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Author Archives: Joyce Nagy

  1. How to Solve Damaged Freight Issues

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    Unfortunately, shipments from any dust collection supplier you work with can sustain damage during transit. While you cannot control what happens in-transit, you can control how you respond to freight that arrives damaged.

    How to Solve Damaged Freight Issues

    How Damaged Freight Affects Your Bottom Line

    Shipping claims and getting replacements for damaged freight can be a frustrating to deal with, but the true price tag of this issue can cost far greater than just a few broken boxes or lost product. Other costs to your business may include:

    Minimizing Damaged Freight Issues

    The U.S. Air Filtration logistics team understands that packaging can play a role in the potential of damaged freight. Your shipment will be handled by many people along the way. So we keep this in mind when we prepare your dust collection order for shipment in the U.S. Air Filtration warehouse, and we follow a system of best practices that can help protect your items as much as possible.

    • Inspection –To avoid shortages we inspect, count, and match up the items to your packing slip.
    • Right Packaging – Our team makes sure that the box is suitable for the item that is shipping.
    • Proper Seals – We distribute tape evenly to ensure your product stays fully sealed in its package. For palletized items, we shrink wrap your freight multiple times to ensure all boxes remains together.
    • Appropriately Sized Pallets – Our warehouse team makes certain that the right sized pallet, also known as a skid, is the right one for the weight and size of the shipment.
    • Clear Shipping Labels – Labels are legible and durable. Paperwork such as a bill of lading or packing slips are placed inside of a protective sleeve.

    How to Solve Damaged Freight Issues 2

    How Do I Receive Freight?

    There is one golden rule of receiving freight that every receiving dock should follow. Do not accept or sign the bill of lading before checking freight for damage, concealed damage, or missing parts.

    It’s critical to pay close attention and inspect all details when you receive a freight shipment. You have the right to record exactly what is missing or damaged. If damaged freight is not recorded, you may not be able to file a successful freight claim.

    When you receive freight, here are the steps you should take.

    Box Count & Damage Inspection

    1. Count the number of boxes received. Compare the box count to the bill of lading for accuracy.
    2. Inspect the shipment for any visible damages. Ensure all packages are consistent.

    Are there any damages present? If yes, then take immediate action with the following steps.

    • Accept the shipment as damaged.
    • Write down all damages or missing box count on the delivery slip.
    •  Take photos to showcase the condition of goods when received.

    TIP: Do not refuse a shipment or discard any damaged freight. Your shipment may get damaged further, or worse, lost in storage. Without your dust collection products in-hand, getting replacements or a freight claim solved can take several weeks longer.

    TIP: Keep a copy of all related documents like the bill of lading, packing slip, and copy of your invoice.

    Communicate Issues

    TIP: There is a limited window of time to submit a freight claim for resolution.

    Report any damages to your supplier within 24 hours of receiving your shipment and they will help your take the next steps. If your shipment was from U.S. Air Filtration here is what you can do:

    • Contact your account manager directly or the USAF main line at 1-888-221-0312.
    • Send all photo evidence and a copy of the delivery slip to USAF.
    • USAF will help start the freight claim process and get you replacements ASAP.

    Damaged freight is a headache that no one wants to deal with. They strain your time and bottom line. If you would like to get help with your damaged shipment, submit your information with our interactive receiving checklist below. Once your information is received, a U.S. Air Filtration rep will be in touch to help.

    Receiving Checklist

  2. Low Temp Filter Bag Media Guide

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    Top 3 Low Temp Filter Bag Media

    If your plant is operating from ambient to 275 degrees Fahrenheit, there are a few low temp filter media bag options you can choose to use in your dust collection system. To guide you to the right one, we’ve gathered information on the three commonly used medias in low temperature dust collection applications. The following filter medias are generally for dry dust applications with very little moisture and no issue heats or acids.

    Low Temp Filter Bag Media

    Polyester

    Polyester is one of the most economical low temp filter bag medias used in the dust collection industry because of its reliable performance in a broad range of applications and availability. This media is used in industries including food manufacturing, woodworking, metalworking, building products, and energy. Polyester is one option if you are continuously operating between ambient – 275 degrees Fahrenheit, and have less than 10% moisture.

    Polyester Filter Bag Media

    CharacteristicRating
    Relative Cost$
    Max Continuous Operating Temperature275 Degrees F.
    AbrasionExcellent
    Energy AbsorptionExcellent
    Filtration PropertiesExcellent
    Moist HeatPoor
    AlkalineFair
    Mineral AcidsFair
    Oxygen (15%+)Excellent
    ProsCons
    Low cost and widely available filter media.Does not perform well with moist heat.
    Applications
    Food Manufacturing
    Woodworking
    Metalworking

    Polypropylene

    Polypropylene is another relatively low-cost, low temp filter bag media. The big difference between polyester and polypropylene is that polypropylene can withstand some moisture. If your continuous operating temperatures are between ambient – 170 degrees Fahrenheit, and you have more than 10% moisture in your application, then Polypropylene could be the right fit for your baghouse.

