OPERATION & MAINTENANCE MANUAL

FOR
FABRIC FILTERS/BAG HOUSES

Bibhas Kumar Dey

15th November 2023

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Contents
1.1 INTRODUCTION 3

1.2 COMPONENT DESCRIPTION 6

1.2.1 CASING 7
1.2.2 HOPPER 7
1.2.3 SUPPORT STRUCTURE 7
1.2.4 GUARD RAILING 8
1.2.5 WEATHER ENCLOSURE & STAIRCASE 8
1.2.6 ROOF HATCH 8
1.2.7 AIR MANIFOLD 8
1.2.8 CLEANING CONTROL 9
1.2.9 SEQUENTIAL TIMER LOGIC OF PULSE CLEANING 9
1.2.10 FILTER BAGS & BAG CAGES 10
1.2.11 CLEANING AIR UNIT 10
1.2.12 DUST DISPOSAL ARRANGEMENT 10

1.3 OPERATION 11
1.3.1 PRE-START-UP 11
1.3.2 START-UP 13
1.3.3 ADJUSTMENT/CHECK-UP DURING OPERATION 15
1.3.4 SHUTDOWN 17

1.4 ROUTINE INSPECTION 20

1.4.1 DAILY INSPECTION 20
1.4.2 MONTHLY INSPECTIONS 20
1.4.3 QUARTERLY INSPECTIONS 20
1.4.4 YEARLY INSPECTIONS 20

1.5 MAINTENANCE 21
1.5.1 MAINTENANCE OF FILTER BAGS 21
1.5.2 MAINTENANCE OF PULSE VALVES 23
1.5.3 MAINTENANCE SCHEDULE 24

1.6 TROUBLE SHOOTING 25

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 1.1 INTRODUCTION
Fabric filter designs vary considerably depending on supplier,
application, and size. To clarify the function of the term fabric filter
and fabric filtration below general description may be of some help.

"Fabric filtration" is the use of a textile fabric to separate

particles from a gas stream so that particles are retained on or
in the fabric as defined by the Industrial Gas Cleaning Institute
(IGCI).

Fabric filters can be classified according to many different criteria,

configuration, cleaning method, shape of fabric etc. Below summarizes
the most common criteria.

i. Cleaning method: Pulse Jet, Reverse Air, Shaker

ii. Cleaning condition: On-line, Off-line
iii. Direction of gas flow: Outside to inside, inside to outside
iv. Shape of filter fabric: Bag, Envelope
v. Filtration velocity: High, Low

A Pulse Jet Fabric Filter may be cleaned on-line or off-line. The filter
media is normally shaped as bags with the gas flow direction from
outside to inside. The filtration velocity is compared to reverse air
cleaned filter regarded "high". These filters are called High Ratio
Fabric Filter (HRFF) and are most widely used in industries across the
world today.

The gas flow, through the filter medium and dust cake with its small
pores, is viscous (low Reynolds number). Consequently, the pressure
drop is proportional to the filtration velocity and the gas dynamic
viscosity. The filter resistance is generally a linear function of the
mass of dust accumulated on the filter during filtration in between
cleanings. The filter resistance can be divided into two parts, namely:

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 i. Residual resistance of the cleaned fabric
ii. Resistance of the dust cake.

The residual resistance of the cleaned fabric depends on several

factors. Below is a list of parameters which increase the residual
fabric resistance:
i. Reduced dust particle diameter.
ii. Decreased bag looseness factor.
iii. Sticky components in gas.
iv. Low cleaning air tank pressure.

The resistance of the dust cake depends on several factors. Below is a

list of parameters which increase the specific dust resistance:
i. Reduced dust particle diameter.
ii. Increased filtration velocity.
iii. Decreased particle cohesion forces.

The flow through the filter casing via inlet and outlet duct with
dampers, in contrast to the flow through the filter media, is turbulent
and not dominated by friction (high Reynolds number). Consequently,
the pressure drop in casing is proportional to the gas density and the
square of the gas velocity.

The dust emission from a fabric filter is normally described because

of:
i. Direct penetration (dust penetrates through the fabric without
being collected).
ii. Seepage (dust, once collected on the bag surface, penetrates
through the fabric later).

Seepage occurs mainly during pulse cleaning due to fabric movement.

Direct penetration is at maximum for cleaned fabric due to high
filtration velocity and minor dust cake. Consequently, the dust

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 emission is strongly related to the cleaning frequency or the cleaning
cycle time.

