Maintenance Tips for Long-Lasting Pocket Filter Operations
The core of maintenance to ensure the long-term stable operation of bag filters lies in establishing a management system centered on "prevention first, timely handling", with a focus on three dimensions: filter bag lifespan, system status, and abnormal troubleshooting.
1. Full-Lifecycle Management of Filter Bags: Precise Control from Selection to Replacement
Filter bags are core filtration components, and their condition directly determines operational stability, requiring full-lifecycle maintenance.
- Adaptive Selection: Choose filter bag materials based on the temperature, humidity, and particle concentration of the medium being treated. For example, glass fiber filter bags are suitable for high-temperature flue gas (>200°C), and oil-resistant polyester filter bags for oil-containing gas. This avoids premature damage or clogging caused by material mismatch.
- Regular Inspection and Replacement: Set a fixed inspection cycle (e.g., once a month) to assess filter bag condition through visual checks or differential pressure monitoring. Replace filter bags promptly if the differential pressure across them exceeds twice the initial value (e.g., rising from an initial 500Pa to 1000Pa), or if damage/deformation occurs. Even if the differential pressure is within the standard range, replace bags according to their rated lifespan (e.g., 6–12 months) to prevent performance degradation.
- Standardized Replacement Operation: Avoid collisions between filter bags and sharp components during replacement. Ensure tight sealing between filter bags and the tube sheet interface during installation to prevent unfiltered gas from bypassing and being discharged directly. Meanwhile, clean dust accumulation on the tube sheet to avoid contaminating new filter bags.
2. System Operation Status Monitoring: Real-Time Tracking of Key Parameters
Monitor core system parameters to identify potential issues early and prevent minor faults from escalating.
- Real-Time Differential Pressure Monitoring: Install differential pressure sensors at the inlet and outlet of filter bags to record pressure changes in real time. A sudden drop in differential pressure may indicate filter bag damage; a gradual increase that cannot be relieved by dust cleaning may signal clogging—both require targeted handling.
- Dust Cleaning System Maintenance: Regularly inspect dust cleaning devices (e.g., pulse valves, injection pipes). For pulse valves, check for diaphragm aging and stable air pressure (usually maintained at 0.5–0.7MPa) to avoid filter bag clogging due to insufficient cleaning intensity. Calibrate the position of nozzles on injection pipes to ensure precise airflow injection onto filter bags and prevent local wear.
- Auxiliary Component Inspection: Inspect fans, motors, and seals monthly. Clean dust from fan impellers to prevent vibration caused by unbalanced rotation. Check motor bearing temperature (not exceeding 80°C) and lubricant level, refilling lubricant as needed. Immediately replace seals (e.g., flange gaskets) if aging or cracking occurs to prevent gas leakage.
3. Rapid Handling of Abnormal Issues: Targeted Solutions for Common Faults
Abnormalities are inevitable during operation, so a rapid response mechanism is needed to minimize downtime.
- Filter Bag Clogging Resolution: If clogging is caused by highly viscous particles or high humidity, first increase the dust cleaning frequency (e.g., shortening the pulse cleaning interval from 30 seconds to 15 seconds) and reduce medium humidity (e.g., installing a preheater). For severe clogging, remove filter bags and blow them backward with compressed air (0.3–0.5MPa), or rinse with clean water (only for water-resistant bags) and dry before reuse.
- Filter Bag Damage Repair: For a single damaged filter bag without severe contamination, repair it with special adhesive or patches. If more than 10% of bags are damaged, or damage occurs in critical areas (e.g., bag mouth, bag bottom), replace the entire set to avoid affecting overall filtration performance.
- Resolution of System Vibration and Abnormal Noise: If abnormal vibration occurs during operation, check for dust accumulation on fan impellers or worn motor bearings. For abnormal noise, focus on inspecting pulse valves in the dust cleaning system for air leakage and filter bags for collisions with the housing. Disassemble and repair promptly to prevent further component damage.