    Polypropylene Filter Bag Media

    CharacteristicRating
    Relative Cost$
    Max Continuous Operating Temperature170 Degrees F.
    AbrasionExcellent
    Energy AbsorptionGood
    Filtration PropertiesGood
    Moist HeatExcellent
    AlkalineExcellent
    Mineral AcidsExcellent
    Oxygen (15%+)Excellent

     

    Acrylic

    Another option for applications with more than 10% moisture is Acrylic. This is similar to polypropylene but more expensive. Acrylic can handle moisture better than polyester and has a higher temperature rating. If you need to run between 200-265 degrees Fahrenheit, but you have moisture, you could use acrylic.

    Acrylic Filter Bag Media

    CharacteristicRating
    Relative Cost$$
    Max Continuous Operating Temperature265 Degrees F.
    AbrasionGood
    Energy AbsorptionGood
    Filtration PropertiesGood
    Moist HeatExcellent
    AlkalineFair
    Mineral AcidsGood
    Oxygen (15%+)Excellent

    Assistance with Low Temp Filter Bag Media

    If you have a unique application we can help get some answers to your questions. Reach a dedicated account manager at 888-221-0312 or email [email protected]

    Are you looking for high temperature media options? Then check out our guide here.

  3. Air Pollution Control & Managing Industrial Dust

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    Disclaimer: The contents of this industrial dust blog are intended to be general safety guidelines. All businesses will still need to refer to OSHA, NFPA, and local ordinances required for their business.

    Industrial Dust Guide

    Dust builds up in your home may simply be a nuisance you take care of while spring cleaning. But in the workplace, dust can become a serious hazard if not properly handled. To get a better understanding of the negative effects of dust in the workplace we will provide a brief overview what industrial dust is, how industrial dust is created , potential dangers you should plan for, and the benefits of a properly engineered dust collection system.

    Industrial Dust Guide

    What is Industrial Dust & How is it Created?

    Dust consists of small particles of dry matter that build-up on hard surfaces such as floors, tools, industrial equipment, ducts, etc. Industrial dust can generate more frequently than household dust. This is because it generates from the daily from the manufacturing or production process. For example, a small woodworking shop could generate dust from activities like sawing, grinding, or cutting. Industrial dust can even break out during processing. Another example, in an agricultural facility process dust can come from sugar, flour, grains, etc.

    Common Types of Industrial Dust

    • Wood – Activities like sanding, high speed cutting, low speed cutting, paning etc. can create dust which is both explosive and fire prone.
    • Food Particulate– Certain food particulate can be explosive, abrasive and fire prone. This can encompass a wide variety of particulate such as flour, grains (corn, rice), soybeans, and more.
    • Cement & Concrete – This dust is abrasive but considered to be less explosive and prone to fire.
    • Paper Products – Dust created from paper products can be both explosive and fire prone.
    • Paint Powder – Paint pigments can be highly explosive
    • Pharmaceuticals – Pharmaceutical dust like dry powder and coating are both explosive and fire prone.
    • Plastic, Chemicals, Stone, Minerals , Metal etc.

    Is Industrial Dust Dangerous?

    The build-up of combustible dust is serious hazard in the workplace. Airborne dust presents a safety hazard to employees. Many types of industrial dust may contain carcinogenic properties that would require removal to keep employees safe, healthy, and to comply with government regulations.
    Airborne dust may also be highly flammable, and safeguards must be implemented to prevent the risk of a dust explosion.

    Conditions for a Dust Explosion

    • Oxygen
    • Enclosed space
    • Ignition source
    • Combustible dust at the right concentration level

    When you are working in an industry that operates with combustible dust, explosions and fires are a constant threat. If you are taking the right steps to ensure a safe working environment you are more likely to avoid a fire or explosion that would cost you the safety of your employees, thousands of dollars in lost production, and regulatory fines. Combustible dust can present itself in a variety of applications. Below are just some of the types of industries that work with combustible dust.

    Common Examples of Combustible Industrial Dust

    • Agriculture (grain, flour, sugar, etc.)
    • Wood
    • Metals (aluminum, zinc bronze, etc.)
    • Rubber
    • Chemicals (coal, Sulphur, etc.)
    • Pharmaceuticals
    • Pesticides
    • Plastics

    There are no short cuts to minimizing dust hazards and ensuring the safety of your employees. But understanding if you are working with combustible dust is the first step in prevention.

    Regulation of Air Pollution Control

    Many industrial industries in the U.S. must comply with strict air pollution control standards. These standards are set by the Environmental Protection Agency (EPA), National Fire Protection Agency (NFPA), OSHA, or local governing entities like the AQMD in California.

