SSPC-Guide 16 August 1, 2003

SSPC: The Society for Protective Coatings

TECHNOLOGY GUIDE NO. 16

Guide to Specifying and Selecting Dust Collectors
1. Scope
1.1 This guide will assist end-users in the selection of dust collectors to be used in conjunction with containment systems to control emissions to the environment, enhance visibility, and reduce worker exposures within the containment. It will discuss the purpose of dust collector use in painting projects; dene dust collector terminology; describe the types of dust collectors and the mechanisms of collection; and discuss efciency, operation, and maintenance of dust collectors. Dust Load: The quantity of dust in the air stream. Usually expressed as grains of dust per cubic foot of air (grains/cfm). ft/min: feet per minute, units of speed (velocity). Grains: A measure of the mass of particles in the air. One pound contains 7,000 grains. Inches of Water: Units of pressure equal to the pressure exerted by a column of liquid water an inch high at standard temperature. Typically expressed in inches w.c. Inlet Loading: The amount of material going into the collector. Extremes of high or low loading might allow slightly higher can velocities. Static pressure (SP): The ow potential force within a duct or device that acts in all directions and is measured relative to the surrounding atmospheric pressure. Static pressure can be positive or negative with respect to the external atmosphere. Velocity pressure (VP): The pressure required to accelerate air from zero velocity to a given velocity, proportional to the kinetic energy of the air stream. Velocity pressure can only be exerted in the direction of airow and is always positive. Total pressure (TP): The algebraic sum of the static pressure (SP) and the velocity pressure (VP); typically in inches of water. TP can be positive or negative. Velocity: The time rate of movement including the direction of movement; feet per minute (ft/min).

2. Denitions
The denitions below do not appear in the SSPC Protective Coatings Glossary. Aerosol: A system of small liquid or solid particles suspended in a gas, in this case air. The aerosol particle can be a single particle or an aggregate of connected smaller particles. The size of these particles can be in the range of 0.002 to 100 micrometers in diameter. Particles that are of the most signicant health concern are between 0.2 and 5.0 micrometers in aerodynamic equivalent diameter. Air to cloth ratio: A size or rating of the fabric lter media that is expressed in terms of air ow capacity versus fabric media area, in units of cubic feet per minute per square feet of fabric. The ratio represents the average velocity of the gas stream through the lter media and is sometimes referred to as the ltration velocity in feet per minute (ft/min). Can Velocity: Also known as Approach Velocity. The velocity of the dust-laden air as it passes upward between the lter media. The can velocity is calculated by dividing the volume of air of the system (cfm) by the effective cross-sectional area of the lter chamber. This effective area is calculated by subtracting the area occupied by the lters (sum of the areas of the number of the bags) from the total cross sectional area of the lter chamber. Dust Collectors: A subset of a larger group of gas cleaning devices. Dust collectors are used to remove large amounts of particulate matter (typically greater than 1 grain per cfm) from gas streams and come in a wide range of designs to meet various industrial applications. For the purpose of this document, the gas stream is assumed to be air at ambient temperatures.

3. The Purpose of the Dust Collector

The purpose of a dust collector is to remove entrained particulate matter from air streams to maintain compliance with particulate emission laws and to reduce damage caused by dust to people, equipment, the nished product, or adjacent property. The concept is very simple; however, the process of separating particulate from air can be complex. The complexity arises from the extremely heterogeneous nature of the size and physical characteristics of particles and from the quality and quantity of the air stream that is to be cleaned. A thorough understanding of the purpose and intended use of the dust collector is needed before selection of a dust collector can be made.

9-69

SSPC-Guide 16 August 1, 2003

The dust collector is a critical component of the containment system for the maintenance painting process. The exhaust fan attached to the dust collector draws contaminated air into the collector. This creates negative pressure inside the containment that draws clean air into the containment from the outside. The airow through the containment helps to remove contaminants from the breathing zone of the workers. Airow can also improve visibility inside the containment. The ability of the dust collector to provide both negative pressure and airow within the containment is directly related to the design, construction, and maintenance of the containment system, dust collector, and supporting parts (e.g. duct work). To prevent contaminants from being released into the environment, all air leaving the containment should pass through the dust collector. The containment system is only as good as the weakest element that makes up the containment system. The primary purpose of the containment system is to contain debris and protect the environment. The primary purpose of the dust collector is to provide airow through the containment to reduce worker exposure to airborne dust, improve visibility, and maintain an inward airow (negative pressure). Containment systems and methods of monitoring releases are discussed in detail in SSPC-Guide 6, Guide for Containing Debris Generated During Paint Removal Operations. Knowledge of the containment structure is critical in selecting the dust collector and will be discussed as needed to aid in the understanding of dust collector functions.

4.3 Electrostatic Precipitator Collectors (EPCs): EPCs separate particulates from the air by introducing a charge into the atmosphere and using a negatively charged plate to precipitate (attract) the charged particles. EPCs are primarily used for heavy-duty dust applications such as utility boilers and cement kilns. While they have the ability to effectively lter the concentration of interest to the industrial painting industry, they generally cannot handle the size range of dust typically generated by industrial painting operations. 4.4 Fabric or Cartridge Filter Collectors: This type of collector separates particulate from air streams by straining, impaction, interception, diffusion, and electrostatic charge. Air must pass through a specially designed fabric that retains the dust on the fabric but allows the cleaned air to pass through. Fabric dust collectors are the type of collector used most frequently in the industrial painting industry. Fabric dust collectors (hereafter called dust collectors) are further broken down into two primary types based on the lter conguration (bag and cartridge dust collectors), both of which are used heavily in the painting industry. Both bag and cartridge systems can attain capture efciencies of 99+% of particles over the entire size range of 0.1 to 100 micrometers. Fabric ltration systems are normally designed to collect dry particulate; therefore, their use with wet removal processes requires careful consideration. 4.4.1 Baghouses: Baghouses or bag collectors account for more than 80% of the fabric dust collection systems used in all dust collection applications today (primarily xed plant facilities, although they are also used in abrasive recycling equipment). Baghouse dust collectors use vertically mounted tubes or bags of fabric media ranging from ve to twelve feet in length to remove contaminants. They can lter a wide variety of materials (e.g. brous, particulate, moisture laden, and hydroscopic materials). They are used at temperatures up to 500 F and can handle extremely heavy dust loads. Many abrasive recycling systems utilize baghouse collection systems due to the heavy to extremely heavy particulate loading (2 to greater than 10 grains per cubic feet of air per minute (gr/cfm), and varying particulate size (0.1 to 100 micrometers). 4.4.2 Cartridge Collectors: Cartridge dust collectors are used on dry dust applications or when high concentrations of small (less than 1 micrometer) particulate are likely, but are capable of ltering a broad range of particulate sizes (0.1 to 30 micrometers). Most mobile dust collectors utilize cartridge collector systems. While the abrasive blasting process generates particulate ranging from 3 to 100 micrometers in size, the dust collection system is primarily responsible for removing ne particulate suspended in the air (i.e., small particulate). Cartridges are composed of rigidly pleated elements providing a large amount of lter area in a comparatively small housing. Cartridges are typically mounted either horizontally or

4. Types of Dust Collectors

There are four major types of dust collectors: centrifugal, wet, electrostatic, and fabric collectors. Each of these will be briey discussed. 4.1 Centrifugal Collectors: These collectors separate particulates from air streams by gravitational, inertial, or centrifugal force. Collection efciency is affected by particle size, particle velocity, collector design, and dust concentration. Centrifugal collectors can be designed to remove large particles effectively and economically; however, they are not generally suitable for the collection of ne particles. Most centrifugal collectors (e.g. cyclones) are used in stationary applications; however, some vacuum systems incorporate centrifugal collectors. 4.2 Wet Collectors: Wet collectors separate particulates from air streams by impacting the particles with water spray. They are commonly referred to as scrubbers. Wet collectors are typically used for high temperature and moisture-lled gas streams. Neither of these conditions typically exists in maintenance painting applications.

