Pulse Jet Dust Collector: Learner Guide

Field Operator Certification
Pulse Jet Dust Collector

Learner Guide
Pulse Jet Dust Collector Learner Guide
Introduction
This lesson on Pulse Jet Dust Collectors, as with your other lessons on Auxiliary Equipment,
consists of two main learning components: a self-directed/in-class component and an on-the-job
component. You are expected to complete both components as part of your Certification Program.
Review the remaining information contained in the Introduction section of this document prior to
beginning the Content section. If you have any questions about this information, speak with your
Instructor.
Objectives
Your learning objectives are broken down into two categories learning objectives for the self-
directed/in-class portion of your learning; and, learning objectives for the on-the-job portion of your
learning. They are listed below for your information.
Self-Directed/In-Class Learning Objectives

1. State the purpose for Pulse Jet Dust Collectors
2. List the main components of Pulse Jet Dust Collectors
3. Describe the principle of operation for Pulse Jet Dust Collectors
4. Explain the difference between positive and negative pressure Dust Collectors
5. Describe the importance of an optimum cleaning cycle configuration
6. Describe the types of filter media used in Dust Collectors and the type of fabric finishes used for
filter media
7. State the purpose and procedure for new Dust Collector bag break ins
8. List the applications for Pulse Jet Dust Collectors
9. Describe the running and static inspections for Pulse Jet Dust Collectors
10. Describe troubleshooting methodologies for common Pulse Jet Dust Collector problems
11. Discuss the safety concerns associated with the Pulse Jet Dust Collector
On-the-Job Learning Objectives

1. Perform a running inspection on a Pulse Jet Dust Collector
2. Perform a complete static external and internal inspection for a Clean Air Chamber
3. Perform a complete static internal inspection for a Dirty Air Chamber and the System Fan
Field Operator Certification 2/10/2017 1

Lesson Outline
The first portion of this lesson, whether self-directed or in-class, involves reviewing specific
information about Pulse Jet Dust Collectors:
Purpose and basic principle of operation, including the primary components of Pulse Jet
Dust Collector
Cleaning cycle
Applications
Troubleshooting
Safety concerns
Pictures and graphics are included, where appropriate, to help you understand how a Pulse Jet Dust
Collector works.
At the end, there is a series of questions which you are required to answer and then review with your
Instructor. They test your understanding of the material thats been addressed in the lesson.
The second portion of the lesson is accomplished on the job (OTJ) and primarily involves
completing several inspections on Pulse Jet Dust Collectors, including both running and static
inspections. Information about these is included in this Learner Guide. When youre ready to
perform these inspections, inform your Instructor.
If youre a new Field Operator, you will complete a series of steps in your OTJ portion, as listed
below:
Step 1
Your instructor will walk through an inspection procedure with you. At that time,
you can ask questions and take down any notes required
This walk-through may be completed out in the field or during a meeting with your
Instructor.
Step 2
Your Instructor will demonstration an inspection procedure in the field.
Step 3
You will conduct an inspection procedure in the field under the supervision of your
Instructor
Your Instructor will provide you with feedback about your performance during the
inspection.
2 09.29.2004 Field Operator Certification

Step 4
You will complete a full inspection procedure without any assistance from your
Instructor
This inspection will be assessed against the inspection checklist contained in this
document. If you do not achieve 100%, your Instructor will provide you with further
feedback and you will have the opportunity to be re-assessed.
If youre an experienced Field Operator, you may already be quite familiar with inspection
procedures. Discuss this with your Instructor; you may only be required to complete Step 4 as
described above.
Reference Material
Produce and Maintain
CECIL
Pre-Requisites
Auxiliary Equipment Modules
Fans
Cyclones
Airlocks