    OSHA regulates industries that are susceptible to combustible dust. When implementing OSHA’s set of standards, you are creating a safe working environment, avoiding property and economic loss from an explosion, avoiding regulatory fines. To learn more about OSHA’s safety standards for combustible dust, visit their guide here.

    The NFPA (National Fire Protection Agency) is another agency that publishes a list of guidelines to help minimize injury or death from combustible dust. The following codes are related to the most combustible types of dust (e.g., sugar, wood, fine aluminum):

    • 664, Standard for the Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities
    • 484, Standard for Combustible Metals
    • 61, Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food Processing Facilities

    How a Properly Engineered Dust Collection System Supports Air Pollution Control

    5 Benefits of a Dust Collection System

    Dust collection systems are engineered and designed to filter airborne industrial dust particles and debris that can cause damage to plant equipment, create a hazardous work environment, and negatively impact plant production. The top 5 benefits of a dust collection system are:

    1. Meet Compliance Regulations and Standards – All agencies require industrial facilities to maintain and meet air quality standards to ensure a safe and clean environment for their plant, employees, and the surrounding community.
    2. Boost Productivity – An accumulation of dust particles and debris on industrial equipment can interfere with overall plant performance. A dust collection system can collect these dust particles before they can interfere and compromise the health and performance of your manufacturing equipment.
    3. Improve Product Quality – Dust can settle and accumulate on products during the manufacturing process. This has a negative impact on the quality and consistency of finished goods. A dust collector will reduce and effectively capture these dust particles, allowing for product quality to improve and maintain consistency.
    4. Enhance Health and Safety Standards – Inhalation of hazardous dust affects human health and a dust collection system is vital to removing these hazards and to keep employees safe.
    5. Preserve the Quality of Equipment – As dust particles and debris are created inside a manufacturing facility, the contaminated dust will settle onto other surfaces such as computer systems and manufacturing equipment. This dust buildup can be harmful and result in malfunctioning equipment. It can also create unnecessary, frequent, and costly maintenance to keep dust and debris from accumulating. With a dust collector system purifying and collecting dust particles, the chances of excessive dust build-up is minimal.

    In addition to adding a dust collection system to your plant, you can also consider some of these dust removal options and explosion venting strategies.

    Baghouse Dust Removal Options

    • Enclosed Box – A simple pipe system funneling dust into an enclosed box, placed underneath your hopper, is one dust removal option.
    • Drum or Bag – A removable drum or bag can be a simple and easy solution to collecting and disposing dust.
    • Rotary Valve – Rotary valves (also known as airlocks, rotary feeders, or airlock feeders) help transition material from a dust collector to a drum or bin.
    • Screw Conveyor for Baghouse Dust Collectors – Large baghouses with heavy dust loads typically use screw conveyors. The screw conveyer would transport dust away from the collector, then send it to a designated disposal area.

    The best method of dust removal from your hopper is dependent on some of the following components:

    Explosion Venting Strategies

    Common Venting Strategies

    •Preventative Maintenance Plan: In conjunction with a protection strategy, every facility should implement a well-designed and operated preventative maintenance plan. Perform regular checks on the health of your dust collection system to prevent more serious issues.

    •Explosion Vent or Panels: Explosion vents or panels are designed to rupture at a set pressure (PStat). When a source of ignition meets a fuel source with sufficient oxygen present, an ignition will occur. As the ignition begins, the pressure inside of the vessel will increase rapidly. Depending on the material’s Kst value, the pressure rise may be slow or extremely rapid. As the ignition progresses, the internal pressure will meet the PStat rating of the explosion panel. The explosion panel will rupture, venting the ignition gasses. The explosion vent provides a relief avenue for the expanding gasses, but the pressure in the vessel will continue to rise until it reaches the Pred pressure. This is the maximum pressure of the ignition event when explosion vents are functioning, so this is usually the pressure rating the vessel is designed to withstand.

    You can use explosion panels with a short length of ducting to allow for interior use without flameless venting. They do require replacement once a rupture occurs, but they are simple, cost-efficient, and easy to install. Explosion vents are typically useful on baghouses and cartridge dust collectors.

    • Explosion Latch: Explosion latches work under the same principle as the explosion panels, but they are not single use. This is a more cost-effective option (versus explosion panels) when you have  a large baghouse or large quantity of vent area.

    Additional Venting Strategies

    • Flameless Venting: Flameless venting can consist of a flame arrestor element, vent panel, and flanged housing. This combines the techniques of explosion venting and flame arresting. You can also install a flame arrestor element over a standard explosion vent. When the vent ruptures, the burnt dust and flames enter the flame arrestor element. The element helps to contain the hazardous dust and flames and prevents it from exiting, where it could potentially ignite a secondary explosion or endanger employees. While flameless venting does stop flames from exiting the vessel, there will be extremely hot gasses exiting the flameless vent. When using flameless venting, make sure to pay close attention to the vents proximity to personnel areas. If possible, always aim flameless vents away from regularly occupied areas.