9-70

SSPC-Guide 16 August 1, 2003

vertically within the lter housing. Cartridge systems should not be used when the loading is expected to exceed 3 gr/cfm.

5. Types of Cleaning Mechanisms

Dust collectors are typically classied by their cleaning mechanism. There are three common types: shaker, reverse pulse, and pulse jet. Baghouses utilize either shaker, reverse pulse, or pulse jet systems. Cartridge collectors utilize either reverse pulse or pulse jet systems. In the industrial painting industry, almost all current equipment uses pulse jet systems. 5.1 Shaker Systems: In shaker systems, dirty air enters at the center of the bag area and the dust cake accumulates on the interior surface. Shaker systems rely on a vibrating mechanism to shake the lters. This creates a sine wave along the top of the bag that ripples down the length causing a portion of the dust cake to change shape and fall into the hopper. Pressure drops across the baghouse determine the shake interval. Typical shake intervals range from 10 to 30 seconds. Shaking speed and frequency are dependent upon the diameter and length of the bag. Multiple baghouse lters are packaged in separate compartments in the dust collector. During cleaning, one compartment at a time is shut down for the shaker process, while the remaining compartments remain in operation. This is called off-line cleaning. Shaker systems have a low air-to-cloth ratio (A/C). This means that the units are typically oversized (i.e., requiring high air volumes) and many bags are required in order to maintain ltration efciency during the cleaning cycle. Additionally, because shaker baghouses have multiple bags per compartment, the time necessary for lter replacement is increased. 5.2 Reverse Pulse Systems: Reverse pulse systems have largely supplanted shaker systems and are currently being replaced by pulse jet systems. The design of the dust collector for reverse pulse systems allows the dust-laden air to enter at the top of the unit. The dust collects on the interior of the bags or cartridges. Heavy particles fall into the hopper, helping to extend bag life. The ltered air is then vented to the atmosphere. Reverse pulse systems are multi-compartment systems. Cleaning is accomplished by isolating one compartment at a time (while the others continue to operate). Pulses of compressed air enter through a venturi nozzle, which creates a shock wave. The wave causes the dust cake on the inside of the bags to fracture and fall into the hopper. Typical pulse durations range from 30 seconds to several minutes. Reverse pulse systems are considered the least aggressive cleaning method, but one which extends bag life. 5.3 Pulse Jet Systems: Pulse jet systems are considered to be the most aggressive and effective lter cleaning
1

approach. An FHWA publication, Lead-Containing Paint Removal, Containment and Disposal (FHWA-RD-94-100)1, published in February 1995, indicated that only those dust collectors using pulse jet cleaning mechanisms were effective over the duration of the study. Pulse jet systems are the only systems where cleaning occurs while contaminants are entering the compartment. In pulse jet systems, the inlet air stream enters the unit and passes vertically between the bags or cartridges. Dust accumulates on the outside surfaces of the lters. Pulse jet systems continuously remove some dust from the bag or cartridge through an adjustable cleaning frequency dictated by a timer or differential pressure across the lters. When the differential pressure point is reached, a high-pressure jet of compressed air is directed inside the lter for 0.1 to 0.15 seconds at intervals ranging from 1 to 30 seconds. The pulse creates a shock wave similar to that used in the reverse pulse system, causing the dust cake to fracture and fall into the hopper. Proper adjustment of the cleaning frequency in these systems is necessary for optimal particulate removal efciency. If the duration of the pulse is too short, cleaning is inefcient. If the duration of pulsing is too long, the bag life is reduced. For optimal operation, the frequency of cleaning should be adjusted so that differential pressure across the collector ranges from 3 to 6 inches water column (w.c.). Some manufactures employ timers rather than differential pressure drops to determine the cleaning sequence. The pressure of the compressed air at the delivery tube can severely affect bag life. Too high a pressure or a misdirected jet of air due to misalignment of the delivery tube can damage the top several feet of the bag or cartridge. Average compressed air pressures range from 40 to 90 pounds per square inch (psi). One of the popular features of pulse jet systems is the on-line cleaning feature, which allows work to continue without interruption of project operations. However, if high can velocities are present, on-line cleaning can have negative impacts due to gravity settling problems and re-entrainment of ne dust on the adjacent row of lters. During on-line cleaning, particles may stay suspended in the air due to the continuous upward movement of air. This can affect lter efciency and overstress the system, because particulates are not removed from the air stream. Solutions to these potential problems would be to conduct off-line cleaning or to utilize a pulse-jet system equipped with multiple compartments (usually in a row).

6. Background on Dust
6.1 Dust Characteristics: Dust particles are generated by many maintenance painting processes. Of particular concern are those particles generated during the removal of potentially toxic paint (e.g. lead-based paint) from structures. It is important to understand the process that creates the particles to obtain

Lloyd M Smith and Gary L. Tinklenberg, Lead-Containing Paint Removal, Containment and Disposal, FHWA RD 94-100, Federal Highway Administration, McLean, VA , February 1995.

9-71

SSPC-Guide 16 August 1, 2003

an estimate of resulting particle size. In general, the majority of particles generated from mechanical action ranges from 3 to 100 micrometers. The larger particles will not stay in the air long enough to cause any great concern. Smaller particles are generated as well, but in smaller quantities. Very small particles (for example, fumes generated during the burning of paints) are so small (0.001 to 0.1 micrometer in diameter) that they will pass right through a typical dust collector lter. A special air-cleaning device is needed for such operations. Specialty air cleaning devices will not be covered in this guide. 6.2 Dust Particle Size and Health: The size of particles is important for three reasons: health, settling velocity, and ltration. The dust collector user should be aware that particle size determines the deposition site within the respiratory tract. Smaller particles will travel further and be deposited deeper within the lung. Air coming from the dust collector may contain aerosols that are hazardous to health. 6.3 Dust Settling Velocity: Size will affect the rate at which the particle falls through the air. The smaller the particle, the longer it will stay airborne. For all practical purposes, the extremely small particle will behave more like a gas, staying airborne indenitely. A particle with an aerodynamic equivalent diameter (AED) of one micrometer will fall at a rate of 0.04 feet per minute. It would take 200 minutes for a 1-micrometer particle to drop 8 feet. If the dust collector is working properly and removing the air from the containment system, the aerosols inside the containment will be removed within minutes after the paint removal has occurred. However, high concentrations of small AED aerosols may remain inside the containment for hours if the ventilation system is improperly designed, operated, or maintained.