Pulse Jet Dust Collector Terminology
Terminology
You must know these terms to describe accurately the actions youre taking and to troubleshoot
effectively.
ACFM: Actual Cubic Feet of gas per Minute
The volume of the gas flowing per minute at the operating

temperature, pressure and composition
Airlock An auxiliary component used to control the flow of material and gases
both entering and exiting the dust collection hopper
Air-to-cloth ratio: The ratio between ACFM flowing through a filter and the square feet
of filter area available
The typical A/C ratios are: Pulse Jet 5-6 to 1 (5-6:1) For critical
process applications A/C ratios can be as low as 3.5:1
Bleedthrough: Particulate migration through the interstices of the filter bag fabric
Blinding: Fabric blockage by dust, fume or liquid not being discharged by the
cleaning mechanism, resulting in a reduced gas flow or increased
pressure drop across the media
Blowdown: Pipe connected to the pulsing system; holes distribute cleaning air to
bag rows in pulse jet units
Cage: The support structures used in conjunction with the filter bag designed
to maintain an open signature of the filter bag during operation
Can velocity: In a Dust Collector with the filter elements suspended from the
tubesheet, can velocity is the upward air stream speed calculated at the
horizontal cross-sectional plane of the collector housing that passes
through the bottom surface of the filters
CFM: The cubic feet of air being moved through the system per minute
Clean air chamber: The Dust Collector area through which gases are directed, located on
the clean side of the bags above the tubesheet in a Pulse Jet Dust
Collector

Collection efficiency: A measure of Dust Collector ability to remove particulate from the
inlet gas expressed in percent
Collection hopper: The lowest section of the dirty air chamber of a Pulse Jet Dust
Collector that is used to capture material from the separation process
Compressed air supply A pressure vessel used to store compressed air for the pulsing
manifold: operation
Dewpoint: The temperature at which condensation begins to form as a gas is

cooled
Diaphragm valve: A quick acting compressed air control valve used to provide flow
between the manifold and the blowdown pipe
Differential pressure: The change in pressure or the pressure drop across a component or
device located within the airstream; the difference between static
pressures measured at the inlet and outlet of a component or device
Differential pressure A measuring device used to indicate the change in pressure or the
indicator: pressure drop across a component or device located within the air
stream; the difference between static pressures measured at the inlet
and outlet of a component or device
Dirty air chamber: The lower plenum in the Pulse Jet Dust Collector located below the
tubesheet
Dust collector exhaust: The plenum used to direct the filtered gases out of the clean air
chamber of the Dust Collector
Dust collector intake: The plenum used to direct gas and particulates into the dirty air
chamber of the Pulse Jet Dust Collector
Dust cake: Desired dust build-up on fabric to filter incoming gases and keep
particulate on fabric surface
Filter bag: The filtering media used to separate material from the gas stream in a
Pulse Jet Dust Collector
Grain loading: The amount of particulate by weight in a given volume of air
Expressed in Grains/cu. ft.; 1 lb (0.454 Kg) = 7000 grains

Inch of water: A unit of pressure equal to the pressure exerted by a column of liquid
water one inch high at standard conditions (70 F a 21C @ sea level);
27.7 inches of water (69 mBar = 703 mm w.c.) = 1 PSI; usually
expressed as inches water gauge (W.G.) or inches water column
(W.C.)
Inlet baffle: A solid or perforated plate located at the end of the dust collector inlet
plenum that is designed to redirect the airflow for initial coarse
fraction separation and even distribution of the gases within the dirty
air chamber
Magnehelic gauge: An instrument used to measure the differential pressure drop in a Dust
Collector
Manometer: A U-shaped tube filled with a specific liquid
The difference in height between the liquid in each leg of the tube
gives directly the difference in pressure on each leg of the tube
Used to monitor differential pressure
Negative pressure Dust A system where fan is located after Dust Collector on the clean air
Collector: side, pulling air through the system
Photohelic gauge: An instrument used to measure differential pressure and control it with
adjustable set points for the desired operational differential pressure
Positive pressure Dust A system with a fan located prior to the Dust Collector on the dirty
Collector: side, pushing air through the system
Precoat: Material added to the air stream on initial process startup to aid in
establishing an initial dust cake on the filter bags
Pulse control system: Electronics used to control the duration and frequency of signals to the
individual solenoid control valves used to initiate the pulsing
operation
Re-entrainment: The phenomenon whereby dust is collected from the air stream and is
then returned to the air stream
It occurs when dust is cleaned from a bag and then caught again by an
upward moving air stream which re-deposits it on a bag