    • No Return Valve: Protecting the dust collector from over-pressure is essential, but it is equally important to stop a deflagration propagation back to the operator space. To prevent this, a No Return Valve is needed in the inlet duct. This valve is a weighted damper that is held open by the air flow during normal operation, allowing air and dust to pass through to the dust collector. In the event that deflagration occurs in the dust collector, the pressure propagation through the duct work will close the No Return Valve. This prevents the deflagration from reaching any process equipment and also limits the risk of secondary explosions.

    • Abort Gate: Abort gates are high speed dampers that contain a spring assisted blade and is typically held in place by an electromagnet. Their purpose is to minimize the risk of an explosion by diverting flame, spark, or debris from entering a facility through a return air system.

    • Spark Detection & Extinguishing System: This method uses infrared sensors, typically located on the ductwork, to detect sparks or burning material in the ductwork upstream.

    Secondary Event Protection

    All the methods described previously are excellent options for managing primary explosions, but one of the most catastrophic outcomes of a combustible dust explosion is an un-controlled secondary explosion.

    When a primary explosion happens, there may be a pressure wave that propagates through the plant. This will “kick up” the layer of ambient dust. If the explosion is not contained in the dust collection system using the methods previously outlined, this ambient dust in the air could come in contact with the primary explosion flame front. This results in an uncontrolled explosion in an occupied space.

    To minimize the risk of secondary explosions, the first step should always be to expect perfect performance from your dust collection system. It is not acceptable to have a dust collection system that does not function properly. Another suggestion is to limit the amount of horizontal surfaces in your plant that cannot be regularly cleaned. Drop ceilings and in-accessible equipment are great examples of this.

    There are many strategies that may fit your unique application or facility. We recommend to consult your local or state building codes and regulations before choosing your explosion venting strategy. Some areas will have specific regulations for fire safety and environmental safety, and you want to ensure you are meeting those guidelines. Here are some questions to consider before implementing an explosion venting strategy.

    Questions to Consider

    At U.S. Air Filtration, we have been eliminating the hazards of industrial dust for 35 years.
    To learn more about how you can manage industrial dust at your facility contact us at 888-221-0312 or [email protected] to speak with an engineer

  4. Shaker Filter Bags

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    How Shaker Filter Bags Collect Dust

    Shaker baghouses collect dust similar to reverse air baghouses. Dust collects on the inside surface of the shaker filter bags, and then clean air exits through the top of the bag. The main difference is how the bags cleaned.

    How to Clean Shaker Filter Bags

    Shaker baghouses are engineered so that filters are hung and tensioned from the top of the unit, and at the bottom they are attached to a tube sheet. Mechanically shaking the filter bags is what cleans them. Shaker baghouses only clean while the system is off-line. Shaker baghouse operation is simple and can be seen in applications where no compressed air is available.

    Construction of Shaker Filter Bags

    Fabric filter bags used in shaker baghouses are typically constructed with woven or light weight media options like polyester sateen, shaker felt, beane knit, and more. Treatments are dependent on a plant’s application and dust characteristics. The most common top and bottom configurations for shaker baghouses are below.

    Most Common Top & Bottom Construction for a Shaker Baghouse

    Top Load Baghouse: Grommet Top, Loop Top, Strap Top
    Bottom Load Baghouse: Corded Cuff Bottom, Double Beaded Snap Band

    If you would like to get a free media recommendation, check out our filter bag media quiz here. There is also a fabric characteristics sheet that you can download below. It takes a closer look at the most common filter bag medias used in the dust collection industry.

    Dust Collector Filter Bags

    Filter Bag Resources

    To learn more about how to select the right filter bags, you can download our filter bag guide with the link below. The guide provides resources on key topics such as; dust properties, filter media, finishes and treatments, construction, and air-to-cloth ratio.

    Looking to start with the basics? Watch this “Guide to Filter Media” video to learn more about the most common medias used in the industrial dust collection industry.

    Guide to Filter Media

    Are ready to get a set of filters? Check out our online product catalog below. You can also request a quote within 24 hours, call at 888-221-0132, or simply email [email protected]

    Filter Bag Request a Quote

     

     

  5. Baghouse Filter Bag Top and Bottom Configurations

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    Filter bag configurations can vary from one dust collector to another. Baghouse filter top and bottom configurations will be dependent on the type of baghouse dust collector you have. The most common types of baghouses are pulse-jet and plenum pulse, reverse air, and shaker.

