10 rules for condition monitoring

Published:  08 July, 2015

Condition monitoring of plant is an increasing common method of preventing failure of

critical equipment and maximising uptime, but many engineers are making some basic,
and costly, mistakes. David Manning-Ohren, an expert in condition monitoring at ERIKS
UK offers 10 rules to ensure that your condition monitoring techniques work for you not
against you.

Effective maintenance management depends on the accurate forecasting and diagnosis of

problems with plant and machinery. Using the wrong maintenance technique can waste time,
money and resources with no effect on uptime of a pump, compressor or machine tool’s
availability.

While condition monitoring can play a vital role in a maintenance programme, all-too-often its
implementation is haphazard rather than strategic, targeting the wrong equipment and having
little effect on productivity.

In my experience there are literally dozens of rules that an engineering maintenance team could
follow when implementing a condition monitoring programme, based upon application and
skillset within the team. However, if I had to pick out ten rules then these are the key ones:

Rule 1 – Never use condition monitoring on its own

Condition monitoring should never be used on its own as a trending tool. For monitoring to work
best it needs to be implemented in harmony with a strong maintenance strategy and repair
feedback from the maintenance team or outside suppliers. Maintenance is an art not a science
and a sound maintenance programme needs to take into account multiple factors, not just trends.

Rule 2 - Spend your money on the most valuable asset

Not everything needs to be monitored. The key to more uptime is assessing what plant is critical
and then devising a schedule that takes into account its failure or repair history and cost to a
business when it is unproductive. A small motor gearbox with a replacement cost of a few
hundred pounds, which can be sourced quickly and easily from a distributor, is not critical
equipment and does not need monitoring.

Rule 3 – Get close to your key plant and machinery

The best condition monitoring device ever invented is man. Tap into the people who are using
the machine every day and notice the rattles, smells, squeaks, drips, bumps that are out of the
ordinary. Every one of these will help you foresee and predict failure before it occurs. The
machine operator is using the machine every day, knows its foibles and its weaknesses. Over
time the operator is the one person who will detect changes in cycle times, efficiency or
increased vibration which can offer clues to what is going on.

Rule 4 – There is no ideal condition monitoring frequency

I’m often asked, “How often should we monitor the condition of machinery?” The answer is “I
don’t know”, because it will depend on many variables from the maintenance regime, through to
the quality and age of the equipment and its criticality. Frequency can only be determined once a
thorough understanding of the plant and its role in production is analysed and understood.

Rule 5 - Keep a vibration database

Vibration is a key part of a strong condition monitoring regime. A good vibration database will
include three types of vibration reading, trend, spectrum and time waveform. Trend records the
overall vibration parameter value and details the date and time of the reading. Spectrum
measures the amplitude of the vibration parameter with respect to its frequency and the time
waveform measures the raw vibration signature without filtering or processing. Vibration checks
every 4-8 weeks is a good starting point.

Rule 6 – Understand the plant and understand the operating conditions

Always walk around a site before taking any readings and switch on any machinery to ensure
that it is warmed up and fully operational. A reading when a piece of plant is cold could be very
different from a machine that has been running flat out for two hours. Also the speed of plant can
change causing vibrations and temperatures to alter non-linearly. Base-lining with respect to
speed and operating load is excellent practice.

Rule 7 – Certification is better than qualification

Condition monitoring is constantly evolving. Any qualification therefore has a shelf-life and
expiry date because the techniques are being constantly updated. Certification, which requires
updating every five years, is therefore infinitely preferable to any qualification. If you are
condition monitoring in-house you need to ensure that your key people are up-to-speed with the
appropriate certificates, as well as aware of new technologies and practises.

Rule 8 – If you going to outsource insist on seeing some paperwork

Due to the fact that condition monitoring is constantly evolving many maintenance teams are
outsourcing to third party suppliers. There are sound reasons for doing this but before employing
anyone ask to see some paperwork to ensure you are only employing the best condition
monitoring experts. Plant users should insist that all engineers sent in by a service provider are
qualified to ISO 18436 and abide by the British Institute of Non-Destructive Testing (BINDT)
code of ethics.

Rule 9 - Judge a condition monitoring provider on more than the day-rate

Condition monitoring is a specialist job but all-too-often price is the key determinant for users of
plant and equipment. Typically, the cost of condition monitoring is based upon the number of
machines that require monitoring multiplied by the expert’s day rate. Unfortunately, this takes no
account of the type of data being taken, software being used or basic competence. Also consider
the support that an organisation can offer to the condition monitoring; expertise on bearings,
gearboxes, pumps and motors are essential to any condition monitoring service provider.

