The common faults of baghouse dust collectors mainly fall into four categories, namely filter bag failures, dust cleaning system malfunctions, fan operation
anomalies, and system sealing issues. The corresponding countermeasures are clear and actionable, which can quickly resolve the vast majority of
operational abnormalities.
Core Baghouse Filter Faults
This is the type of fault in baghouse dust collectors that most easily causes environmental protection emission exceedances.
Filter Bag Breakage: Manifested as ash emission from the chimney and a sharp surge in outlet dust concentration, this fault is mostly caused by excessive pulse jet
pressure, scraping from burrs on the filter cage, or flue gas corrosion. For treatment, directly replace the damaged filter bag, polish off the burrs on the filter cage
and adjust the pulse jet pressure to the reasonable range of 0.3~0.5MPa.
Bag Clogging and Blockage: The equipment resistance continues to rise, and conventional dust cleaning is completely ineffective. It is mostly caused by flue gas
condensation and the adhesion of viscous dust. For treatment, the flue gas temperature needs to be raised to more than 25°C above the dew point, and the insulation
of the casing shall be strengthened. Slight clogging can be cleaned by offline back-blowing, while for severe clogging, the filter bag shall be directly replaced.
Dust Caking: A hard, closed crust forms on the surface of the filter bag, rendering dust cleaning completely ineffective. This is an irreversible fault, mostly
caused by moisture exposure or failure to perform dust cleaning before equipment shutdown. For this situation, the filter bags can only be replaced in full
batches to avoid continuous sharp rise of equipment resistance and sharp increase of energy consumption.
Common Faults of the Dust Cleaning System
Abnormalities in the dust cleaning system will directly lead to rapid clogging of filter bags and a sharp drop in dust removal efficiency.
Weak Pulse Jet: The pulse jet produces a dull sound with poor dust cleaning effect. Check whether the air source pressure is lower than 0.3MPa, whether the
diaphragm is damaged, and whether the nozzle is clogged. Unclog the blocked nozzles, replace the aged diaphragm, and stabilize the air tank pressure above
0.4MPa to restore normal operation.
Solenoid Valve Fails to Operate: The pulse valve shows no response at all. Investigate whether the coil is burned out, whether the circuit has poor contact,
and whether the controller outputs no signal. Repair the circuit or directly replace the faulty solenoid valve component.
Persistent High Differential Pressure: After excluding filter bag-related problems, check whether the pressure measurement port is blocked and whether the
connecting air pipe has cracks. Clean the pressure measurement port and calibrate the differential pressure gauge to solve the problem.
Abnormal Operation Faults of the Fan
Fan faults will directly lead to insufficient dust suction air volume, resulting in incomplete dust collection at the workstations.
Low Current and Insufficient Air Volume: Mostly caused by excessive resistance of the dust collector, slipping of the fan belt, or reverse rotation of the motor
Reduce the system resistance, adjust the belt tension, and confirm the correct rotation direction of the motor to restore the required air volume.
Severe Fan Vibration: Check if the impeller has dust accumulation, if the bearing is worn, or if the pulley is out of balance. Clean the dust accumulated on the
impeller, replace the worn bearing, and perform dynamic rebalancing to eliminate vibration.
Abnormal Flue Gas Temperature: Excessively high temperature is likely to burn the filter bags, while excessively low temperature easily causes condensation
and bag clogging. Coordinate with upstream equipment to adjust the combustion conditions. When overtemperature occurs, open the bypass flue or cold
air valve; when the temperature is too low, start the ash hopper tracing and insulation system.
System Sealing Faults
Air leakage is the most easily overlooked hidden fault, which will cause a large number of secondary problems.
Air Leakage at Casing/Access Door: External cold air flows backward into the casing, causing condensation and bag clogging. Replace the aged and hardened
sealing strips, tighten the flange bolts evenly, and repair the leaked welds on the casing.
Air Leakage at Dust Discharge Valve: The air locking failure causes a large amount of cold air to enter the ash hopper, leading to dust moisture bridging. Adjust
the blade clearance of the unloader, and directly replace the blades if they are severely worn to ensure the air locking effect.
Air Leakage and Dust Escape in Pipes: Cracks occur at pipe welds and elbow connections, leading to loss of dust suction negative pressure. Repair the cracked
welds, reinforce the loose pipe supports, and prevent repeated air leakage caused by operation vibration.