SCFM: Standard Cubic Feet per Minute
The volume of gas flow per minute at standard temperature and

pressure conditions (70 F or 21C @ sea level)
Solenoid valve: An auxiliary component of the pulsing system used to exhaust a small
amount of air within the diaphragm valve
Tubesheet: The physical division between the dirty air chamber and the clean air
chamber used to support the dust collector cage and bag assembly
Venturi: A cone-shaped device located at the top of each filter in the Pulse Jet
Dust Collector.
The venturi creates a negative pressure at its inlet during the pulsing
sequence which pulls an additional volume of air down into the filter
element during pulsing.
The venturi increases the velocity of air entering the bags to enhance
the shock wave and thus the cleaning efficiency
The venturi directs the compressed air to the center of the cage to
reduce the abrasion on the dust collector bags

Pulse Jet Dust Collector Learning Content
Purpose
The primary task of the Pulse Jet Dust Collector is to separate solid particulate matter from a
gas stream in order to maintain environmental compliance
In most cement manufacturing applications, the Pulse Jet Dust Collector returns the solid
particulate matter back to the operation for further processing
Components
P ULSE J ET D UST C OLLECTOR
1. Dust Collector Intake
2. Deflector, Diffuser, or Baffle Assembly
3. Dirty Air Chamber
4. Collection Hopper
5. Airlock
6. Filter Bag
7. Cage
8. Venturi
9. Tubesheet
10. Pulse Control System
11. Compressed Air Supply Manifold
12. Solenoid Valve
13. Diaphragm Valve
14. Blow Down
15. Clean Air Chamber
16. Dust Collector Exhaust
17. Differential Pressure Indicator

Principle of Operation
P RINCIPLE OF O PERATION
The system fan creates the airflow
through the Pulse Jet Dust Collector
Dust-laden gas enters the Pulse Jet Blowpipe
Dust Collector through the inlet duct Induced
Tube Sheet
at velocity x Secondary
Snap Band
Pulse
Initial separation takes place as the gas Venturi
velocity slows down due to the Cage
increase in volume as it enters the
dirty air chamber
This decrease in gas velocity Shockwave
allows coarse material to fall out
of suspension
Dust
The separation of coarse material is
further enhanced by an inlet baffle, or Normal flow
deflection plate, that forces the gas to
make an abrupt change in direction
within the dirty air chamber
This sudden change in direction forces the coarse material to fall out of suspension
The inlet baffle also serves to diffuse the airflow evenly throughout the Dust
Collector, ensuring even wear of the filter media
Material fine enough to remain in suspension is carried upward and deposited on to the
surface of the filter bag
The collected material builds up in the form of a cake on the surface of the Dust Collector
bag
To maintain airflow through the Pulse Jet Dust Collector, the bags are cleaned regularly by a
blast of compressed air injected through the venturi located in the top opening of the filter
bag
The venturi, at the top of the filter cage, has three distinct roles:
It increases air velocity into the filter bag to enhance the
shock wave created by the compressed air pulse
It reduces filter bag abrasion by directing the compressed air
blast to the centre of the filter bag
It creates a secondary induced draft from the clean air
chamber that helps fill the bags with air, enhancing the effect of
the shock wave and dramatically improving cleaning efficiency

The blast of compressed air stops the normal flow of gases within the bag and creates a shock
wave that travels down the inside of the cage and back up
This shock wave removes the agglomerated material cake from the surface of the bag
The agglomerated material falls as a mass into the bottom of the dirty air chamber by
gravity
Superfine particles are re-entrained
After passing through the filter media, the clean gas stream exits the clean air chamber
through the Pulse Jet Dust Collector exhaust duct
Material collected in the hopper is metered out of the Pulse Jet Dust Collector by some form
of airlock
The purpose of the airlock at the material discharge of the Pulse Jet Dust Collector is to serve
as a barrier between the flow of solids and fluids
The solids refer to the material existing the Pulse Jet Dust Collector
The fluids refer to the air trying to enter the Pulse Jet Dust Collector from the hopper
discharge (in leakage)

Positive and Negative Pressure Dust Collectors
Positive Pressure Dust Collectors

A positive pressure Dust Collector uses a fan on the
dirty side of the Dust Collector to push the dust-
laden gas through the system
Manufacturers construct positive pressure Dust
Collectors with no pressure differential on casing and
sidewalls; the only additional pressure is
atmospheric
As a result, positive pressure Dust Collectors are
generally less expensive than negative pressure Dust Collectors
But there are limitations Operating and maintaining a positive pressure Dust Collector is
significantly more expensive than the negative pressure Dust Collector. Fan impeller wear,
along with proper maintenance to ensure a completely sealed Collector, increases operating
costs.
Negative Pressure Dust Collectors