Rule 10 – Delay failure with good maintenance

Be sure you are taking the appropriate measures to delay the failure as long as possible by doing
the obvious little things like appropriate lubrication, dusting down cooling fans on motors,
running a vacuum over the distribution board and cleaning the pool of oil under the machine so
any new drips are noticeable. Some people call this 'preventive maintenance' but it’s just
common sense.

For further information please visit www.eriks.co.uk

Dust Collector Troubleshooting Guide
Dust Collection Blog, Dust Collector Troubleshooting

Introduction to Dust Collector

Troubleshooting
Operating and maintaining an equipment system as complex as an Industrial Dust Collector can
be a challenge. Here at Baghouse.com we pride ourselves on being experts in our field, with
decades of experience designing, installing, maintaining and servicing every kind of Dust Collect
design available. We have prepared this short troubleshooting guide in order to help you solve
some of the more commonly encountered issues involving Dust Collectors.

Table of Contents

1. Blower (Fan) & Ductwork Issues

2. Common Baghouse Issues (All Designs: Shaker, Reverse Air, & Pulse Jet)
3. Baghouse Design Specific Problems
1. Shaker
2. Reverse-Air
3. Plenum Pulse-Jet
4. Pulse-Jet

Blower (Fan) & Ductwork Issues

Many Baghouse difficulties originate as problems with the main Blower, or Fan and the supply
and exhaust Ductwork.

Problem: Insufficient Airflow Rate coming from the Blower, or Ductwork System

 Is your Blower (System Fan) powering on and operating properly?

 Action: Check electrical connections and turn on the Blower.

Addition Questions

 Is the motor pulling the specified proper amount of Amps?

 Action: Check wiring
 Is the fan turning in the right direction?
 Action: Make sure that motor leads are attached to the proper terminals.
 Is there excessive vibration?
 Action: Ensure that there is no excess build up of material on the fan blade, or Blower housing.
Are you getting the proper amount of Air Flow (Cubic Feet per Min) from the Blower?

 Is the Fan Dampener Open?

 Action: Close Dampener.
 Is the air volume at fan rated capacity?
 Action: See Below.
 (If your Blower output is normal) Has the Ductwork System been inspected for obstructions,
leaks or design flaws that increase static resistance?
 Action: Redesign Ductwork System to have lower resistance.

Addition Questions

 Are there elbows, or other directional changing Ductwork immediately preceding the Blower
Inlet?
 Action: Redesign Ductwork to remove any Elbows, or similar configurations near the Blower.
 Is there an obstruction near the outlet of the Ductwork?
 Action: Removed any obstruction and try again.

Problem: Excessive Airflow Rate

 Is the Blower set to the proper speed?

 Action: Check setting and adjust.
 Is the Ductwork System oversized?
 Action: Evaluate the Ductwork System and consider redesigning if needed.
 Are there any access ports on the Ductwork that are open?
 Action: Close all ports, and ensure they are sealed properly.

Problem: You have High Static Pressure and a low Airflow Rate

 Are there any obstructions in the Ductwork System?

 Action: See above
 Is the Ductwork System to restrictive?
 Action: See above

Common Baghouse (All Designs: Shaker, Reverse Air, & Pulse Jet) Issues

Many of these issues can be resolved with a simple maintenance procedure; others may require a
qualified service technician to implement a solution a particular problem.

Problem: There is a higher than anticipated Pressure Drop in the Baghouse

 Have all gauges and pressures sensors been checked for accuracy?
 Action: Clean all pressure taps, check houses for leaks, for proper fluid level in Manometer, and
diaphragm in gauge.
 Is the Baghouse the undersized for the application?
 Action: Consider upgrading to a larger unit.
 Is the cleaning mechanism adjusted to the proper settings?
Addition Questions

 Is the cleaning timer working properly?

 Action: Reset the timer. Check wiring, and replace if needed.
 Is the dust not able to be removed from the Filter Bags by the cleaning mechanism?
 Action: Check for condensation on Bags. Dry clean bags, or replace them. Take dust samples and
send them to the manufacturer for analysis.
 Is there excessive reentrainment of dust on the Filter Bags?
 Action: Empty Hopper continuously.

Problem: Dirty discharge at stack

 Are the Bags leaking from either the clamps, or are from being too porous?
 Action: Replace Bags, isolate leaking compartment or module. Allow sufficient filter cake to
form. Check and tighten clamps. Change to a different Filter Bag; smooth out Bag before
clamping.
 Are the seals between the different compartments  (Dirty Air, and Clean Air Compartments) of
the Baghouse leaking?
 Action: Repair by caulking or welding seams.

Problem: Moisture in the Baghouse

 Is the Baghouse temperature below the dew point?

 Action: Raise gas temperature; insulate unit.