The bag life depends on the effect of the following factors on the
constituent fibres and coatings, if any:
i. Chemical degradation
ii. Thermal degradation
iii. Mechanical abrasion

The actual bag failure is normally caused either by one of the above
factors or by the compound effect of these factors.

The chemical degradation is caused by contaminants in the gas and

dust. Further the rate of degradation is influenced by the
temperature. For instance, a temperature peak that is not severely
harmful, could accelerate the chemical degradation and thus cause
substantial damage.

Mechanical abrasion could be separated into blasting on the surface,

internal wear due to fines penetrating the fabric, and abrasion
between fabric and bag cage.

Chemical degradation of the fabric progresses at an exponentially

decreasing rate, whilst the mechanical damage is accumulative and
proportional to the number of flex cycles and time of exposure from
erosion and abrasion from dust particles.

Each type of fabric and fibre has its susceptibility to chemical attack.
Common to most synthetic fibres, however, is the acceleration of the
degradation with the temperature.

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1.2 COMPONENT DESCRIPTION
Pulse Jet Fabric Filter consists essentially of an airtight casing
containing filter bags, bag cages, hopper, dust discharge equipment,
compressed air cleaning system and an electronic pulse controller.
The compressed air cleaning system consists of a main header and
branch headers (nozzle pipes) with an opening for each bag. Each
nozzle pipe is fitted with an angle type diaphragm valve with integral
solenoid operator controlled through electronic controller for pulsing.

SCHEMATIC DIAGRAM OF ON-LINE PULSE JET FABRIC FILTER

TYPICAL CONSTRUCTION - OFF-LINE PULSE JET FABRIC FILTER

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1.2.1 CASING

The filter casing is generally fabricated of mild steel plates and

reinforcements and is of all welded construction. The casing is
divided into two sections. The upper and lower sections are separated
by the bag holding plate (tube sheet). The upper section houses the
nozzle pipes. This is also the clean air chamber of the filter.

The clean air outlet is flanged on one side of casing upper section.
Another side of the upper panel is having required number of round
openings for connecting nozzle pipes with air manifold tank through
distance pipe and solenoid valve. The lower section of the casing from
bag holding plate houses the filter bags and bag cages.

1.2.2 HOPPER

Bag filter is provided with either pyramid hopper or trough hopper

based on size, geometry, and layout. The hopper is a transition piece
to convey the dust collected from the bags to the dust handling
equipment for further processing/storage/disposal. Hoppers in Bag
Filters should not be used as Storage Hoppers. Care should be taken
by proper maintenance system and alarm systems vide Dust level
indicators to avoid dust accumulation in Hoppers. Hoppers are also
equipped with suitable devices to prevent dust build-up and eventual
choking like pneumatic hammers or fluidization system at the bottom
of the hopper.

1.2.3 SUPPORT STRUCTURE

The Support Structure comprises members of legs, horizontal and

diagonal bracings fabricated out of mild steel rolled sections.

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1.2.4 GUARD RAILING

Since the filter top is used for maintenance purposes, protective

railing which surrounds the top of the nozzle house / clean air
chamber is provided. It is manufactured of steel tubes and is
delivered in parts to be fitted and welded together at erection.

1.2.5 WEATHER ENCLOSURE & STAIRCASE

This is provided so that maintenance of the filter can be carried out in

any weather conditions especially during monsoon when there is
continuous rain over a long period. The height depends on the filter
bag length. The ventilation is normally made by natural draft. It is
accessed through a staircase.

1.2.6 ROOF HATCH

Servicing of bags and cages is done from the top of nozzle house where
roof hatches are provided. They are clamped on top with the help of
nuts and bolts and channel which is welded with two side plates.
Leakage is prevented using gaskets.

1.2.7 AIR MANIFOLD

It is placed by the side of the casing upper part by brackets. Solenoid

valves are placed on the top of the air manifold, and they are easily
accessible from the top of the nozzle house. The air manifold tank is
provided with 25 NB female sockets at either end, one socket is used
for compressed air connection and the other for safety valve. The
compressed air supply pressure should be adjustable between 5-7 bar
depending on application.

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1.2.8 CLEANING CONTROL

The cleaning function is controlled by the Sequential Timer which is

suitable for mounting on the wall or on the base plate of the panel.
The bag cleaning sequence is time or DP controlled. The pause time
can be set between 10 sec and 16.5 min. The activating time can be
set between 10 and 990 milliseconds.