points would be the two limits of the fan performance curve. The intermediate points on the airow versus pressure graph describe the slippage characteristics of the fan. This graph is a universal way of describing fan performance, however, this information can also be given in tables. 7.2 Fan Power: Power considerations for driving the fans propeller are usually addressed by the fan manufacturer. An end-user will normally purchase the fan and engine (or motor) in combination. Increasing the number of fan rpm increases the capacity of the fan to move air or overcome static pressure. However, there are limits to the rpm at which each fan is rated to operate. Exceeding the rpm rating can reduce the life of the fan and may become a safety hazard. The fan and motor should be matched to meet the needs of the operations. 7.3 Fan Selection: The selection of a fan for a given application is best done by a professional. In most cases, the fan is located downstream from the ltration housing, protecting it from air streams that are heavily loaded with dust. In order for the dust to be transported to the dust collector, duct velocities (called transport velocity) of 4,000 ft/min or higher are needed. The high transport velocities are needed to keep the dust airborne so that it does not settle out in the duct. The higher the duct velocity, the higher the resistance to airow. High velocities commonly result in large losses of static pressure, 5 inches w.c. or more. Thus, the fan must be rugged and have the capacity to overcome high static pressure losses. A backward-curved fan is typically used in dust collectors for this industry. It is intended to move air after ltration. For moving air laden with dust, a more rugged fan design, such as a radial tip wheel, should be considered. Other fan types include: propeller fans, tube-axial fans, vane-axial fans, centrifugal fans, multiple-blade fans, forward-curved multivane fan, paddle-wheel fans, and airfoil fans. 7.4 Can Velocity: Can velocity is generally described as the upward velocity of the air through the entire body of a dust collector including the open area between the lters. Can velocity is an important factor in the proper design and functioning of a dust collector. If the can velocity is too high the dust pulsed off of the lters during the cleaning cycle will not fall downward into the hopper area. Rather the dust will be held suspended in the air stream and reattach to the lters. This will result in a greater drop in pressure (reduced air ow), excessive use of compressed air, and shortened lter life. High can velocity can be almost impossible to correct on an existing collector. Can velocities are an important consideration when deciding the location of the inlets on the collector body. If the inlets are placed low on the collector and dust-laden air is introduced into the hopper area, the velocities will be highest at the very bottom of the lters. If the can velocities are too high, this could form a barrier for the dust falling from the lters. High velocities in the hopper area could also cause dust already settled in the hopper to be reintroduced into the

7. Dust Collector Selection Criteria

7.1 Fan Performance: Fan performance is dependent on the design of the fan blades. Different fan designs will yield different characteristic performance curves. However, the performance of a fan can be generalized and discussed in relatively simple terms. The performance of a fan can be described by a graph of the airow capacity (x-axis, abscissa) and the resistance to airow or static pressure (y-axis, ordinate), as illustrated in Figure 1. Fan characteristics can be evaluated experimentally for different fan revolutions per minute (rpm). For the present discussion, assume the fan and motor have been matched and sold as a unit. In the extreme, when running the fan with the outlet closed off, and reducing the ow rate to zero, the pressure developed inside the duct would, for all practical purposes, be the maximum that the fan could deliver. This pressure is called the static no delivery (SND) pressure. At the other extreme, if the fan were running without any obstructions, at zero resistance, with minimal connecting ductwork, the fan would be operating at maximum air movement. This is called the free delivery or wide-open operating condition. The SND and the wide-open

9-72

SSPC-Guide 16 August 1, 2003

FIGURE 1 FAN CURVE

the operator to inspect on the clean side of the lter system, rather than the dirty side. In side access systems, the exterior of the lters is easily viewed. This would provide easier inspection of the lters for determining the amount of abrasion. Since visual observation of lter leaks is also important, a properly designed side-access system should provide a man-way or other access into the top (clean) portion of the collector for this purpose. The end-user should verify that the dust collector provides adequate access to both the clean and dirty side of the unit for inspection and maintenance. 7.7 Horizontal versus Vertical Filter Mounting: Some of the older dust collectors currently in use on abrasive blast cleaning projects utilize horizontally mounted lters. Most new models utilize vertically mounted congurations. In horizontally mounted lter systems, the cleaning mechanism pulses the dust from the lters and it falls onto the lters below. Therefore, many of the lters never properly release their dust cake. This will result in decreased air velocity and premature lter wear and clogging. Filters mounted vertically allow the dust cake to fall directly into the hopper without impacting other lter banks.

air stream. This could be further exaggerated if the hopper is not emptied on a regular basis. To optimize can velocity within the collector, the designer must consider the size of the collector body and the spacing between lters. The designer must also consider such variables as inlet loading, bulk density, particle size, and particle characteristics. 7.5 Off-line versus On-line Cleaning (Pulse Jet): One of the reasons that pulse jet systems are so popular in the industrial painting industry is the ability for the lters to be cleaned on-line without interrupting production. If the system is equipped with only one compartment, on-line cleaning can have high suspended dust levels and ineffective cleaning that ultimately increases static pressure. In a single compartment design, the on-line cleaning process can prevent effective gravity settling of the particulate due to the continuous upward movement of air (can velocity). It also fosters the re-entrainment of smaller dust particles (less than 10 micrometers) into the air and onto adjacent or recently cleaned lter media. As a result, the overall lter efciency and lter life may be reduced. Consideration should be given to specifying multi-compartment pulse jet systems to maintain the benets of on-line cleaning (i.e., production) while reducing the effect on the ltration system. These compartments or dividers are usually the length of the lters and separate the lters by row. 7.6 Top versus Side Access (Pulse Jet): Pulse jet systems can be provided with top or side access to the lter media. Top loading systems allow the easiest access for visual observation for lter leaks and tears by providing a view down the inside of the lter. Top access systems also allow

7.8 Access Area for Inspection (Shaker, Reverse Air, and Pulse Jet): Regardless of whether the system provides top or side load access, the access area should be large enough to allow personnel entering it to wear supplied-air respirators as required by conned space regulations (29 CFR 1910.146). Many older systems do not allow sufcient room for maintenance personnel to wear the required respiratory protection when entering the access area to perform cleaning and maintenance. 7.9 Hopper Size (Shaker, Reverse Air, and Pulse Jet): If the hopper height is too shallow it could result in dust accumulation and resulting turbulence, causing particulates to remain in suspension and the pulse jet systems to energize more frequently. This can lead to accelerated deterioration of the media and leakage through the lters. It also has the effect of increasing the static pressure of the system. If the end-user does not empty the collector on a regular basis, the higher dust bed levels will keep dust suspended in the air stream. A hopper that is too small can also result in higher can velocities, which could cause turbulence and higher abrasion on lters and metal parts. 7.10 Design of Filter Cleaning Jets (Pulse Jet): Poor design of the venturi in the pulse cleaning systems can cause bags and cartridges to abrade or rupture when they are moved or shocked by the pulse. Additionally, the air delivery tube (at the top of each lter) should be secured to prevent misalignment after lter replacement.

