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Pressure Gauges: Monitor the Health of Your Dust Collector Filters

Pressure Gauges: Monitor the Health of Your Dust Collector Filters

Pressure Gauges: Monitor the Health of Your Dust Collector Filters

There are plenty of tell-tale signs that indicate when your dust collector – and its critical components like filter media – are in need of repair and maintenance. If left unaddressed, what could simply be a quick fix may lead to costly repairs down the road or even cause unplanned downtime that puts your entire operation at risk. That’s why it’s critical to understand the importance of continuously monitoring the measurements on a pressure gauge to gain real-time insights into the condition of your filters.

Here are five reasons why gauges are critical to dust collector system performance.

Understanding the Effectiveness of Your Filters

A pressure gauge measures the cleanliness and effectiveness of your filters. The gauge is connected to two air pressure ports on the collector – one on the clean-air side and the other on the dirty-air side. The gauge shows the differential pressure (DP) between the two sides, indicating the resistance of the filter, or simply, how dirty the filter is.

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As dust accumulates on the filters, the DP increases. The normal range of the pressure drop varies depending on the type of collector, filters and even the properties of the dust being collected. Once the DP is too high it prevents sufficient airflow for the process – potentially leading to a jam in your entire operation. You can prevent air loss by adjusting cleaning cycles to more frequent intervals.

By monitoring the differential pressure on an ongoing basis, your team can determine when it’s time to clean or replace your filters to maintain peak performance.

What if Your Differential Pressure is Too Low?

If you notice a sudden drop in the differential pressure compared to your normal operating range, it could be an indicator that there is a leak in your system, a ripped bag or a broken filter. This leads to inefficient operations where your filter media won’t clean and parts of your system won’t function properly.

C&W’s standard gauges are referred to as Magnehelic and Minihelic gauges. Both gauges are designed to provide highly accurate pressure readings, and only differ in size. A Magnehelic gauge features a four-inch dial, whereas a Minihelic has a two-inch dial size.

Knowing When to Change Your Filters

So, you notice your gauge reading is maintaining a higher DP than your usual baseline and can no longer be brought down between the normal operating ranges – what does this mean? For C&W’s Cartridge and Bag Pulse Dust Collectors, when the pressure gauge reads higher than 8” W.C., it’s time to replace your filters. And for RA Units, it’s time for filter replacement when the gauge reads 6” W.C. or higher. If by conducting standard maintenance on your dust collector and full system you are unable to bring your readings back down to normal operating ranges, it is time to replace your filters, cartridges or bags.

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Learn additional signs and considerations to know when it’s time to replace your dust collector filters here.

Meeting Regulatory Compliance

Equipment calibration and monitoring are crucial in meeting emission requirements set by regulatory bodies such as the Environmental Protection Agency (EPA) and Occupational Safety & Health Association (OSHA). Especially since customers may be audited for compliance with regulatory requirements.

Without daily monitoring of your gauge readings, you won’t be able to identify when your filters need to be replaced. This can lead to your operation releasing hazardous dust into your plant and the environment – which is in direct violation with regulatory requirements. By failing to accurately monitor your system, you may find yourself among the companies fined as a penalty.

Ensuring Employee Safety

employee-safety

A properly designed dust collector – and its critical system components – are key to increasing efficiency, minimizing risk and ensuring peak performance. Because gauges are designed to measure the effectiveness of your filters, they inherently help protect what matters most – especially your employees. With effective filters, you mitigate slip and fall accidents due to dust settled on surfaces and remove risk of inhaling dust that can pose a health safety threat.

To ensure optimal employee safety, gauges should be positioned for easy access. For most collectors, including Central and Mobile units, gauges are typically mounted four to five feet off the ground to ensure easy access and readability. For Silo Dust Collectors, that are typically stationed 50 to 100 feet off the ground, customers can ask for an adapter mounting kit that will run a hose from the silo collector to the ground level. Otherwise, your dust collector operator or maintenance personnel will need to climb to the top of the silo every six months, pull out the filters, assess how caked over they are with dust and determine if they need to be replaced. By mounting the gauge at an easier access point, you remove all of the guess work and what could lead to a very risky operating process.

Talk with your dust collection partner to learn where it makes sense to mount your pressure gauge.

Leverage Mechanical Pressure Gauges to Ensure Peak System Performance

Don’t overlook the important role gauges can play in maximizing the performance of your dust collection system. Whether you’re using it to monitor the health of your filters, checking how clean your ducting is or using it to meet regulatory requirements, a pressure gauge is key to keeping your system running at peak performance. Importantly, it’s critical to ensuring the safety of your employees, process and surrounding environments.

Contact THE dust collection experts today to learn more about the benefits of a pressure gauges.

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