Common Problems and Solutions for Baghouse Dust Collectors (Part 1)

High Differential Pressure

Main causes and troubleshooting: 

Incorrect differential pressure reading: Clean the pressure measurement port, inspect air pipes for cracks, check the differential pressure gauge. 

Improper pulse jet system settings: Increase pulse frequency; low compressed air pressure – raise the pressure, inspect the dryer and clean if necessary, check for blockages in pipelines.

Malfunctioning pulse jet valves: Inspect diaphragm valves, check control solenoid valves. 

Faulty pulse controller: Verify if the controller indicates each contact point, check the output of each terminal.

Clogged filter bags: Condensation on filter bags (see below); send filter bags to a laboratory for cause analysis. Dry and clean the filter bags or replace them, reduce air volume, 

increase compressed air pressure, raise cleaning frequency, inject neutral conditioning powder to form a protective layer and a porous, loose primary dust cake. 

Excessive secondary dust resuspension: Empty the hopper continuously; clean filter bags/ cartridges in random sequence instead of sequential order. Inspect inlet dampers to ensure they are clean.

Excessively High Air Volume

Main causes and troubleshooting: Pipeline leakage: Seal the cracks. 

Insufficient static pressure: Close the air valve, reduce fan speed.

Dust Escaping from Suction Points

Main causes and troubleshooting: 

Low air volume: Refer to the above solutions. 

Pipeline leakage: Repair cracks to prevent dust from bypassing suction points.

Improper pipeline balance: Adjust the dampers of branch pipelines. 

Unreasonable suction hood design: Enclose open areas around suction points. 

Check if the flat suction ventilation device can overcome suction force, and verify if dust is carried out of the suction hood by belts.

Dust Emission from the Stack

Main causes and troubleshooting: Leaking filter bags: Replace filter bags if torn or with small holes.

 Inspect the installation of spring rings to ensure a tight seal.

 Leaking tube sheet: Caulk or weld the gaps.

 Insufficient dust cake formation: Lower compressed air pressure, reduce cleaning frequency, inject neutral conditioning powder to form a primary dust cake. 

Excessive porosity of filter bags/cartridges: Conduct a permeability test on filter bags/cartridges and consult the manufacturer.

Severe Fan Wear

Main causes and troubleshooting: 

Fan handling excessive dust: Refer to the above solutions.

 Inappropriate fan: Confirm if the fan is suitable for the working conditions and consult the manufacturer.

 Excessively high fan speed: Consult the manufacturer.

Severe Fan Vibration

Main causes and troubleshooting: 

Dust accumulation on impeller blades: Clean the blades and check if the fan is handling excessive dust. Inspect the fan installation position, drain condensed water or moisture,keep the fan dry. 

Unsuitable fan impeller for working conditions: Consult the manufacturer. 

Unbalanced pulley: Perform dynamic balancing on the pulley. 

Worn bearings: Replace the bearings.

Excessively High Compressed Air Consumption

Main causes and troubleshooting:

Over-frequent cleaning cycles: Extend the cleaning cycle if possible. 

Overlong pulse jet duration: Reduce the duration (all air volume is wasted except for the initial impact; the pulse jet is usually set to 0.1 seconds). 

Excessively high pressure: Inspect diaphragms and springs (see the analysis of valve malfunctions above). 

Air pipe leakage: Conduct a bubble test and repair the leaks.

Low Compressed Air Pressure

Main causes and troubleshooting: 

Excessively high compressed air consumption: Refer to the above solutions.

Resistance in air pipes: Check for blockages in air pipes.

Clogged dryer: Replace the desiccant or bypass the dryer if working conditions permit. 

Worn compressor: Consult the manufacturer or refer to the compressor maintenance manual.