9-73

SSPC-Guide 16 August 1, 2003

7.11 Mixing Chamber: Some units employ a mixing chamber between the tube inlets and the cartridge lters. This slows the incoming air prior to it reaching the lters, allowing larger particles to drop out of the air stream and better dispersion of incoming air across all of the lters in the collector. Slowing the incoming air also allows for lower can velocities and less abrasion on the lters. 7.12 Blast Plates (Diffusers): All units should have a blast plate (diffuser) mounted across the inlet duct to reduce direct abrasive impact on the lter media and to reduce approach velocities. The diffuser should be inspected for wear regularly.

8. Filter Selection Criteria

8.1 Air-to-Cloth Ratios: Another factor in selecting the size of the dust collector for a specic application relates to the air-to-cloth ratio (A/C), which is the size of the lter media expressed in terms of dust collector capacity (cubic feet per minute) versus fabric media surface area (square feet). This is also called ltration velocity, and denes the average velocity of the air stream through the lter media. A low A/C ratio denotes a large unit (in terms of air volume). Selection of dust collector A/C ratios is typically based upon particulate loading and particle size distribution, as well as the type of lter (bags or cartridges). A lower A/C is better within each range. Generally, a lower A/C ratio is desired when the particle size distribution includes a higher concentration of small particles or when the particulate loading is high, both of which are factors to be considered in the industrial painting industry. Actual A/C ratios also vary greatly based on the type of collection system and lter media utilized. Pulse jet systems generally operate with higher A/C ratios of 5:1 to 10:1; shaker systems generally require A/C ratios ranging from 3:1 to 6:1; and reverse pulse systems generally require A/C ratios of 2:1. Closely pleated lters typically require an A/C ratio of 3:1, while lightly pleated or non-pleated lter materials would allow for higher A/C ratios. Most cartridge dust collectors currently in use in the industrial painting industry have standard A/C ratios ranging from 3:1 to 3.5:1, dependent upon the type of lter media utilized. 8.2 Filter Efciency and Permeability: Fabric lter selection is a careful balance between maintaining permeability (the ability of the fabric to allow air to pass through) and lter efciency (the amount of dust captured). The best lter efciency (and worst permeability) occurs right before the lters are cleaned. The highest inefciency or penetration typically occurs during start-up and immediately after reconditioning. Fabric permeability typically ranges from 25 to 40 cfm/ft2. Choosing lter material with better efciency or greater permeability but lower lter efciency is not as critical as it may seem. The efciency of a particular fabric lter is only relevant when rst put into service. Once the fabric lter has been in service for any length of time, the dust cake on the lter performs almost all of the ltration.

Particulate that is all the same size is difcult to lter, as it creates a dense mass that restricts the ow of air through the lter (reduced permeability). Fine particles (less than 10 micrometers in size) may be too small for some lter media to collect and can bleed through the lter and exit the collector, resulting in emissions. In some cases, pulse jet systems preferentially retain small particles (less than 1 micrometer) during the cleaning process. Another consideration is the effect of lter permeability on total dust collector airow. Heavily caked lters can reduce the airow generated by the dust collector by 50% or more. As most dust systems are used for multiple purposes (i.e., to improve visibility, reduce worker exposures, prevent emissions to the environment) the designer and/or operator must be aware of these diametrically opposed conditions. Maximum efciency in ltration may result in inadequate airow in the containment. Therefore, careful balancing of all factors is required for optimal dust collector operation. 8.3 Filter Types 8.3.1 Bags: Bag collector lters are typically long tubular shaped lters consisting of woven and non-woven bers. They are hung vertically in rows and typically are approximately 4.5 to 8 inches in diameter with standard lengths of 5 to 12 feet. Because of their simple (non-pleated) shapes, thicker fabrics can be used. Employing thicker fabrics can provide a longer lter life and higher abrasion resistance. Bag lters accommodate many types of media including hydroscopic, sticky, brous, and moisture-laden dusts. Because of their smooth shape, they will release their dust cakes more readily than pleated designs. Due to their shape and the ability to use thicker fabrics, bag collector lters are generally specied for applications requiring higher negative pressure levels. These characteristics also allow bag lters to be pulse-cleaned at higher pressures ranging from 80 to 100 psi. 8.3.2 Cartridges: Cartridge lters use rigidly pleated elements making it possible to accommodate a larger amount of surface area in a smaller lter. Pleated lter cartridges provide as much as a 300% increase of ltration surface area, resulting in lower air-to-cloth ratios without increasing the size of the collector body. They are typically used for dry dust applications and exhibit high efciency when used on moderate concentrations of dry dust such as is generated from ventilating abrasive blast cleaning containments. Cartridge systems are typically used for low to moderate dust loading conditions (approximately 3 gr/cfm ). Cartridge type lters are usually pulse-cleaned at pressures ranging from 75 to 85 psi. Cartridge lters may not be appropriate for moist or hydrocarbon environments or for wet methods of removal, due to the impact of moisture on some types of lter material. Cartridge lters made of cellulose or paper may be damaged by moisture, causing lter failure or solidication of the dust cake, affecting cleaning and ltration efciency. For wet applications, use of moisture resistant materials such as Teon or polyester

9-74

SSPC-Guide 16 August 1, 2003

may be necessary. However, regardless of the lter type and lter material used, reduction in lter efciency and problems with dust-cake release are still very likely in wet applications. Suitability of specic cartridge lters for use during wet applications should be conrmed with the lter media provider prior to project start-up. 8.4 Filter Materials: Filters may be constructed of any brous material (natural or synthetic) that can be spun, woven, felted, or impacted to create a ltering mass. Woven fabrics are typically characterized by thread count and weight of fabric per unit area (ounces per square foot). The weave pattern of woven fabrics can inuence the porosity of the dust cake accumulating on the fabric surface. Gaps between the weave can be more than 50 micrometers in size. Woven media can be used in all three types of dust collector systems. Felted media is comprised of randomly oriented bers attached to an open weave material (i.e., a scrim). Felted ber media is primarily used in pulse jet systems. Many media manufacturers apply a coating to woven or felted media to improve certain characteristics such as heat or abrasion resistance. One of the more common material additives is Teon. The application of Teon to lter media reduces ber-to-ber abrasion, and improves dust-cake release and its ability to handle hydroscopic (e.g., water attracting) particles. 100% Teon or blended Teon coated lter media should be considered during wet removal applications. Typical materials and their characteristics are summarized in Table 1. Dust collector manufacturers in the industrial painting industry typically equip their systems with polyester or cellulose fabrics. However, as most lter material is interchangeable (can be used in most dust collectors), contractors can select more or less efcient media for lter replacement. Consideration should be given to specifying the type of lter material for specic operations (i.e., wet methods). Note that blended materials are also available that can combine multiple lter characteristics (e.g. 80% cellulose/20% Teon). Felted materials are usually thicker than cellulose or blended materials. They cannot be pleated as heavily as the thinner materials. Having less pleats within a cartridges diameter would mean less ltering area per cartridge and thereby a higher A/C ratio if the collector size is maintained. This is not necessarily a negative as the thicker material may provide desirable characteristics that the thinner material cannot. Some projects are of a short duration and require lter disposal at the end of the job; in such instances, a less expensive lter could be the best choice. In other projects where the unit may be on site for an extended period of time and/or the production schedule will not allow for down time to change lters, or if the unit is located where physical access to change lters is limited, a premium lter should be used. If the dust collector has a high can velocity, the user may want to select a thicker fabric media to reduce leaking due to abrasion. 8.5 Filter Selection: Most lter media is now available to t almost any dust collector. However, the selection of a particular