1.2.9 SEQUENTIAL TIMER LOGIC OF PULSE CLEANING

The system shall have an AUTO/MANUAL key. When the key is

selected for MANUAL, then individual channel shall be purged by
pressing the manual pulsing switch.

In AUTO, there shall be two modes of operation, namely ‘CYCLIC’ and

‘DP’ where the DP mode shall be an optional mode. Each group shall
receive separate command inputs from CCR for the sequence start up
in Auto mode.

1.2.9.1 CYCLIC MODE

In this mode, the sequence shall be initiated by remote ON command

and the sequence shall continue irrespective of DP. On energising the
last solenoid valve, another sequence shall be initiated automatically
& the operation continues likewise till such time the power supply to
the timer is ON.

1.2.9.2 DP MODE

In this mode, the Differential pressure switch contacts are connected

to the unit. The system shall use two contacts i.e., DP LOW and DP
HIGH. Purging shall stop when DP LOW contact opens and only
resume when the same contact is closed i.e., when the pressure is
normal. When DP is high & DP HIGH contact is closed, then the timer

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shall go in crash mode and purging shall be fast at pre-selected
timing, which shall be programmable.

1.2.10 FILTER BAGS & BAG CAGES

Filter bags are the heart of Bag Filter. Fabrics suitable for the
application are stitched in the form of cylindrical bags closed at one
end and open at the other. At the open end a special arrangement is
made so that bags can be snapped in at the holes of bag holding plate
and hang freely.

To prevent the collapse of the bags due to suction, bag cages of

longitudinal wires and transversal rings are provided inside the bags.
They are hung freely and separately from bag holding plate so that
weight of cage does not act on the filter bags.

1.2.11 CLEANING AIR UNIT

The compressed air should be free from water and oil as much as
possible (Instrument grade). In case the compressed air from existing
supply or separate compressor does not meet the demands on purity,
a cleaning air unit which is an optional item should be connected
before the air manifold of the filter. The cleaning air unit is available
with different capacities. The cleaning air should be located indoors,
if possible, as near to the air manifold of the filter as possible and is
connected before compressed air enters manifold.

1.2.12 DUST DISPOSAL ARRANGEMENT

Bag Filter is provided with two different types of hoppers of different

sizes. For discharge of the dust from pyramid hopper suitable rotary
air lock valve is provided. While for trough type hopper a screw
conveyor with a rotary air lock valve is provided.

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 1.3 OPERATION
Operation of bag filter is divided into four phases:

i. PRE-START-UP
ii. START-UP
iii. ADJUSTMENT DURING OPERATION
iv. SHUTDOWN

1.3.1 PRE-START-UP

1.3.1.1 SAFETY PROTOCOLS DURING START-UP

i. Ensure that no repairs or maintenance works are in progress and

all inspection doors are closed properly.
ii. Ensure that the compressed-air system is turned on and the same
meets the requirements specified.
iii. Ensure that the pressure switch of the compressed-air cleaning
system is set correctly.
iv. Ensure that safety switches are ON.
v. Ensure that all switch gear groups are ON.
vi. Ensure that all pre-determined set-point values in all instruments
(Differential Pressure Switches, Differential Pressure Transmitters,
Pressure Switches, Temperature Transmitters, RTDs, Limit
Switches, Level Switches, and Sequential Timers etc.) are set
correctly.
vii. Ensure that the pulse cleaning system is turned on.
viii. Ensure that the product silo can receive dust (check the level).
ix. Ensure that the filter compartments are online.

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 1.3.1.2 CHECKLIST OF ACTIVITIES DURING START-UP

i. Check and ensure that inlet duct is clean as well as the Fabric
Filter gas entry and bottom hopper. Hopper walls must be smooth
and free from any left-over debris.
ii. Check that there are no obstructions at Hopper Outlet.
iii. Check tightness of inlet dampers, operate, and adjust operation
speed to achieve a smooth movement.
iv. Check and ensure that the nozzle house is cleaned with a vacuum
cleaner and no debris is left over.
v. Check and ensure that all filter bags are correctly mounted on the
tube sheet and there is no gap between the snap-in collar of the
filter bags and tube sheet hole.
vi. Check and ensure that nozzle pipes tubes are fixed properly and
the blow holes in the tubes are aligned concentrically with the filter
bags.
vii. Check and ensure that sealing for inner cover has no damage.
When putting the cover in place, check that the sealing is proper,
and it is gas tight.
viii. Check and ensure that the cleaning of outlet duct and tightness of
the outlet dampers and eventual by-pass dampers. Adjust
operation speed to achieve a smooth movement. Note that to
ensure good sealing the cylinder in outer position should have
approx 5 mm left of stroke.
ix. Check and ensure the gas-tightness of the air manifold and pulse
valve units. Fill the tank to a pressure of 2 bar, close the inlet valve
to the tank and observe the pressure decrease. If the decrease is
less than 0.5 bar in one minute, it is ok. If the decrease is more
than 0.5 bar in one minute, try to detect which valve has higher
leakage. Dismount the valve, check the components, and mount it
again after due rectification, if any. Note that the overall sealing
will improve after some time in operation.