A negative pressure Dust Collector uses the fan on the
clean side of the Dust Collector, pulling the air
through the system
Negative pressure Dust Collectors filter process
streams containing high moisture, corrosive gases and
high concentrations of abrasive dust
The Dust Collector structure must be re-inforced
because of the pressure on the shell
Since the housing is under negative pressure, any leakage is contained inside the Dust
Collector unit, preventing emissions from reaching the atmosphere
The wear on the fan is less than with a positive pressure Dust Collector, since the fan only
comes in contact with clean air

Cleaning Cycle Configuration
An Optimum Cleaning Cycle Configuration

Maintains rated airflow through the Dust Collector at all times
Maintains stable dust return to the process
Optimizes the use of expensive compressed air
Ensures longest possible service life of the filter media
by pulsing system frequency, duration, and sequencing
The pulsing system regardless of type or complexity is used to control the firing frequency
and duration of the individual diaphragm solenoid valves
The firing frequency is configured to maintain a stable differential pressure which ensures a
stable airflow through the Collector
The duration or on time of the solenoid valve, is adjusted to ensure optimum use of the
supplied compressed air in the cleaning process
Frequency
Pulsing too often
Premature bag failure
High energy consumption
Pulsing too infrequent
Large drops of material and unstable dust return to the process
Also creates instability in airflow
Duration
Pulsing too long
Waste of compressed air
Increases header pressures regain timing.
Pulsing too short
Shock wave not strong enough to remove filter cake

Sequencing
Never pulse two adjacent rows of bags one after the other
Clean bags are the path of least resistance to airflow through the Dust Collector
Pulsing an adjacent row will result in material being released from one set of bags, some of
which will be deposited directly on the surface of the adjacent clean row of bags
Pulse every other row as a minimum

Types of Pulsing Controllers

Timer board systems
Pulsing system runs continuously during operation
with defined frequency and duration
Local pulse on demand systems
Timer board cycle starts and stops based on target
differential pressure
Programmable logic controllers (PLC)
Computer controlled pulsing system capable of on
demand pulsing and greater sequencing flexibility
S EQUENCING IN THE C LEANING C YCLE

Do not clean rows in sequence. If you clean
one row and then blow the row next to it,
youll just move the dust over one row, as the
clean row sucks the dust back on to itself
For those with timing boards: listen for a
solid thump at each pulse. Any longer is a
waste of compressed air. Too short and youll
hear only a weak expression of air. Check it
regularly
For those with PLCs: it depends on the scan
time. If its loaded and is scanning at 40-60
ms, then you may want a longer pulse than 50
ms, so the PLC doesnt miss a row
If youre using a PLC, you can use it to
control the differential pressure to a set point, but let it vary the time between firings.
Nominally, we aim for 4-6 WG. This may vary with design

Types of Filter Media and Finishes

Primarily two types of filtration technologies on the market today
Conventional depth filtration
Membrane surface filtration
Conventional Depth Filtration

Conventional depth filtration technology relies on a primary dust cake being formed within
the cross-section of the filtration media
Particulate-capture efficiency is dependant upon the maintenance of this filter cake
During normal filtration, a secondary dust cake accumulates on the outside of the filtration
surface
Ideally, the secondary dust cake is removed during a cleaning cycle
Over time, the primary dust cake becomes denser, eventually decreasing permeability
This is reflected in a steadily increasing differential pressure across the Pulse Jet Dust
Collector over the life of the filter media
Membrane Surface Filtration (Gore-Tex or Teflon)

In the membrane-surface filtration technology, a surface laminate, consisting of
polytetrafluoroethylene (PTFE),is applied directly to a conventional filtration fibre
This laminate is a microporous node and fibre structure that has an effective pore size
much smaller than that of conventional-depth filtration media
Material is collected at the surface of the filtration media, so a primary filter cake is not
required
The surface membrane provides a smooth surface from which the filter cake is released
during the cleaning cycle
Since no internal dust cake develops, the permeability recovers to almost original
levels, with no gradual decrease in permeability over time
The result is a consistently lower differential pressure across the filter media and less
abrasion on the individual fibres, with increased airflow and increased filter life