Additional Questions

 Are there any cold spots where pipes or other components connect?
 Action: Eliminate direct metal line through insulation.
 Has the Baghouse been sufficiently preheated (Certain applications only)?
 Action: Run system with hot air only before process gas is introduced.
 Is the system purged properly after each shutdown?
 Action: Run fan for an additional 10 min after processing is shut down.

Problem: Material is bridging in the Hopper, thus preventing proper operating of the Baghouse

 Is there excess moisture in the Baghouse?

 Action: (See previous solutions)
 Does the Hopper retain too much material, or is it cleaned on a regular basis?
 Action: Clean Hopper on a regular schedule.
 Is the Hopper slope sufficient to allow for the collected material to fall?
 Action: Redesign and replace.
 Is the opening for the Screw Conveyor (Or similar device) of adequate size?
 Action: Redesign and replace.
Problem: The Bags fail prematurely, or wear or faster than they should

 Is the Baffle Plate worn out?

 Action: Replace with a new Baffle Plate; Determine whether the Gas stream is striking the Baffle
Plate correctly, if it is not, consult with the manufacturer, redesign and replace.
 Is the dust load to high for the particular Baghouse, or Bags?
 Action: Install a Primary Dust Collector (Pre-Filter) to reduce dust loads to the Baghouse.
 Are the Bags being cleaned at the proper intervals?
 Action: Clean less often.

Baghouse Design Specific Problems

The most common variations in Baghouse design regard the cleaning mechanism.  The three
most common are Shaker, Reverse Air, & Pulse Jet. While the proceeding information applies to
all Baghouse designs, the following covers specific design related problems.

Shaker Baghouse Type Specific Issues

Problem: Cleaning Mechanism Does Not Function Properly

 Does Shaking action take place, as it should?

 Action: Check pins, Keys, Bearings, Etc and repair if necessary.
 Is the Shaking action strong enough?
 Action: Increase Shaking rate.
 Have the Filter Bags been checked to have proper tension?
 Action: Tension Bags to proper rate.
 Are any other Baghouse functions affected when Shaking process begins (Fan, or Isolation
Dampener, etc)?
 Action: Repair Isolation Damper, or stop Fan.
 Are the different compartmental isolation dampener valves functioning properly?
 Action: Check linkage, Valve Seals, and Air supply of the Pneumatic Operators.
 Is the cleaning cycle set to the proper interval?
 Action: Set to the shortest interval possible between compartments.
 Is the Air to Cloth Ratio at least 3:1?
 Action: Add Bags; Consider installing a larger unit.

Problem: Filter Bags fail prematurely

 Is the shaking mechanism set too high?

 Action: Slow down shaking mechanism.

Reverse Air Baghouse Type Specific Issues

Problem: Cleaning Mechanism Does Not Function Properly

 Are the different compartmental Isolation Dampener valves functioning properly?

 Action: Repair if necessary.
 Do the Bags have the proper amount of tension?
  Action: See above.
 Is the Reverse Air Fan powering up/running properly?
 Action: Run Fan and check differential pressure.
 Does the Reverse Air Fan spin in the correct direction?
 Action: See section:  Blower (Fan) & Ductwork Issues
 Is the Air to Cloth Ratio at least 3:1?
 Action: Consider acquiring a larger Baghouse.

Plenum Pulse Jet Baghouse Type Specific Issues

Problem: Cleaning Mechanism Does Not Function Properly

 Is the air pressure at the Pulse Valves within the recommended levels and are all Solenoids and
Diaphragms operating properly?
 Action: Check for leaking solenoids and pulse valves; check compressed air source and check
differential pressure.
 Are the cleaning pulses at set to the correct duration (0.1 sec)?
 Action: Reset to 0.1 sec.
 Is cleaning interval at the lowest setting the will allow air manifold pressure to rebuild?
 Action: Change setting, and check the differential pressure.
 Do all poppet valves seal properly?
 Action: Adjust and/or repair all valves and check differential pressure.
 Is the Air to Cloth Ratio at least 4:1?
 Action: Switch to pleated media; Consider installing a larger unit.

Pulse Jet Baghouse Type Specific Issues

Problem: Cleaning Mechanism Does Not Function Properly.

 Is the manifold pressure within the manufacturer’s suggested range?

 Action: Check for leaks at the solenoids and pulse valves; Check compressed air source and then
check differential pressure.
 Are the cleaning pulses at set to the correct duration (0.1 – .015 sec)?
 Action: Set to 0.1 – 0.15 duration.
 Is cleaning interval at the lowest setting the will allow air manifold pressure to rebuild?
 Action: Change setting and check differential pressure.
 Is the compressed air pressure at the proper level?
 Action: Check for leaks; Increase pressure.
 Is the Air to Cloth Ratio at least 6:1?
 Action: Switch to pleated media; Consider installing a larger unit.