In today’s episode of the Dust Safety Science podcast, Chrissy Klocker, technical services manager at Donaldson Company, goes over five misconceptions about dust collector maintenance.
Dust collection systems are critical in industrial settings because they keep the environment safe and ensure compliance with safety and emissions standards. These systems, however, are often misunderstood when it comes to maintaining them. Proper maintenance can prevent expensive downtime, yet certain misconceptions sometimes lead to unnecessary work or improper system function.
In this discussion, Chrissy clarifies five of the most common misconceptions. Her goal is to offer practical advice for anyone using a dust collection system and to outline maintenance practices that can keep systems running optimally.
Misconception #1: Maintenance on Dust Collection Systems Is a Daily Chore
The first misconception many have about dust collector maintenance is that it requires daily, time-consuming work. Chrissy says this isn’t entirely accurate. While regular maintenance is essential, much of it is predictable and can be scheduled based on the needs of the system. Maintenance can actually be straightforward if a few simple practices are followed.
Chrissy explained that daily maintenance may only involve checking the differential pressure across filters. This tells you if the filters are working well. Other tasks, like emptying discharge bins, depend on how much dust the system processes and may only be needed once a week or less often, depending on dust volume.
Establishing a preventative maintenance schedule can reduce daily tasks. For example, combustible dust equipment often needs checks every quarter or bi-annually, depending on the system. Checking with equipment vendors for guidelines can help tailor the schedule to meet the system’s needs. Having a maintenance schedule that includes daily, weekly, monthly, and yearly tasks helps streamline the work and reduces the chance of overlooked issues.
New systems may require frequent checks initially, but over time, you’ll get a sense of how often each component needs attention. Preventative schedules allow you to address potential issues before they become costly problems, saving time and effort in the long run.
Misconception #2: Dirty Filters Need To Be Changed Right Away
Another common misconception is that a dirty filter needs to be changed immediately. Chrissy explained that dust filters are meant to get dirty as they trap dust particles from the air. In fact, having some dust on the filter can improve its efficiency since the dust helps capture additional particles.
Instead of taking a filter’s appearance as a sign for replacement, Chrissy suggests checking the differential pressure gauge. If the gauge shows consistently high pressure that doesn’t recover after cleaning, this indicates the filter may need replacing. However, if the pressure is stable or falls after cleaning cycles, the filter is likely functioning well.
“Another sign of a filter that needs changing is reduced airflow,” she said. “When filters get clogged, airflow drops, leading to lower capture and conveying velocities throughout the system.”
Maintaining the right airflow and pressure levels ensures the system operates at peak efficiency. Regularly monitoring these values will help you identify the right time to change filters without doing so unnecessarily, saving both time and resources.
Misconception #3: Dust Collectors Are Designed to Store Material
One misconception Chrissy often encounters is that dust collectors are designed to store dust. While they are intended to collect and filter dust, they are not storage containers. The hopper on a dust collector is meant to direct dust into a disposal bin or other discharge device, not to store it for extended periods.
When dust accumulates in the hopper, it can cause issues with the system’s ability to clean itself. Dust that piles up can prevent new dust from moving through, creating a buildup that impacts differential pressure and the system’s efficiency. When dust is recirculated, it can get redeposited onto the filters, making it harder for the system to maintain optimal airflow.
In some systems, dust flow issues may require additional equipment, such as flow aids or larger airlocks, to ensure smooth movement. Regularly emptying the dust collector’s hopper helps prevent clogs and keeps the system running efficiently. Neglecting to clear the hopper can lead to production downtime, increased maintenance needs, and potential safety risks.
Storing dust in the hopper also raises the risk of fire or explosion, as dust can ignite under certain conditions, especially when there’s a spark or high heat. Chrissy explained that letting dust accumulate in the hopper can increase the amount of combustible material in the system. This is a serious safety risk, particularly for facilities dealing with combustible dust. Proper maintenance reduces this risk by keeping dust from accumulating and storing where it isn’t meant to stay.
Misconception #4: The Fan is Running So the System is Working Properly
Fans are essential for moving air through a dust collection system, but a running fan doesn’t mean everything is functioning well. Chrissy emphasized that while fans are a critical component, they’re only one part of the system. Optimal dust collection relies on achieving specific airflow levels that match the system’s design.
If airflow falls below required levels, the system may not capture dust effectively, causing dust to escape back into the facility. Conversely, too much airflow can disrupt the process by pulling excessive particles into the collector. Both scenarios can affect the system’s efficiency and increase maintenance needs.
Ensuring the fan operates within the correct airflow range is key. Chrissy recommended regular airflow and pressure checks to determine if the system is capturing dust effectively. If the facility has changed production processes or increased output, the dust collection system may need recalibration to accommodate these changes.
In complex systems, periodic assessments by a professional can be invaluable. A technician can measure air velocity, airflow, and capture efficiency to determine if the system needs adjustments. Dust collection systems are expensive to install and maintain, so ensuring they operate within set parameters helps protect the investment and keeps operations running smoothly.
Misconception #5: Dust Collection Systems Can Only Be Operated Manually
With advances in technology, monitoring dust collection systems has become less manual and more automated. In the past, technicians would have to manually take readings and inspect various points in the system. Today, many systems have sensors that provide real-time monitoring of airflow, differential pressure, and emissions.
These systems can generate reports and send alerts when values go outside the acceptable range. Automated monitoring reduces the risk of human error and eliminates the need for technicians to record data manually, saving time and effort. Chrissy pointed out that these tools also help detect issues early, allowing maintenance teams to address them before they become major problems.
However, Chrissy cautioned that it’s not enough to see that airflow is within range; it’s also essential to understand what each reading means for the overall system. If airflow drops too low, it could indicate that dust is settling in the ducts, which could lead to blockages or increased fire risk. Higher-than-expected airflow might mean that adjustments are needed to balance the system.
Someone knowledgeable in the system’s design can interpret readings accurately and make adjustments as necessary. Setting appropriate thresholds for each parameter also helps ensure the system is maintained within safe and efficient levels. With automated tools, monitoring becomes much simpler, allowing teams to focus on keeping the system in optimal condition without unnecessary hassle.
Conclusion
Maintaining a dust collection system doesn’t have to be complicated or overwhelming. With a well-structured maintenance plan, it’s possible to keep dust collectors running efficiently, reduce downtime, and minimize safety risks. Chrissy’s insights shed light on common misconceptions, helping facility managers and technicians understand the best practices for dust collection maintenance. By focusing on essential tasks, establishing a preventative maintenance schedule, and using automated monitoring, facilities can optimize their dust collection systems and avoid common pitfalls.
If you would like to discuss further, leave your thoughts in the comments section below. You can also reach Chrissy Klocker directly:
Website: https://www.donaldson.com/en-us/
LinkedIn: https://www.linkedin.com/in/chrissy-klocker-5143666/
Email: [email protected]
If you have questions about the contents of this or any other podcast episode, you can go to our ‘Questions from the Community’ page and submit a text message or video recording. We will then bring someone on to answer these questions in a future episode.
Resources mentioned
The resources mentioned in this episode are listed below.
Dust Safety Science
Combustible Dust Incident Database
Dust Safety Science Podcast
Questions from the Community
Companies
Donaldson Company
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DSS286: Five Misconceptions About Dust Collector Maintenance with Chrissy Klocker