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 x. Put the main switch of the sequential timer unit in position “ON”
and check the opening and closing of the valves. By closely
listening to the sound from the valve, it is possible to find faulty
ones. If necessary, dismount the faulty valve, check the
components, and mount it again after due rectification, if any.
xi. Check and ensure that all the heating elements for hoppers are
installed and working. The heaters should be working for at least
24 hours prior to start-up.
xii. Check and ensure that there are no leakages in the in-coming
compressed air pipes, check valves, filter-regulator/lubricator unit
etc upstream of the bag filter.
xiii. The compressed air for the cleaning is available at desired pressure
(5 – 7 bar) and required quality. The compressed air supply should
be free from dust moisture and oil as far as possible (maximum 10
gm of moisture/m3 + and 0.02 gm of oil/m3 of free air.
xiv. The Air Receiver dedicated for pulsing of Bag Filter, if any,
indicates correct pressure of 8-10 bar.
xv. Manual/Motorized Slide/Knife Gates are working smoothly.
xvi. The rotary airlock valves are working smoothly.
xvii. The Double Dump Valves, if any, are working smoothly.
xviii. The screw conveyors, if any, are working smoothly.
xix. The Chain Conveyors, if any, are working smoothly.
xx. Pneumatic Conveying System, if any, is working smoothly.
xxi. The ID fan/fans downstream of bag filter is/are working normally.

1.3.2 START-UP

The instructions below should be followed to maximise the filter bag

life. The procedures imply that the amount of moist, acidic, and sticky
dust collected on the filter bags during the start-up phase is
minimised. The dust cake left on the filter bags (dust cake from pre-
coating or dust left on the bags when the fabric filter was taken out of
operation) additionally protects the filter bags.

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 i. Verify that all measures before start-up have been taken.
ii. Check and ensure that the gas temperature is at least 10 °C above
the dew point.
iii. In case the gas temperature is close to or below the dew point, all
measures shall be taken to rapidly raise the gas temperature to the
recommended level.
i. Start the dust conveying system i.e., the rotary feeder/ Double
Dump Valve/screw conveyor/ Chain Conveyor/Pneumatic
Conveying System.
ii. Start the ID fan.
iii. Start the compressed air supply to the air manifold.
iv. Put the main switch of the sequential timer for pulse cleaning unit
in “ON” position.

1.3.2.1 PRE-COATING OF THE FILTER BAGS

When the filter bags are new, the gas can easily pass through the
fabric. The resistance to the gas flow, however, will increase gradually.
To achieve a cost-effective operation, low emission of unwanted matter
and long service life, it is important that the filter bags are deployed in
a correct way. The filtration effect is achieved by the combination of
bag material and solids.

Follow the procedure specified below to provide the bag material with
a 'filling' of solids, uniformly distributed across the bag surface:

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 i. Switch off the bag cleaning system.
ii. Air is drawn through the filter by means of the ID-fans
through the opened manholes upstream in the ducting
from the place where the lime is blown in.
iii. Lime of the type of Ca (OH)2 is blown into the duct
upstream from the bag filter.
iv. The rate of airflow shall be as high as possible for the lime
to be carried with the air and distributed among the bags
and deposit a protective layer of limestone dust.
v. Start the process equipment.
vi. Start the filter as described before in the start-up section.
vii. Start the bag cleaning.

NOTE:
The Filter bags should be pre-coated with slaked lime.
The pre-coating is done with an I.D. fan in operation and
at approx 60 % of normal gas flow. Recommended dosage
of lime: 300 g/m2 of filter surface.