type (e.g. cartridge or bag) or material (e.g. felted or Teon coated) should be made through an analysis of the actual dust characteristics that will be encountered. For plant operations using dust collectors for air pollution control, the engineer typically quantitatively assesses a variety of characteristics using EPA Methods before specifying either the dust collector or lter media. Factors that are typically identied include: particulate loading, particulate size, inlet air temperatures, moisture and particle content, particle composition, available space for the dust collector, desired life expectancy of the lters, and maintenance issues. In the industrial painting industry, lter media is often selected using one size ts all approach or based upon cost considerations rather than dust characteristics. Selection of different lter media may be warranted based upon the process or removal methods. In the industrial painting industry, most of the particles generated during mechanical action (i.e., abrasive blast cleaning, power tool cleaning) typically range from 3 to 100 micrometers in size. Filters used for these applications must be capable of handling a wide range of particulate sizes without clogging the media. For wet methods, a water-resistant media such as Teon should be considered.

9. Verication and Measurement

9.1 Base Filter Capacity: This test is designed to determine the true dust collection capacity of the dust collector lter media. With the dust collector running at its designed speed, a measured amount of test dust can be introduced into the unit, with the lter cleaning system (e.g. pulse jets) turned off. Dust is added until an amount sufcient to restrict the airow to the advertised airow capacity is reached. At this point, the amount of dust consumed versus the airow restriction across the lters is recorded. This indicates how much dust the unit can store in its lter media during operation before it has a negative impact on air ow capacity. 9.2 Dust Load Capacity: This test is designed to determine the active dust load that the unit can handle while still maintaining its advertised capacity. Unlike the Base Filter Capacity test, the dust collector is in full operational mode with the automatic lter cleaning system engaged. A test dust load is introduced into the collector until the advertised ow rate is reached, and the load continues at that rate for a predetermined amount of time. Any subsequent drop in airow rate is recorded during this time. This sustainable dust load rate is a true measure of the Dust Load Capacity of the unit. This number will tell the user if the dust load to be generated may overwhelm the unit. At the end of the test, the unit is shut down, and the amount of dust collected in the lter hopper is measured. The difference between the amount of dust input and the amount removed indicates the amount of dust retained by the lters. 9.3 Dust Cake Release Test: This simple test is designed to determine how the lters will clean in an off-duty mode.

9-75

SSPC-Guide 16 August 1, 2003

After completion of the Dust Load Capacity test (see Section 9.2), the duct inlets are closed and the blower shut down. The unit is allowed to pulse down the lters for a specied period of time or number of pulse cycles. After the pulse down cycle, the hopper is unloaded again and the amount of dust released from the lters measured. Then, the unit is run again to determine its refreshed airow rate and pressure drop across the lters. This determines how well the unit cleans between work cycles. 9.4 Filter Cleaning Efciency: This is the measure of the ability of the collector to clean the lters while in use. It should be noted that no lter cleaning system completely cleans the lters. Some residual dust, along with dust cake, will fall from the lters during shutdown and movement of the collector, sometimes resulting in the assumption that the collector was not emptied after the last use. A new dust cake will build up on the lters at the beginning of the next use of the collector. Operating dust cake thicknesses and lter differential pressures vary with the type of lter or cartridge in use and the model and type of dust collector. Pressure differential over the lter is usually measured using a static pressure gauge such as a magnehelic gauge or manometer. The greater the operating lter differential pressure, the less pressure is available for moving the air through the containment area. Therefore, two collectors with the same overall pressure rating but different pressure differentials at the lter will have different air ow capacities. 9.5 EPA Reference Methods: The EPA has established several methods for evaluating fabric lter performance used

in stationary source applications. The total lterable particulate mass emission rate can be measured using EPA Reference Method 5 or EPA Reference Method 17. The total lterable PM10 emissions can be determined by EPA Reference Method 201 or 201a.2 While these methods are commonly used in stationary source evaluation of dust collectors, several problems may limit the applicability of these test methods on ltration systems. The testing is expensive, ranging from $3,000 to $5,000 per set of three runs. Other problems are related to the fact that most mobile dust collectors do not have conventional stacks to support the required test equipment.

10. Sizing of Dust Collectors

10.1 Dust Collector Capacity: The amount of air a dust collector can process is dependent on both the exhaust capacity (volume of air in cfm) and the resistance to airow (static pressure in inches of water) the system must overcome. The resistance of the system includes pressure drop within the dust collector as well as pressure drops from ductwork, air inlets, and all other parts connected to the dust collector. The fan performance curve and all the pressure drops of the system must be considered in order to estimate the actual air ow rates within the system for each given application. A fan, which is the central component of a dust collector, operates in accordance with a specic curve corresponding to a specic fan speed (rpm). The actual exhaust capacity in the eld is based upon where the system static pressure loss intersects the fan curve. For example, a dust collector rated at 40,000 cfm may only provide 30,000 cfm exhaust capacity at 14 inches of static pressure loss (see Figure 2). Typical static

TABLE 1 FILTER MEDIA PROPERTIES

Generic Name Natural Fiber, Cellulose Polypropylene Common Name Cotton Tensile Strength Good Abrasion Resistance Good Moisture Resistance Good Fiber Characteristics Good permeability

Polypropylene

Excellent

Excellent

Average

Strong ber, low moisture absorption Rugged ber Good in acid conditions High tensile strength Excellent chemical and moisture resistance Least expensive, prone to abrasion in pulse jet systems