Filter Fabrics
Typically, felted fabrics are used in Pulse Jet Dust Collectors to provide durability in the
rougher cleaning environment
They tend to allow particles to migrate through over time and blind the bag
Felted fabrics need a thicker precoat than membrane bags due to the higher fabric
porosity
Fibreglass filters are also common for higher temperature applications
They have shallow particulate penetration, last longer and require less precoat than
the felted fabric.
F ILTER F ABRICS
Coarse Polyester
Felt:
deep penetration
Fine Membrane:
shallow penetration

The most common types of filter fabrics are described in the table below
C OMMON T YPES OF F ILTER F ABRIC
Fabric Max Op Temp Filtration Abrasion Cost
Polypropylene 76 C Good Excellent $
Polyester 134 C Excellent Excellent $
Acrylic 140 C Good Good $$
Fibreglass 260 C Fair Fair $$$
Fabric Finishes
Fabric finish is an important part of filter bag performance. Like the filter bag fabric, the
finish should be selected based on operating variables, such as operating temperature and gas
stream chemistry.
The most common types of fabric finishes for cement manufacturing are:
Non-fibreglass (typically polyester or glass felt), and
Fibreglass

M OST C OMMON T YPES OF F ABRIC F INISHES IN C EMENT M ANUFACTURING

Non-Fibreglass Fabric Benefits
Finish
Singe controlled direct flame Improves cake release
Glaze/Eggshell surface fibre Provides short-term improvements for cake release

melt and compression
Silicon surface spray Aids in initial dust cake development and provides limited water
repellency
Flame retardant surface Retards combustibility (not flame proof)

spray
Surface membrane laminate Improves capture of fine particulate, filtration efficiency, cake
process release and airflow capacity
Fibreglass Fabric Finish Benefits
Silicon, graphite, teflon fibre Protects glass yarn from abrasion, adds lubricity
treatment
Acid resistant fibre treatment Shields glass yarn from acid attack
Singeing and glazing are both mechanical finishes whereas silicone, surface coatings and
flame retardant are all chemical finishes

New Bag Break In
Purpose
Dust Collector bag conditioning agents are used to develop an optimum primary dust cake
within the cross-section of conventional depth filtration media
The process of conditioning or breaking in, new Dust Collector bags can improve Collector
efficiency through enhanced cake release and fine particulate capture efficiency.
Conditioning agents are not typically used on surface membrane filtration media due to the
lower porosity of the material enhancing particulate capture
An example of a common conditioning agent is Aluminium Silicate powders; they have a
wide variety of particle shapes and sizes
Chemically stable, inert and non-flammable
Hydrocarbon and moisture absorbency
Injection Guidelines for Collectors with a Full Set of New Bags

1. Isolate the Pulse Jet Dust Collector cleaning system by disabling the pulse control system or
isolating the compressed air supply to the manifold
2. Start the Pulse Jet Dust Collector fan and operate at 75% of target air flow by adjusting damper
position or speed of drive system
3. Add the recommended amount of conditioner to the inlet duct of the fan. Conditioner quantity is
calculated based on filter surface area (approx 0.25 kg/m2)
4. Start the main process line, maintaining airflow at 75% of target
5. Operate under normal conditions and allow differential pressure (DP) to reach 4-5 Water
Column (WC)
6. Once the DP has reached 4-5, re-establish the cleaning system by enabling the pulse control
system or by re-establishing the compressed air supply
7. Over the course of one (1) hour, slowly increase airflow from 75% to normal operating flow
8. Monitor the Pulse Jet Dust Collectors DP until the process line has stabilized at normal flow
rates. It may be possible to reduce the frequency and/or the duration of cleaning while
maintaining adequate DP and flow. Optimizing the cleaning system will improve bag life and
reduce compressed air requirements
Note: Material produced during normal process conditions can also be used to pre-coat the filter
media by following the same procedure but omitting Step 3.