    Dust Collector

    Pulse-Jet and Plenum Pulse Baghouse

    Pulse-jet and Plenum Pulse baghouses collect dust on the outside of the filter. Dust-laden gas floods the dust collector, and clean air exits through the inside of the bag while dust particles collect on the outside filter surface. A pulse-jet is one of the most common styles of baghouses will see across a variety of industries and applications. The most common types of filter top and bottom configurations in this style of baghouse are:

    Top Load Baghouse Filter: Double Beaded Snap Band Top, Disc Bottom
    Bottom Load Baghouse Filter: Raw Top, Disc Bottom

    Reverse Air Baghouse

    In reverse air baghouses dust will collect on the inside surface of the filter. Air enters the dirty side (inlet) of the baghouse and flows upwards through the bag. The bag filters and collects the dust on the inside, then clean air exits through the top of the bag. Reverse air baghouses are typically seen in large air handling applications like energy.

    Top Configuration: Compression Band with Cap & Hook
    Bottom Configuration: Compression Band, Corded, Double Beaded Snap Band

    Shaker Baghouse

    The way shaker baghouses collect dust is similar to reverse air baghouses. Dust is collected on the inside of surface of the filter. Dust particulate is filtered and collected on the inside of the filter, then clean air exits through the top of the bag. The difference in this system is in how the bags are cleaned. Filter bags are hung and tensioned from the top of the unit, and at the bottom they are attached to a tube sheet. As the name suggests, you clean the bags by mechanically shaking them. Shaker baghouses are generally simple, and can be seen in applications where there is no compressed air available.

    Top Configuration: Grommet Top, Loop Top, Strap Top
    Bottom Configuration: Corded Cuff Bottom, Double Beaded Snap Band

    Filter bag construction and dimensions vary between industries, applications, dust collector types and manufacturers. Here are some of the filter bag top and bottom configurations you may come across.

    Top and Bottom Construction Filter Bag Configurations

    Most Common Baghouse Filter Configurations:

    • Double Beaded Snap Band
    • Disc (with or without wear cuff)
    • Sewn Flat
    • Open Hemmed
    • Raw Edge

    Least Common Baghouse Filter Configurations

    • Disc with zipper
    • Spout
    • A-hanger
    • Flange
    • Belt Loops
    • O-Ring

    Other Baghouse Filter Configurations

    • Envelope
    • Grommet
    • Strap
    • Loop
    • Snap Ring
    • Corded
    • Double Disc
    • Compression with Cap and Hook

    Baghouse Filter Resources

    To learn more about how to select the right filter bags , you can download our filter bag eBook with the link below. The ebook provides resources on key topics such as; dust properties, filter media, finishes and treatments, construction, and air-to-cloth ratio.

    Filter Bag eBook

    Video: Guide to Filter Media

    Guide to Filter Media

    Find Your Baghouse Filter

    Are you ready to find your filter? If you are looking for a quote, click on the link below to submit your information. We’ll get a quote back to you within 24 hours.

    Request A Quote: Filter Bags

  6. How to Replace Your Dust Collector Diaphragm Valve

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    Is your dust collector showing signs of trouble? It could be your diaphragm valve.

    As your dust collector goes through it’s life cycle, your parts start to wear out. Diaphragms are one of the 5 most commonly replaced dust collector parts. These are the common warning signs of trouble and how you can replace a diaphragm valve.

    Common Symptoms of a Worn Out Diaphragm Valve

    • Rubber has crack or holes in it
    • Diaphragm kit is pitted, allowing air to leak through
    • Any holes tears or imperfections indicate it’s time to change it out
    • Is your spring broken? It’s time to replace your diaphragm valve.

    Once you’ve diagnosed your issue, you’ll need to fix it. Below is a short video guide that provides step-by-step instructions on how to replace a diaphragm valve.

    Replace a Diaphragm Valve Video Transcript:

    Hi, this is Bob with US air filtration. And today I’m going to show you how to change out the diaphragm inside a solenoid pulse valve.

    Pulse Valve Types

    As you can see here pulse valves come in a lot of different sizes and shapes. Some valves have coils on the top, and some don’t. Pulse valves can have two diaphragms or one. Others have couplings, threads, or flange connectors. But the process of changing out the diaphragm is really very similar in all of them.

    First Steps to Replacing a Diaphragm Valve

    I’m going to show you today, on this particular valve, how to change out the diaphragm.

    First thing that we’re going to do is remove the bolts that are holding on the top of the belt. I’m using a socket set and I’m going to loosen these up. Once I get all the valves loose I can pull off the top.

    I’ll tell you, sometimes when these valves have been sitting, especially out in the sun for a while getting this top piece off isn’t really easy. You may need to take a screwdriver and a hammer and just tap it lightly there where the rubber is to help get the top off.

    But once you get the top off you can remove the spring and you can peel off the diaphragm.

    Diaphragm Valve Bleed Hole / Pin

    Now in some pulse valves, well in all pulse valves, there’s a little bleed hole. And often times, there’s a pin this particular one, has a little pin right here that this allows the air pressure to equalize between the two halves of the valve.