Polyamide Acrylic Polyester Fluorocarbon

Nylon Orlon Dacron Teon or Teflon-coated Fiberglass

Excellent Good Excellent Average

Excellent Good Excellent Average

Good Good Average Excellent

Fiberglass

Excellent

Average to Poor

Average

9-76

SSPC-Guide 16 August 1, 2003

pressure losses include loss through air inlets, duct work and the dust collector itself. 10.2 Static pressure loss through air inlets: The major containment design factors that may affect dust collector performance are the location and the conguration (i.e. area) of the make-up air inlets and the type of exhaust port (i.e. duct type) entry point(s). Air inlet openings are typically sized to provide inward air velocity ranging from 200 to 600 ft/min. As a basis of design, static pressure losses for air inlet openings are estimated between 0.25 to 0.50 inches w.c. by the ACGIH Industrial Ventilation Manual.3 Exhaust ports or hoods (i.e. the way in which the duct is attached to the enclosure) also affect static pressure. Although there are a variety of designs, the three most common types are the plain duct end (duct is placed into the enclosure without any hood), anged duct end (duct is connected to at sheet metal or plywood), and tapered duct end (duct is connected to tapered hood or plenum). The Industrial Ventilation Manual establishes formulas for calculating static pressure losses based upon the type of congurations utilized. 10.3 Static pressure loss through ductwork: When air is drawn through a duct, two types of pressure are associated with airow; static pressure (SP) and velocity pressure (VP). The ductwork system that connects the exhaust equipment to the containment is frequently the largest contribution to static pressure loss. 10.3.1 Static pressure (duct work): This is the pressure exerted on the walls of the ductwork by the dust collector or by friction related losses. Static pressure losses are a function of ductwork conguration, air velocity in the duct, roughness of the duct surface, duct diameter, and air density and viscosity. To determine static pressure loss through ductwork, the total equivalent length must be calculated. This method factors in duct diameter, the total length of straight runs of duct, and the equivalent length of straight runs of duct for each of elbow (e.g. bends) in the system. The Industrial Ventilation Manual provides information on calculating static pressure losses based upon these factors. 10.3.2 Velocity pressure duct work: This is the pressure associated with the speed of the airow through the duct. 10.4 Static pressure loss through the dust collector: Design features such as inlet sizes, the total area of the lters, spacing between rows of lters, the volume (cubic feet) within the dirty side of the collector body, the volume (cubic feet) within the clean side of the collector body, reinforcements and other objects within the air stream, and the design and shape of the transition duct from the collector body to the fan, all affect the
2

amount of air passing through the lters and therefore the static pressure created by a dust collector. New lters create a slight static pressure ranging from 1 to 2 inches w.c., while older, dirty lters may have a static pressure as high as 6.0 inches w.c. In most instances, design calculations that allow a pressure drop of 4.0 inches w.c. for the lters is reasonable. 10.5 Sample Calculations: By determining static pressure throughout the make-up air inlets, through containment, and through the ductwork, air lters, the system static pressure that the fan must overcome can be calculated. Duct friction-loss tables can be obtained from duct suppliers and general tables can be found in the Industrial Ventilation Manual. Using the fan curve in Figure 2, one would expect the following: System Static Pressure Estimate
Based on (3) 20 diameter exhaust ducts @ 15,667 cfm per duct 50-ft section of 20 diameter duct @3.02/100 Three 90 elbows @ 46 equiv. lineal feet each Loss through containment Loss through fabric lters 1.54 w.c. 4.25 w.c. 1.65 w.c. 4.00 w.c.

Total Estimated System Static Pressure 11.44 w.c. Total Available Exhaust Capacity 47,000 cfm

The fan curve presents the fans capacity to deliver varying volumes of air. This capacity depends upon the static pressure. The designer must match the calculated static pressure for the design system to the fan curve. In this case, the designer has calculated losses from ductwork, elbows, and lters to be 11.44 inches w.c. of static pressure. This requires 47,000 cfm of exhaust air from the dust collector to achieve design goals. 10.6 Calculating Air Flow: Once the actual capacity of the dust collector is known, calculations can be performed to verify that dust collector capacity and proposed containment area will achieve the recommended air ow (or control velocity) in feet per minute. It must be noted that denitive guidance on recommended airow does not exist. The preamble to 29 CFR 1926.62 states that it believes an exposure reduction factor of 50% will be achievable through mechanical ventilation systems but does not provide a minimum number. The construction industry ventilation standard (29 CFR 1926.57) refers to ANSI Z9.2 Exhaust Systems Abrasive Blasting Operations Ventilation and Safe Practice.4 ANSI Z9.2 provides suggested downdraft velocities of 60 to 90 ft/min or 100 ft/min crossdraft when removing coatings containing toxic metals by dry abrasive blasting. SSPC recognizes that xed abrasive blast rooms are not the same as eld containment structures, and this guide makes

US Environmental Protection Agency (EPA), 1200 Pennsylvania Avenue, NW, Washington, DC 20460. Text of EPA Reference Methods may be downloaded from http://www.epa.gov/ttn/emc/promgate.html (3/03)

9-77

SSPC-Guide 16 August 1, 2003

no recommendations regarding the suitability of the velocities (whether too much or too little). For example, Federal Highway Administration research involving air movement inside containment when removing lead paint by abrasive blast cleaning (FHWA RD-94-100) found no signicant differences in worker lead exposures at crossdraft velocities of 70 to 300 ft/min. ANSI Z9.2 indicates that large solid particles usually cannot be captured by conventional airow patterns, but that airow patterns should ensure that hygienically signicant particle sizes (i.e. less than 10 micrometers in size) are captured. It suggests that the larger particle sizes should be allowed to fall to the oor to be removed through housekeeping practices. As a result, when designing ventilation systems for containment, primary consideration should be given to the movement of the hygienically signicant particle sizes through the enclosure to the exhaust hood in combination with good housekeeping practices to remove the heavier particles. ANSI Z9.2 states that when data on control velocity and volume of air are not available in reliable published information, control velocity and volume can be determined by measurement of actual airow velocities. As a result, the specier may consider allowing the contractor to demonstrate that the proposed air velocity inside containment will provide the necessary and desired controls (i.e. reduced worker exposures, control of emissions, etc.) to comply with the OSHA Lead Standard mandate for engineering controls. The size of the dust collector is based on the cross-sectional area of the containment and the selected control velocity of the air according to the equation:

containment by such methods as hanging interior tarps inside the containment and moving the air intakes and exhausts to the working portion. If Q is within the calculated capacity of the dust collector, the system is designed adequately. If not, the cross-sectional area can be reduced to meet the target airow.

11. Operation and Maintenance

11.1 Differential (Static) Pressure: Differential pressure across the lters is a critical operational issue and can be an early indicator of potential system failure. Differential pressure is measured using a magnehelic gauge with ports located within the lter housing, one port in the dirty side, and one port in the clean side. Most systems are designed to operate in the range of 1 to 4 inches w.c. (pulse-jet systems operate at a slightly higher range). Both high and low differential pressures can have a negative effect on overall system performance. Potential causes of high differential pressure can include insufcient compressed air, improper (low) pressure regulator settings, mis-rotated compressed air delivery tubes (pulse jet), lters exceeding their useful life, insufcient lter area, and full hoppers. The effects of the high differential pressure can result in lter damage, reduction in total system air volume, and excess lter caking. Potential causes of low differential pressure can include leakage or blockage of air in the delivery tubes, ttings, and valves, using less than the required amount of delivery tubes (i.e. 1 of 4 available inlets), clogged or obstructed air lines leading to the magnehelic gauge, a faulty magnehelic gauge, a FIGURE 2 FAN CURVE

Q=VxA
Where: Q is the amount of air exhausted (cfm), i.e., the size of the dust collector V is the velocity of air (ft/min), and A is the cross-sectional area of the containment (ft2) For example, if a containment were 20 feet high by 40 feet wide by 80 feet long, it would be normal to decide to move the air along the length of containment (i.e. crossdraft). The cross-sectional area of containment (the area through which the air will pass), therefore, is 20 ft x 40 ft, or 800 ft2. The control velocity selected is 100 ft/min. The size dust collector needed is:

Q=VxA = (100 ft/min) x (800 ft2) = 80,000 cfm

One method for obtaining the desired control velocity when there is insufcient dust collector capacity to match the size of the containment is to reduce the cross-sectional area of the
3

The ACGIH Industrial Ventilation Manual may be obtained from the American Council of Governmental and Industrial Hygienists, 1330 Kemper Meadow Drive, Cincinnati, Ohio 45240, 513-742-2020, or online at http://www.acgih.org.