1.3.3 ADJUSTMENT/CHECK-UP DURING OPERATION

i. Check whether there is any leakage at flange

connections/door seals etc.
ii. Check that the suction fan functions normally. Note
down current drawn by the motor, bearing vibration and
lubrication.
iii. Check whether the u-tube manometer indicates the
normal pressure drop over the filter bag, typically,
between 120 mm WC to 150 mm WC.
iv. Check whether the dust concentration in the cleaned gas
is abnormally high. A good indication is obtained from
the colour of the discharged gas. Accurate information
can be obtained from opacity monitors, if installed.

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 During the starting phase of operation, it is checked whether the plant
functions properly and necessary adjustments are made to attain the
desired cleaning effect. The demand on the cleaning equipment to
obtain the desired results is mainly based on:
i. Type of dust in the plant
ii. Dust concentration
iii. Desired pressure drop across the bags.
iv. Desired collection efficiency

It is practically impossible, as a rule, to calculate and set the time

interval between the cleaning sequences or determine the required
pressure in the air manifold in advance.

These parameters must often be adjusted by experience during the

start-up period. It should be noted that a steady condition of the filter
material cannot be obtained immediately. The pressure drop reading
on the U-tube manometer remains, as a rule, very low during start-
up. This is also the case after changing the filter bags. It may take
several weeks before a steady condition is achieved.

However, a too low pressure drop across the filter bags is adjusted by
increasing the time interval between two consecutive cleaning pulses
or by reducing the pressure in the manifold. And similarly, a too high-
pressure drop is adjusted by decreasing the time interval between two
consecutive cleaning pulses or by increasing the pressure in the
manifold. When the desired cleaning efficiency is attained, the set
values of pressure drop, manifold pressure and timing sequence are
noted in the operational Logbook for future adjustments after
changing of filter bags or after repair work.

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 1.3.4 SHUTDOWN

During both short and extended shutdown of the operation, the

heating equipment shall normally be kept turned on. It is also
important that inspection doors are kept open as little as possible to
prevent ingress of ambient air inside the bag filter.

1.3.4.1 *SHUT DOWN FOR SHORT PERIOD (<1 WEEK)

During short shut-down, the dust cakes may be allowed to remain on

the filter bags which means that the bags do not need to be pre-coated
before restarting the plant.
i. Turn off the main switch of the pulse control unit at an early stage
of the shut-down phase (the fabric bags will now be coated with a
layer of dust).
ii. During the shut-down phase switch to by-pass mode when the flue
gas temperature has dropped to 10°C above the acid dew point.
iii. Turn off the ID-fans by activating the stop sequence.
iv. Turn off the pulsing by activating the stop sequence in the timer.
During stoppages for less than 1 week, the dust discharge and heating
equipment shall normally remain in operation.

1.3.4.2 SHUT DOWN FOR LONG PERIOD (>1 WEEK)

When the plant is shut down for an extended period, the shutdown
sequence will be same as above except the following:
i. After the complete evacuation of flue gas from the Bag Filter and
switching off the ID Fans, initiate 5 cleaning cycles for the fabric
filter (done manually from the pulse control unit).
ii. Switch off the Dust handling equipment only after manually
inspecting the hopper and ensuring there is no dust left.

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 1.3.4.3 ISOLATION OF SINGLE FILTER COMPARTMENT

For shorter inspections or emergency reasons it is possible to isolate a

section of the Fabric Filter. In general, only one compartment at a
time should be closed and the closing time should be as short as
possible to minimize the temperature decrease in the closed
compartment.

The Fabric Filter itself accepts higher A/C ratio but to maintain the
upstream process and to keep the low emission a reduction of the gas
quantity to the filter before closing a compartment is advisable. The
procedure is as follows:
i. Reduce gas volume to a level corresponding to remaining filter size.
ii. Stop filter cleaning in the actual compartment by closing the shut-
off valve. Reduce the pressure in the tank for example by initiating
one pulse.
iii. Close outlet damper for the said compartment.
iv. Close inlet damper for the said compartment.
v. Close damper at Hopper outlet for the said compartment.
vi. Lift the upper (insulation) cover and place it on a nearby cover.
vii. Open the pressure balance door.
viii. Lift the inner cover and place it above the upper cover.
ix. When taking the compartment into operation again the procedure
is the opposite.
x. Before opening the inspection door in bottom hopper do always
check dust level in hopper. Don't stand in front of the door when
opening; always use protection equipment to avoid direct contact
with dust.
IMPORTANT:
1. DRIVES OF ROTARY AIRLOCK VALVES/SCREW
CONVEYORS/CHAIN CONVEYORS OR ANY OTHER DUST
DISCHARGE SYSTEM AND MOTORS OF ID FANS SHOULD BE

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 INTERLOCKED SO THAT THE FANS CANNOT BE STARTED
WITHOUT STARTING THE DUST DISCHARGE SYSTEM.