Applications
Raw Grinding system
Pyroprocessing system
Solid Fuel Grinding system
Finish Grinding system
Transfer Points
Air Slide ventilation
Bucket Elevator ventilation
FK Pump feed hopper ventilation
Silo ventilation
Clinker Cooler ventilation

Inspection Points
Dust Collector Running Inspection

Check For OK
Record the differential pressure indicated on the Magnehelic or Photohelic

Record compressed air supply pressure on blowdown manifold
Check the operation of all solenoid and diaphragm valves. Adjust Photohelic target to initiate pulse
sequence if required
Check the compressed air regain in the manifold after pulsing sequence
Check Pulse Jet Dust Collector discharge for proper material flow
Check the airlock and material evacuation system for proper operation, abnormal noise, temperature and
vibration
Check Pulse Jet Dust Collector casing and ductwork for in leakage
Check that all access doors and inspection ports are closed and properly sealed
Dust Collector Fan Running Inspection

Check For OK
Observe fan or stack outlet for emissions visually, or review history from continuous monitoring system
Inspect the fan drive motor for material build-up on cooling fins and cooling fan inlet screen. Remove
build-up
Palm-test the motor casing temperature. If too hot to touch, record temperature with hand pyrometer or
contact thermometer
Inspect the condition of the final drive V-belt condition, tensioning, sheaves, direct coupling
Palm-test fan bearing temperatures. If too hot to touch, record temperature with hand pyrometer or
contact thermometer
Listen for abnormal noise or vibration in the fan or drive system
Inspect the damper linkage and damper drive for loose or worn components
Verify damper drive selected for automatic control
Test damper drive for excessive hunting or malfunction. Rotate hand wheel and verify control response
Inspect fan casing for wear or in leakage

Dust Collector External Static Inspection

Check For OK
Check Dust Collector casing, hopper, doors, inspection ports for in leakage, corrosion, and seals
Check for air leaks in the compressed air supply, manifold, solenoid valves, and diaphragm valves
Check airlock for damage and wear
Inspect inlet ductwork for wear, damage and material build-up
Inspect outlet ductwork for wear, damage and material build-up
Dust Collector Internal Static Inspection Clean Air Chamber

Check For OK
Inspect clean air chamber for material build-up. Remove all build-up prior to putting Dust Collector back
in service
Perform fluorescent die check with black light to identify material migration points
Inspect all dust collector cage venturis for wear
Inspect tubesheet for damage, cracked welds, wear and corrosion
Inspect exhaust duct for material build-up, wear and corrosion
Inspect blowdown pipes for proper orientation, support and wear
Inspect blowdown casing connections for proper seal
Check fan for corrosion and blade wear
Inspect access doors or inspection ports for gasket/seal condition

Dust Collector Internal Static Inspection Dirty Air Chamber

Check For OK
Inspect Dust Collector bags for filter cake condition, blinding and abrasion
Inspect inlet diffuser or baffle for damage and wear
Inspect discharge hopper for degree of material evacuation
Inspect access doors or inspection ports for gasket/seal condition
Inspect casing and hopper for wear, corrosion, and in leakage
Dust Collector Internal Static Inspection Fan

Check For OK
Inspect the fan impeller for build-up, corrosion and wear

Check the alignment of the impeller in the fan casing
Check the alignment of the inlet horn in relation to the fan casing and fan impeller
Inspect the condition of the drive belts, check tensioning, sheaves, or drive coupling
Inspect the fan drive motor for material build-up on cooling fins and cooling fan inlet screen. Remove
build-up
Inspect airflow control damper for internal wear and corrosion
Inspect damper linkage, bearings, bushings and connections for wear, damage and free operation

Troubleshooting
Problem Possible Signs Actions to Take

Reduced System Airflow Equipment operating under positive Verify all Dust Collector system components are in standard unit
pressure control
Loss of production capacity Determine if Dust Collector fan is pulling design load amps, kW
Dust Collector system not operating or flow
with all auxiliary components Ensure that fan drive is intact (motor, belts, drive couplings)
required for proper operation Ensure that fan rotation is correct
Confirm that the fan damper is operating properly, with smooth
Ex. DC fan running remotely linkage in operation. Test damper drive remotely, then from unit
without pulsing system energized to control, if applicable
control differential pressure For DCs with multiple-point collection, verify the position of all
manual balancing dampers used to manage multiple dust
collector lines
Determine if air volume is at fan-rated capacity. Take airflow
measurement and compare to benchmark reading or fan curve
Check for build-up in the dust collector hopper (Material build-
up in hopper can eventually block off the dust collector intake
duct)
Check the airlock operation at the bottom of the hopper.
Visually verify evacuation of material from the collector