9-78

SSPC-Guide 16 August 1, 2003

partially closed outlet damper on the fan (if the fan is equipped with one), over-cleaning of the lters, or a very low dust loading. A unit may have low differential pressure and still have high total system static pressure (as would be the case if only one of four available inlets was being used). In pulse jet systems, improper pulse frequency (too high or low) is a common problem. Pulse valve malfunctions are typically caused by diaphragm failure or dirt, oil, and/or moisture entering the valve body. These situations can be avoided by a scheduled maintenance and inspection program. For reverse pulse systems, one manufacturer recommends monitoring the differential pressure during the cleaning cycles. This includes: Before the module starts to cleanAny reading indicates potential leakage When the module is isolated before the reverse air damper opensAny reading other than zero is an indication that the damper is not sealing properly. When the reverse air is energizedShould be consistent with the manufacturers recommended differential (typically 1 to 4 inches w.c.) During the null period after reverse airShould be sufcient duration to allow particulate to fall into the hopper (visually observed) When the module is returned to service (typically 1 to 4 inches w.c.) 11.2 Hoppers: Manufacturer procedures indicate that dust should not be allowed to be stored in the hopper (which frequently occurs on industrial painting projects) and should be removed daily. Storing of material in the hopper can lead to dust build up and solidication, particularly if moisture is drawn into the system. This reduces air velocity and the particulate can be drawn back into the ltration system, shortening the lter life. Solidication in the hopper can also lead to overloading and malfunction of the waste removal system (i.e. auger). 11.3 Visible Emissions: Manufacturer troubleshooting guides all indicate that any particulate that can be seen discharging from the exhaust stack is indicative of a system breach or bag failure. All of the manufacturer guidelines call for immediate shut down, leak detection (i.e., operator inspection for the source of the leaks), and corrective action if emissions are observed. Additionally, fans located downstream of the collector (as in most negative pressure systems) can be damaged by abrasion or become imbalanced (resulting in reduction of total air volume) if particulate is discharged from the lters through the fan to the discharge stack. Emission observations alone may not provide adequate feedback on the effectiveness of system operations. Additional leak detection methods are discussed later.

11.4 Temperature and Wet Removal Methods: Temperatures below which water may condense, or wet removal methods, can cause premature lter failure due to clogging and solidication of solids in the hopper. This is of particular importance when steel grit abrasives are utilized due to the potential for steel in the abrasive blasting debris to rust and solidify in the presence of moisture. Careful selection of the dust collection system and lter media is warranted when high moisture levels are likely to be present (e.g., wet removal methods). 11.5 Air Inltration and Corrosion: Filtration systems operating under negative pressure, such as those used in the industrial painting industry, are vulnerable to air-inltration-related bag damage and water damage. Access hatches should be equipped with functional gaskets and all seams and unit components (e.g., hoppers, exterior casing, etc.) should be of sound construction to prohibit air or moisture inltration into the collector body. 11.6 Start-up Procedures: Use of manufacturer-recommended dust collector start-up and shutdown procedures is important in preventing premature damage to the unit and lter media. Manufacturer guidelines all agree that new lter media are not to be exposed to the full air volume of the fan. Typically, the dust collector should be brought on line slowly to avoid damage of the lter media. Before protective dust cakes form, clean lters are sensitive to dust abrasion and penetration of ne particles. Most manufacturers recommend start-up at a low velocity until sufcient dust cake has been formed. This is indicated by a pressure differential of 1 to 2 inches w.c. Following this initial seasoning or conditioning of the lters, the differential pressure can be brought up to a consistent operating range. 11.7 Filter Installation/Position: One of the more common, though frequently overlooked reasons for lter failure is improper lter installation. Bent or damaged lter cages (these are metal cages or frames used to support the cartridge or bag) may not be able to properly support the lter. Cages can become corroded and abrade or puncture the lter during exing in the cleaning cycle. For pulse jet systems, it is recommended that lter cartridges be positioned so that all seams are facing the same direction. This provides a reference point to help identify abrasion problems. Reverse air systems should have seams positioned at a 45 angle to the access door. This provides the greatest distance between bags, reducing the possibility for bag-to-bag abrasion. Additionally, for reverse air systems, proper tensioning of the bags is critical for performance. Loose bags do not provide for proper collection and the resulting bagto-bag abrasion may lead to premature failure. Over-tensioned bags will lead to stress on the lter bag. Shaker systems are

American National Standards Institute, 1819 L Street, NW, Suite 600, Washington, DC 20036. Standards downloadable from www.ansi.org

9-79

SSPC-Guide 16 August 1, 2003

also prone to the same bag tension problems. Manufacturers recommend use of tensioning tools for proper bag positioning and tension. Another common problem with lter systems is misalignment between the lter and gasket. Improper seating of the lter on the gasket will allow particulate to escape the ltration bed resulting in emissions through the exhaust port. Continuous emissions are typically representative of improper lter seating. Periodic inspection of the lter media is mandatory in most manufacturer guidelines. Inspection should include visual observation of the clean air side of the system for leaks (i.e., visible material) and the lter media for tears. Observations of lter media should occur when the dust collector is presumed to have been cleaned (following the end of a shift). If the lter media is covered with a layer of dust, it can be presumed the cleaning system is not functioning properly. If the dust is hardened on the bags and is not easily discharged, it is likely that moisture has entered the system. 11.8 Filter Replacement: Should an inspection of lters or observation of visible emissions indicate excessive wear, tears, or caking, the lters should be replaced. The preferred practice is to replace all lters (at least in the same bank or bed) at the same time. Replacing only one or two lters creates a path of least resistance to airow (due to high permeability of the new lters) when the unit is returned to service. This prevents proper conditioning or seasoning of the new lters and exposes them to high airow rates and differential pressures, which may result in premature wear or damage. 11.9 Filter Disposal: The nes collected by the dust collector must be disposed in accordance with federal and state regulations. If the dust collector has been used to lter toxic dust streams, the disposal of the lters will need to follow the requirements of hazardous waste disposal. Often, there is signicant cost associated with such disposal. SSPC-Guide 75 presents information on waste characterization and disposal. 11.10 Explosion Hazards: Under certain operating conditions, explosive concentrations of combustible dusts and/or gases could develop in some dust collector systems. If the possibility of explosion exists, consideration should be given to dust collector housings with explosion vents and spark resistant fan construction. Explosion vents are quick opening hatches or rupture disks that facilitate the rapid release of explosive pressures. The National Fire Prevention Association (NFPA) Code 68, Guide for Venting of Deagrations,6 provides additional information on venting in event of an explosion.

