.  Dust that becomes hard (like concrete) will prevent air from passing through.  When one of these issues develop in a dust collector the pressure drop across the dust collector will increase.  Over time, an increased pressure drop will lower the airflow being pulled through the system.  This will decrease the airflow being picked up at hoods, therefore lowering dust collection at where operators are located.

Humidity can also be introduced in the dust collector in the compressed air.  When air is compressed, the temperature of the air increases, thereby increasing the water content of the air.  The compressed air is at its saturation point.  As the air moves through the line, it cools, thereby condensing water in the system.  If additional drying technology isn’t installed, the compressed air will have water droplets in it as it is used in the dust collectors.  This will cause the filter cake to wet and cause issues as described above.  This is why it is important to dry compressed air when dealing with dust that is affected by water.

However, sometimes no matter how you treat your compressed air, you continue to have issues.  This could be because the airline travels outside and in winter time it gets very cold. It could be because you are located near a large body of water, and humidity is high.  One way to minimize the effect on your dust collector is to minimize the dust getting to your dust collector.  Cyclone pre-filters are ideal for these applications.  Cyclones collect dust and water droplets using centrifugal motion.  This means they aren’t affected by the changes to the dust as a filter is.  Cyclone pre-filters can often remove up to 80% of the dust before a dust collector with filters.  This means you can lower the number of water droplets going into your dust collector and minimize the cleaning required, thereby not getting as much water from the compressed air system. 

To learn more about the different types of Dust Collection methods,  please contact our experts at 440-543-7400 or click on the button below to get our whitepaper, Top 5 Reasons to Use a Cyclone as a Pre-Filter.