    It’s really important that we don’t block this hole or damage this pin when we put the valve back together.

    New Diaphragm

    Once we pull off the old diaphragm kit, we can grab the new diaphragm. And the first thing we want to do is find out where that bleed hole is in the diaphragm. Here, it’s this hole right here. We’re gonna place that right over the pin.

    The teflon disc or it’s a rubber disc on your diaphragm goes down so that it seats up against this part of the valve. It’s not a bad idea to look and make sure that there’s no damage to the the body of the valve.

    Typically though these aluminum bodies; it’s really hard to damage them. I don’t usually see problems with them. It’s usually the diaphragms that go.

    We’re gonna line up the hole with the bleed hole. And make sure our holes line up and put our diaphragm back then.

    Then we need to make sure that we have the spring that comes with the repair kit that goes back on top of the diaphragm and then we’re gonna put the top back on.

    Now just like I mentioned, with this bleed hole, there’s a place where the bleed hole on this top cover goes. We need to make sure we’ve lined that bleed hole up with the bleed hole here.

    If we block it, the valve is not gonna work. Or if you don’t put it on correctly, and there’s a pin, you’ll squash the pin. And then you’re gonna have to buy a new valve just to replace this little pin.

    We’re gonna line this up. And I can kind of feel it set on the right. And then we’re just going to tighten down all the bolts.

    Tighten Bolts

    Now once I get everything finger tightened I want to go ahead and tighten these bolts down.

    If I don’t tighten the bolts down properly, and you don’t get this clamping this diaphragm together, you’re gonna get a leak outside of the valve.

    The best practice is, with your ratchet, is to tighten the bolt on one side and then go to the opposite side and tighten it down. And then just keep going about 180 degrees so that your getting a nice even pressure.

    Upper Smaller Diaphragm

    Okay now we need to do the little diaphragm.

    I’m gonna pull off this coil, which I could have done before. And actually if you have electrical wires connected to this, it helps to pull off the coil.

    I might add too, before you start this you need to turn off the compressed air to your valve. Or as soon as you start releasing this, it’ll just start blowing everywhere

    Okay. So to change out this upper smaller diaphragm we need to loosen up these four bolts here with an allen wrench.

    I’m going to loosen all of these up and then remove these bolts.

    Okay once all the bolts are loose, you can lift off the top. Once again, there’s a spring and the diaphragm. You’ll grab the new diaphragm with the little metal side down.

    Again there’s a little tiny pin right there for the bleed hole. Every diaphragm is gonna have a bleed hole somewhere that you need to make sure you line up.

    There are a few types of valves that the bleed hole is actually in the body of the diaphragm.

    In those cases you don’t have to worry about it too much. But a lot of valves have these pins.

    So, I’m gonna line this bleed hole up and put it on. And take the new spring and put it on. And then I’m going to make sure that my hole right under here, where the bleed hole goes, is gonna go right over that bleed hole.

    I can feel it seat down on there. And again I’m gonna tighten the bolts.

    Everything’s good and tight. Put our coil back on.

    And now we’re ready to turn the compressed air back on, and test our valve to make sure it all works.

     

    Related Resources:

    Dust Collector Change Out Check List

  7. Benefits of PTFE Membrane

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    Are you spending too much time and money on costly change-outs?

    Would you like save yourself from the headaches that come with change-outs? Then PTFE may be the answer to your problem. Our brief video guide will provide some information on how PTFE membrane works and its benefits when its added to your filter media.

    Video Transcript

    Hi this is Bob from US Air Filtration.

    • Do you want to get twice the life out of your filter bags and reduce costly change-outs?
    • What if your dust collection system captured more dust?
    • Would you like to get consistent airflow or suction through your dust collection system while reducing wear and tear and reducing maintenance costs?

    If the answer to any of these questions is yes, then PTFE membrane filter bags may be the answer. For you to understand how PTFE membrane bags can accomplish these things let’s first look at how a standard filter bag works.

    How a Standard Filter Bag Works

    On a standard bag dust builds up on the outside of the bag and creates what is known as the filter cake. The filter cake actually does the filtering while the bag fabric acts only as a support for the cake. When the bags are pulsed most of the filter cake releases and the build-up of dust begins again.

    Over time however, some of the dust gets embedded deep into the bag fibers. Eventually, the bags will completely plug and need to be replaced.

    Conversely, when PTFE is added to the bag it acts as the filter cake. Commonly known as Teflon. PTFE is used in many different applications from cookware to outerwear and more. When a PTFE membrane is laminated to a filter bag media it can enhance the performance of both the filter bag and the dust collection system.

    How PTFE Membrane Works

    Let’s take a closer look at how a PTFE membrane works. If we zoom in on the PTFE membrane we can see that it is actually made out of tiny microscopic holes like Swiss cheese. The holes are large enough to allow air molecules and vapors to pass through but small enough to inhibit even the smallest dust particles from getting through.