the gauge be held level. The preferred method is to mount the gauge outside containment using a level to assure it is at and vertical. A piece of tubing is attached to the low-pressure port on the gauge. The tubing is then placed at various locations within the containment and the negative pressure measured. High-pressure sources such as blast nozzles should not be in operation when negative pressure is measured, as bursts of high-pressure air can affect readings. A regular pattern based upon the width and height of the containment is used in determining locations to take measurements. The average of these measurements is the average negative pressure inside containment. 12.2 Air Flow Inside Containment: Measuring airow inside containment can be performed with a rotating vane or hot wire anemometer, velometer, or smoke bomb. Anemometers and velometers are the most common instruments used. Air speed is measured directly, but these instruments do not indicate the direction the air is moving. (Eddy currents can be present, so the air may be moving in the opposite direction.) Operate the anemometer or velometer in accordance with the manufacturers instructions, holding the instrument as far away from the body as possible. Be sure not to stand in front of the air intakes and exhaust ducts. Take measurements in a regular cross-pattern at different heights within the containment. Average the measurements to determine the average airow inside containment. To measure airow with a smoke bomb, measure off a known distance inside containment from the smoke bomb to the air exits. Set off the smoke bomb and time how long it takes the smoke to reach the marked point. The distance, in feet, divided by the time, in minutes, is roughly equivalent to the average air velocity. Measure airow inside containment without any airow sources present, such as operating blast nozzles. Compare airow measurements to target velocities of 100 ft/min crossdraft or 60 ft/min downdraft, or other specied criteria. 12.3 Air Flow Inside the Exhaust Ducts: Airow inside exhaust ducts are measured with a Pitot tube, velometer, or hot wire anemometer. Select a location in the exhaust duct that is at least eight duct diameters away from any obstruction such as a bend or change in duct size. Insert the Pitot tube into the duct pointing the opening towards the direction of airow. Perform a ten-point traverse. Make another hole inside the duct 90 degrees from the rst hole and perform another ten-point traverse. The locations inside the duct for these ten points are dependent upon the diameter of the duct. Standard texts, such as the Industrial Ventilation Manual, give information on locations as well as charts or converting the velocity pressure (VP) to velocity (V) before averaging when using a Pitot tube. The twenty readings taken are averaged to determine the average airow through the duct. A minimum target transport velocity (Vt) of 4,000 ft/min is recommended. The transport velocity can be calculated using the equation

12. Evaluating System Performance

12.1 Negative Pressure Inside Containment: Negative pressure inside containment is measured with a magnehelic gauge or inclined water manometer. While negative pressure across lters in a dust collector is usually on the order of a few inches of water column, the most commonly cited negative pressure for the containment is 0.03 inches w.c. It is imperative that

Q =Vt x A 9-80

SSPC-Guide 16 August 1, 2003

except that A is now the cross-section area of the duct, Q is the volume of air, and Vt is the measured transport velocity. 12.4 Throat Static Pressure: This method provides an estimate of airow at the inlet to the dust collector. The technique involves measuring static pressure (SP) through 1/16" to 1/8" drilled (not punched) tapholes one to three duct diameters from the throat of the dust collector connection. Measurements should be made after the system performance is veried using the above methods. An increase in throat SP indicates a downstream clog. A decrease means a drop in dust collector fan performance. 12.5 Phosphorescent Powder/Fluorescent Dye: Several varieties of phosphorescent powders and uorescent dyes are commercially available for leak detection. These materials are used routinely in plant dust collection operations. The material is generally released into the dust collector under normal operating conditions with the lter cleaning system shutdown. After a few moments, the clean air side of the lter is inspected with an ultra-violet light ("black light"), which will detect the material. Presence of the material on the clean side of the lter (varies based on system) indicates poor lter seal, holes or tears in the lter media, improper seating of the lter to the gasket, or leaks in the system itself (i.e., gaps in welds). These areas can then be inspected to determine where or why the failure is occurring. 12.6 Mass Flow Broken Bag Detector: This application uses electrical output readings (pico amperes) proportional to mass concentration of the particulate (gr/cfm). If the expected mass concentration of the particulate is exceeded, the unit can be set to sound an alarm or shut down. Mass ow detectors are typically mounted at the exhaust air outlet of the dust collector. 12.7 Triboelectric Bag Leak Detector and Dust Monitors: This application has been used for approximately 25 years, since the advent of dust collection in plant applications. It utilizes a probe mounted in the exhaust air outlet. As dust particles collide with the probe, they generate a charge transfer. This methodology requires determination of a baseline value for the material being ltered (gr/cfm). If the charge exceeds two times the baseline value, an alarm is activated to alert the operator. Discussions with manufacturers indicate that triboelectric detectors could likely be used on mobile dust collection systems. 12.8 Differential (Static) Pressure Gauges: All dust collection systems (including recycling and vacuuming equipment) should be equipped with static pressure gauges (i.e., magnehelic gauges) to measure pressure drop over the entire ltration system. Each compartment should also be equipped with an independent static pressure gauge.

12.9 Compressed Air Regulators: Compressed air regulators should be provided on all dust collection units that utilize compressed air to verify that proper air pressure (as specied by the manufacturer) is provided to the cleaning system. 12.10 Inspection and Maintenance Programs: Whether or not leak detection technology is utilized, a properly conducted scheduled operation and maintenance program (OMP) may be the best available method of proactive prevention of dust collection system failure. All manufacturers provide guidance on scheduled inspection and maintenance procedures; however, the industrial painting industry has not actively adopted implementation of these programs. Manufacturers agree that scheduled inspection and preventive maintenance of their equipment will assure proper operation, and they recommend scheduled maintenance regimes. Many provide inspection logs along with the dust collectors. Common components of inspection and maintenance programs include: Record differential pressures by graph or log Maintain lter replacement record or chart Visually inspect the lters, hopper and exhaust stack for leaks Check doors and inlet seals for leakage Check timer control for proper pulse sequence and duration (pulse jet), and bag tension (shaker and reverse pulse) Clean pressure taps (differential pressure gauge lines)

13. Disclaimer
13.1 This guide is designed to describe, review, or analyze new or improved technology and does not meet the denition of a standard as dened by SSPC. A guide differs from a standard in that it is not suitable for referencing in a specication or procurement document. 13.2 While every precaution is taken to ensure that all information furnished in SSPC guides is as accurate, complete, and useful as possible, SSPC cannot assume responsibility nor incur any obligation resulting from the use of any materials, coatings, or methods described herein, or of the guide itself. 13.3 This guide does not attempt to address problems concerning safety associated with its use. The user of this guide, as well as the user of all products or practices described herein, is responsible for instituting appropriate health and safety practices and for ensuring compliance with all governmental regulations.

9-81