Tips & Tricks to Spotting Dust Collection Equipment Failures

Posted by Earl Parker on Oct 20, 2014 3:55:00 PM

Catch dust collector failures early on with effective triboelectric technologies.Most often, dust collector equipment failures stem from the view that they are simply a necessary compliance tool. Viewed form that perspective they don’t get a lot of proactive attention since they serve to “check the box” rather than create business value.  So systems are managed to satisfy compliance, and frequently small issues snowball into system failures in short time.

Fortunately, these system failures can be largely avoided with the right monitoring tools and dust collector maintenance practices. Triboelectric monitoring devices, which can preemtpively scan both the AC and DC signal spectrums for trending particulate emissions, can substantially alter traditional approaches to how companies maintain baghouses and upkeep their dust collection systems. 

Optimizing Baghouse Management with New Technologies

One of the most effective techniques for spotting and managing dust collection equipment problems is through the use of triboelectric broken bag detectors, which measure small changes in particulate flow, and can alert users to impending filter failure. With multiple alarm levels, maintenance and engineers are warned of deteriorating performance and filter leaks early on.  As a result consequences of these failures can be minimized, and future incidents even prevented.

These capabilities come from thoroughness with which dust collector monitors scan for leaks and baghouse issues. While older triboelectric monitoring systems could only detect up to 80% (DC signals) or 20% (AC signals) of the triboelectric spectrum, today’s technologies can detect particulate flow changes across the entire spectrum; by unifying AC and DC spectrum scanning, companies can fine tune and manage complex, extensive industrial dust collection systems.

Innovations to triboelectric dust collection monitors have made responding to bag leaks and system failures nearly instantaneous – actually often before the fact! Conventionally, managing collector baghouses and individual unit leaks was an after-the-fact process; engineers could only respond to bag failures after a failure and reportable event occurred, and were limited to replacing a baghouse full of bags on a systematic, arbitrary schedule.

This expensive, responsive process, however, is avoided with today’s triboelectric/electrostatic monitoring technologies; new innovations in particulate scanning are the best tools for finding and correcting failures in dust collection systems

Collector Baghouse Lifespans

The greatest positive changes new generations of triboelectric monitors have brought to dust collector maintenance concern the technology’s accuracy with detecting baghouse performance. These scanners can alert engineers of when individual bags are near failure allowing for replacement before a dust event can even occur.

While mitigating the effects of one failing or leaking bag on nearby, neighboring units, these technologies also enable the most practical bag replacement possible. With one of these triboelectric units installed, engineers will only have to replace baghouse units as needed, when the likelihood of a failure is detected.

In the dust collector industry, manufacturers must create estimated lifespans to both sell their products and meet environmental compliance needs. In the task of meeting both of these requirements, manufacturers are forced to create lifespan estimations below what is typically possible. With triboelectric dust collection monitoring systems, engineers can manage and replace their baghouse units on a performance-based schedule, as opposed to the arbitrary, often inefficient seasonal schedules set forth by manufacturers. 

Download the ebook Now Modern Software and Equipment Failure Detection

Along with innovative, triboelectric bag detectors come the advanced software solutions that ease the traditional hassles of monitoring multiple systems, collecting parametric data from diverse sources, logging and reporting.

In short the accuracy, flexibility and capability of these systems change the character from a necessity for compliance to a tool to support business in a substantive and meaningful way – including driving down costs..  And of course it improves compliance with various environmental and industrial regulations.

Perhaps the most important of these regulations, the Environmental Protections Agency’s MACT (Maximum Achievable Control Technology) standards pose strict requirements for dust collection systems. Complying with these standards often only requires monitoring for ‘events’…but the systems are capable of more.

Fortunately, today’s triboelectric monitoring software makes dust collection maintenance simple, allowing for almost instant troubleshooting and leak management. Unified AC/DC dust collector monitoring tools and software are the easiest way for engineers to comply with necessary environmental standards, while also saving money in their maintenance and bag replacement needs. 

Proving Their Worth: Monitoring System Savings Over Time

The best tip we can give on spotting dust collection system failures is to find the best triboelectric solution for your unique needs – and this may not be simply the latest generation of your traditional solution. Contact triboelectric industry professionals and gain their insights about dust collection monitoring in your situation, and use this guidance to determine the best technologies for your needs.

The following are some things to consider when searching for the ideal dust collection monitoring system for your applications:

  • Event history in your facility, including costs, frequency, causes and eventual impacts of events on your operations
  • A full inventory of collection sensors and reporting equipment
  • How monitoring systems support your reporting requirements
  • How maintenance processes and scheduling operate in your facility, and what models would best serve to simplify those processes
  • What procurement challenges you’re likely to face internally, such as issues and frustration with earlier triboelectric detection models and budget constraints

Spotting dust collection equipment failures can be a frustrating process for some, but with the right tools, catching these failures early and minimizing their effects is made simple. Finding the right triboelectric monitoring system is a business decision that can completely change how your maintenance staff handle and anticipate baghouse failure events; because of this, it’s not a check-box, “throwaway” decision.

Take your broken bag detector decisions seriously, and you’ll see the great financial and compliance rewards modern systems are known to bring. To learn more about dust collection monitoring tools, or for more best practices on finding collection equipment failures early on, contact us today.


Topics: Dust Collection