    Because the membrane keeps the dust on the surface of the bag particles never get embedded in the bag fibers and the bags will not fail from plugging up. Typically PTFE membrane bags wear out before they plug up. Usually lasting twice as long as standard bag.

    Benefits of PTFE Membrane

    With twice the lifespan costly change-outs and plant shutdowns are cut in half reducing maintenance costs and increasing plant production. Since the bags are not gradually plugging up over time, PTFE bags give the additional benefit of providing more consistent airflow or suction from your dust collection system.

    Because of the small pore size, PTFE membrane bags are up to eight times more efficient than a standard filter bag. This means it can cut out dust collector emissions by up to 800 percent.

    Additional Advantages of PTFE Membrane

    Another advantage of PTFE membrane bags is that they clean easier because of their slick surface. This means less bag pulsing. Which also means less wear and tear on the bags as well as the diaphragms and solenoid valves. It also means the system uses less compressed air resulting in reduced energy costs.

    It can also improve performance when higher moisture levels or sticky dust are present. PTFE membrane can be added to any bag media and can replace standard bags and almost all applications. While there is a cost to add the membrane, the extra cost easily pays for itself. It provides longer life, reduced maintenance cost, reduced wear and tear, and lower emissions.

    To find out if PTFE membrane filter bags are right for you call and talk to one of our experts today.

    Related Resources:

    Filter Bag Construction

  8. Dust Collector Change Out Check List

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    How do you know when it’s time for a dust collector change out?

    There are typically two reasons people have a dust collector change out.

    1. The build-up of filter cake is so excessive that it is blinding your filters.
    2. You have a hole/leak in your filter(s).

    Your dust collector is a major investment. Maintaining your system’s vital components is going to play a critical role in keeping your production down time and maintenance costs to a minimum. To help you determine if your filters are compromised and it’s time for a dust collector change out, check out our brief video below.

    Are you ready to change out your dust collector? Download this check list below.

    Check out our full checklist here.

    Dust Collector Change Out Video Transcript:

    Factors that Influence Filter Life

    Hi, I’m Bob from U.S. Air Filtration. Today, I would like to answer a common question that we are often asked. That is, “When is it time to change my filters?”

    There are several key indicators and considerations that will help you determine the answer to this question.

    Before we discuss these, let’s review the two main reasons for changing filters. One, either the filter fabric has become compromised by a hole or tear in the fabric which now allows dust to pass through. Or two, the filter fabric has become fully entrained or clogged with dust particles which permanently restrict air flow through the filters.

    Dust Collector Change Out Indicators

    Ok, Let’s talk about the indicators:

    This may seem obvious, but the first indicator is if you see dust coming out of the clean side of the collector. This means you likely have either a hole in the filter or the filter’s seal has been compromised.

    You can find bad filters by conducting a visual inspection. Sometimes the holes may be very small or hard to find. In these situations, you can find the leak by conducting a leak test.

    This is accomplished by introducing leak powder into the system. The powder will concentrate around any leaks and become visible under a black light. Call us to learn more how this product works.

    Differential Pressure

    While damaged filters with holes or a poor seal will leak dust, clogged filters do not leak dust. Instead the dust becomes embedded into the fibers of the filter. This increases the resistance of the air flow, which increases the differential pressure reading on your dust collector.

    Differential Pressure is the difference in air pressure between the clean and dirty sides of a collector.

    A consistently higher differential pressure indicates that it is more difficult for the air to get through the filter media and usually means filters are nearing the end of their life span.

    When you consistently see Differential pressure readings of 6 or above and they don’t drop significantly during the collectors cleaning cycle, it’s generally a sign that it’s time to change your filters.

    Loss of Suction at Pick Up Points

    Another indicator that points toward a filter change-out is when your pick up points are not getting the suction you’re used to seeing. It is the permanently entrained dust that causes the reduced air flow, and as we mentioned, the higher differential pressure.

    Dust Collector Change Out General Rules

    Let’s discuss a few other considerations.

    As a general rule, it is better to change out all the filters in a collector than a few at a time. Air flow always follows the path of least resistance, and you can quickly wear out new filters if they are doing all the work in your collector.

    Some of our clients like to change out filters during scheduled plant shut downs or on a maintenance schedule.

    Filters may have some life left, but this is a good option if the risk of having a problem before a scheduled shut down is too great, or the predictability of filter life is fairly certain.

    Laboratory Tests

    One final thing to consider is using a laboratory test to determine how much life remains in a set a filters. This testing is not common and is typically only when the bag cost is substantial and there is a lack of history with the bag life or there is some other unique problem that can’t be otherwise solved. In most cases, the other mentioned indicators are sufficient to determine when to change out your filters.

    How Long Filters Last

    Another question we are often asked is how long do filters typically last.