Operating with High Dust Collector magnehelic Note: High differential pressure can be the result of a partially
Differential Pressure indicating high differential pressure plugged sample line to the low pressure side of a magnehelic or
across the filter media photohelic.
High differential pressure indicates If there is no apparent process degradation to support the high
that the filter media is causing differential pressure, verify that the magnehelic indication is
restricted airflow in its current accurate
condition To so verify, disconnect the two sample lines from the high and
low ports of the magnehelic. Using compressed air, back purge
the lines into the dust collector
Check the disconnected magnehelic for proper zero indication
and adjust with the set screw on the front face as required
Reconnect the magnehelic sample lines to the high and low
pressure ports. Note: the high pressure port connects to the
clean air chamber and the low pressure port connects to the dirty
air chamber
If the differential pressure now indicates within the normal
ranges (4-6 of water), the sample line(s) were likely plugged. If
this is a chronic issue, consider installing a line filter for the
magnehelic/photohelic sample pipe
Field Operator Certification 09.10.2004 25


Operating with High If the differential pressure reading appears to be valid, then:
Differential Pressure, contd
Ensure that there is power to the pulse sequence timer board or
programmable logic controller (PLC)
Verify pulse sequence on timer boards that are connected in
series. Light emitting diodes (LEDs) on the control boards
indicate the firing sequence. Ensure that all connected terminals
are firing (as indicated by LEDs)
Ensure that the compressed air manifold at the tubesheet level of
the dust collector has sufficient operating pressure (on most
systems, it ranges 80-100 psi)
Check the operation of all solenoids and diaphragm valves.
Record the location of all malfunctioning units
Listen for the pulse on duration to determine if the timer
setting has the diaphragm valve open for too long a duration,
lowering manifold pressure, or for too short a duration, resulting
in a poor cleaning cycle
Check the manifold pressure immediately after a diaphragm
valve fires to determine if complete pressure regain takes place
before the next pulse sequence. If pressure regain has not
occurred, investigate air supply for leaks, partial isolation, or
supply limitations


Operating with High If pulse system appears to work properly, shut down the fan.
Differential Pressure, contd Then pulse the Dust Collector continuously to determine if the
differential pressure falls. If the differential pressure is reduced
to normal levels during this period, this indicates that either:
the dust collector may be re-entraining dust due to in leakage, or
the pulsing system needs to be modified for higher pulse
frequency or higher operating pressure, or
the collector is under-sized for the current process demands
Inspect the Dust Collector for in leakage that could contribute to
re-entrainment of material, paying particular attention to the
airlock and the collection hopper
If there is no change in the differential pressure after pulsing
with the fan off, remove a bag for a permeability test to see if the
bag is blinding. If the test indicates the bag is blinded, replace
the bags and perform a root cause failure analysis
Continuous Emissions at the Continuous particulate emission This condition can be the result of bag failure, improper installation,
Dust Collector Stack indicates material is passing tubesheet damage or wear, or loss of filter cake due to over-cleaning
unobstructed between the dirty air Determine the source of the leak by injecting fluorescent die into
chamber and the clean air chamber the dust collector intake while operating. The fluorescent die
settles on the tubesheet closest to the source of the leak
Detect the die with a black light
Repair the leak
Inspect the system fan to determine the extent of any abrasion
damage or build-up on the fan impellers
Field Operator Certification 09.10.2004 27


Intermittent Emissions at the Intermittent particulate emission During the cleaning cycle, the filter cake is removed, exposing the
Dust Collector Stack generally coincides with pulsing a hole. Material is carried through the hole during the pulsing
row of bags. Small holes or tears in operation. Once the filter cake is re-established, the damaged section
the filter fabric are covered as the of the bag is covered and the emissions stop
dust cake is re-established after Determine the source of the leak by injecting fluorescent die into
cleaning the dust collector intake while operating or identify which row is
pulsing during emission episode.
Conduct a thorough internal inspection to identify the source of
the leak (the fluorescent die settles on the tubesheet closets to the
source of the leak), detecting the die with a black light
Repair the leak
Inspect the system fan to determine the extent of any abrasion
damage or build-up on the fan impellers