    This is a really tough question to answer because there are so many environmental factors that come in to play. We have seen filters last anywhere from a few weeks up to 5 years or more. On average, life expectancy is about a year, but it really varies.

    Here is a list of some of the factors that influence filter life. To find out more about these factors or to ask one of our experts if it’s the right time for a dust collector change out, give us a call.

    1. Air to cloth ratio
    2. Volume of dust loading
    3. Size of dust
    4. Presence of membranes or coatings
    5. Dust characteristics (powdery, sticky, shape)
    6. Air velocity through the filters
    7. Moisture in the dust
    8. Ambient air moisture
    9. Cleanliness of compressed air
    10. Presence of chemicals – oils, acids, etc.
    11. Operating temperature
    12. Frequency of cleaning cycle
    13. Average differential pressure
    14. Proper cage fit
    15. Proper installation
  9. Baghouse Dust Removal Options

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    Why Baghouse Dust Removal Matters

    The right baghouse dust removal method can help minimize problems that arise due to dust build up in your hopper.

    A hopper is designed to be temporary storage for your discharge. What happens if you have excessive dust build up in your hopper? This can result in your air flow being blocked off and would cause a loss of suction throughout the dust collection system.  This can also become a hazard because it’s more opportunity for combustible dusts to create a dangerous explosion. The right dust removal method for your application can help you avoid these issues.

    Key Components

    The best method of dust removal from your hopper is dependent on some of the following components:

    • What’s your Dust Collector Type? Baghouse or Cartridge Dust Collector?
    • What are the characteristics of your dust? For example, hazardous or non-hazardous?
    • What are the loading rates of your dust?

    Baghouse Dust Removal Methods

    Baghouse Dust Collector

    Enclosed Box

    A simple pipe system funneling dust into an enclosed box, placed underneath your hopper, is one dust removal option. Your maintenance team would be required to monitor and empty the box once capacity has been reached. Prompt removal of dust build up in your enclosed box helps prevent backup or an overflow of the box itself. Non hazardous dust and light dust loads typically use enclosed boxes.

     

    Drum or Bag

    A removable drum or bag can be a simple and easy solution to collecting and disposing dust. Once a drum or bag fills up, maintenance simply removes it by hand or forklift. Once empty, the drum or bag can then be put back into its place. This is ideal for non toxic dusts that you can easily handle.

    Rotary Valves for Baghouses

    Rotary Valve

    Rotary valves (also known as airlocks, rotary feeders, or airlock feeders) help transition material from a dust collector to a drum or bin. It seals a pressurized system against loss of air and pressure. This minimizes product loss during processing. Dust collection, pneumatic conveying, mixing, weighing, feeding, and blending use rotary valves. Larger baghouse systems with over 10,000 CFM  can also use rotary valves.

    Screw Conveyor for Baghouse Dust Collectors

    Large baghouses with heavy dust loads typically use screw conveyors. The screw conveyer would transport dust away from the collector, then send it to a designated disposal area. This is ideal for hazardous or reused materials.  Agriculture, mining, foundries, wood production, and chemicals are applications that use screw conveyors.

    Would you like to learn more about design considerations for a new dust collection system? For more information, download our dust collector purchasing guide.

    Dust Collection Design Considerations 7

  10. Different Baghouse Styles: Advantages and Disadvantages

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    When it comes down to finding the right dust collection system, there are a few different baghouse styles to choose from. So how do you know which one is best for you?

    Baghouse Styles

    Before we dig into the differences between some of the baghouse styles, you need to consider your dust properties and air-to-cloth ratio.  Baghouses are ideally suited for large volume applications with airflow exceeding 1,000 CFM or when high temperature applications are above 375 degrees.  In these environments, a baghouse will handle and most efficiently filter your dust laden air. 

    There are three main baghouses styles (e.g. shaker, reverse, and pulse-jet)  that are commonly used in most industrial processing and manufacturing applications.  Here’s a brief overview on the pros and cons of each to help guide you in identifying the right option for your work environment.

    Pulse Jet Baghouse 

    Pros:    Cons:
    Constantly cleaned so there is minimal dust build up in the dust collector   Requires dry compressed air
    Space Efficient   Cannot be used when there is humidity of high moisture content present
    Requires fewer bags   Cannot handle high temperatures (unless you use special filter media
         

    Reverse Air Baghouse 

    Pros:  Cons:
    Can handle high temperatures Needs to be cleaned often
    Gentle cleaning which allows for longer bag life Residual dust build up is hard to remove
    Units are typically compartmentalized into sections which allows them to be cleaned without shutting off the entire baghouse Low air-to-cloth ratio
       

    Shaker Baghouse 

    Pros:     Cons:
    Very simple to operate     Cannot handle high temperatures
    Low initial investment cost     Not space efficient (takes up a large area)
    Units are typically compartmentalized into sections which allows them to be cleaned without shutting off the entire baghouse     Energy and time sensitive