Safety- Work Page

Safety
Run cleaning mechanism 20 mins with the fan off to clean filter bags
Discharge all material from the collection hopper
Shut off, blank and tag compressed air supply and relieve pressure in the header
Lock out electrical power on all rotating equipment to be services
Follow confined space entry procedures to the letter
On units operating under oxygen-deficient atmospheres, the Pulse Jet Dust Collector must be
purged with fresh air. Secure access doors in an open position or remove doors. Perform gas
sampling to ensure a safe working atmosphere
Be aware of high internal surface temperature. Cool the Pulse Jet Dust Collector internals
prior to entry
Wear a properly fitting respirator or dust mask when working inside the Pulse Jet Dust
Collector
Take extreme care when working inside the Pulse Jet Dust Collector. Know that the two (2)
significant tripping hazards are the dust collector blowdowns and the perforated tubesheet
30 2/10/2017 Field Operator Certification

Review Exercise
Complete each of these questions and review your answers with your Instructor
1. What is the purpose of a Pulse Jet Dust Collector?
2. List 5 components of the Pulse Jet Dust Collector
3. What are the 3 functions of the venturi?
4. What happens to the gas velocity as it enters the Dust Collector?

5. The magnehelic or photohelic is used as to measure what process parameter and between
which 2 points on the Dust Collector?
6. Why is a positive pressure baghouse more expensive to maintain than a negative pressure
baghouse?

7. State 2 reasons why an optimum cleaning cycle configuration is important
8. What are the two main types of filtration technology used in Dust Collectors today?
9. Why is it important to break in new conventional depth filtration type Dust Collector bags?
10. State 2 applications for Pulse Jet Dust Collectors in cement manufacturing

11. State 5 inspection points for the Pulse Jet Dust Collector
12. Describe 5 conditions that could explain reduced airflow in a Dust Collector

13. Describe 3 safety hazards associated with the Pulse Jet Dust Collector

Pulse Jet Dust Collector: Learner Guide

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Field Operator Certification

Pulse Jet Dust Collector

Self-Directed/In-Class Learning Objectives

On-the-Job Learning Objectives

Field Operator Certification 2/10/2017 1

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Field Operator Certification 2/10/2017 3

Pulse Jet Dust Collector Terminology

Pulse Jet Dust Collector Terminology

ACFM: Actual Cubic Feet of gas per Minute

The volume of the gas flowing per minute at the operating

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Pulse Jet Dust Collector Terminology

Dewpoint: The temperature at which condensation begins to form as a gas is

Grain loading: The amount of particulate by weight in a given volume of air

Expressed in Grains/cu. ft.; 1 lb (0.454 Kg) = 7000 grains

Field Operator Certification 2/10/2017 5

Pulse Jet Dust Collector Terminology

Manometer: A U-shaped tube filled with a specific liquid

Used to monitor differential pressure

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Pulse Jet Dust Collector Terminology

SCFM: Standard Cubic Feet per Minute

The volume of gas flow per minute at standard temperature and

Field Operator Certification 2/10/2017 7

Pulse Jet Dust Collector Learning Content

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Field Operator Certification 2/10/2017 9

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Positive and Negative Pressure Dust Collectors

Positive Pressure Dust Collectors

Negative Pressure Dust Collectors

Field Operator Certification 2/10/2017 11

Cleaning Cycle Configuration

An Optimum Cleaning Cycle Configuration

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Field Operator Certification 2/10/2017 13

Types of Pulsing Controllers

S EQUENCING IN THE C LEANING C YCLE

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Types of Filter Media and Finishes

Conventional Depth Filtration

Membrane Surface Filtration (Gore-Tex or Teflon)

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Polypropylene 76 C Good Excellent $

Polyester 134 C Excellent Excellent $

Acrylic 140 C Good Good $$

Fibreglass 260 C Fair Fair $$$

Field Operator Certification 2/10/2017 17

M OST C OMMON T YPES OF F ABRIC F INISHES IN C EMENT M ANUFACTURING

Singe controlled direct flame Improves cake release

Glaze/Eggshell surface fibre Provides short-term improvements for cake release

Flame retardant surface Retards combustibility (not flame proof)

Fibreglass Fabric Finish Benefits

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New Bag Break In

Injection Guidelines for Collectors with a Full Set of New Bags

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Dust Collector Running Inspection

Record the differential pressure indicated on the Magnehelic or Photohelic

Dust Collector Fan Running Inspection