2. THE DUST DISCHARGE SYSTEM MUST BE ALLOWED TO RUN

FOR AT LEAST HALF AN HOUR AFTER THE FAN IS STOPPED
TO ENSURE COMPLETE EVACUATION OF DUST FROM
HOPPER.

3. BAG FILTER SYSTEMS SHOULD BE IN OPERATION A FEW

TIMES EVERY DAY DURING LONG SHUTDOWN PERIOD TO
AVOID CLOGGING OF THE FILTER BAGS.

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1.4 ROUTINE INSPECTION
1.4.1 DAILY INSPECTION

i. Check the clean gas flow through the inspection window.

ii. Check the pressure drop across the filter bags.
iii. Check the cleaning functions.
iv. Make sure that all solenoid valves work normally.
v. Check functioning of dust conveyors.

1.4.2 MONTHLY INSPECTIONS

i. Inspect the tightness of the inspection windows, service

doors etc.

1.4.3 QUARTERLY INSPECTIONS

i. Check the lubricants in the bearings of all rotating

equipment.

1.4.4 YEARLY INSPECTIONS

i. Make a thorough check up of the general condition of the

filter.

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1.5 MAINTENANCE
To avoid disturbances in the operation of the Fabric Filter it is of
greatest importance that inspection and service is made regularly.
This will minimize the risk of sudden shutdowns and reduce the
overall cost for the maintenance.

1.5.1 MAINTENANCE OF FILTER BAGS

The nozzle house is equipped with service doors on the roof of the
nozzle house. Dust emissions from damaged or worn-out filter bags
are easy to locate through service doors. By means of the bag
shutters, defective filter bags (up to 10% of the total number) can be
shut off during a short shutdown. The change of filter bags can thus
be postponed to a reasonably major shutdown.

The shut off and exchange of defective filter bags is made from the
clean gas side of the filter through the removable service doors on the
roof of the nozzle house. Remove the nozzle pipe. Take out the bag
cage. Disengage the filter bags from Bag Holding Plate by pressing the
snap band. Pull the bags gently out. To avoid a too heavy load on
other bags, the bags which were shut off due to faults should be
changed at the earliest opportunity.

1.5.1.1 CAPPING & REPLACEMENT OF FILTER BAGS

An increase in emission is normally an indication that there is bag

damage. The compartment in which the damaged bag is located
can normally be found by closing one compartment after another
and watching the emission at same time.

Within the compartment dust build-up around the filter bags on

the surface of the tube sheet normally indicates which bag has
failed. The corresponding filter bag is capped off by a bag-cap.

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 Before capping, the whole bag plate should be cleaned from dust to
minimize the dust emission and to make future bag failure
detection easier.

Up to 10 % of the total number of bags can be capped off in that

way. When 10 % filter bags are capped off, all filter bags should
be changed during a planned shut-down.

1.5.1.2 HANDLING OF NEW FILTER BAGS

i. Filter bags must always be weather protected even during internal

transport and must be kept indoors in dry conditions. They must
be protected from possible damage by rats.
ii. Packing must not be damaged during handling. It shall be open
only during installation.
iii. No welding is allowed on or in the filter casing after installation of
bags without special permission and with special supervision.
iv. Bags should gently be inserted in bag plate to avoid damage.
v. Longitudinal seams should be placed to the opposite direction of
the incoming gas stream to avoid direct impact and eventual
damage.
vi. Be sure that the position of bag top is correct relative to the cell
plate and that bag snaps in along the whole circumference.
vii. The bag cage should be gently inserted in the bag.
viii. When the installation in one nozzle house is interrupted or
finished, always put the top cover in place.
ix. The changing of the filter bags is made with I.D. fan in operation
giving a slight under pressure in the compartment.

1.5.1.3 REPLACEMENT OF FILTER BAGS

i. Close inlet and outlet damper to the compartment and lift covers as
said above.

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 ii. Clean and remove all nozzle tubes.
iii. Avoid walking on top of bag cages.
iv. Take out the bag cages. Vacuum clean the bag cages.
v. Take out the filter bags.
vi. Vacuum clean the tube sheet surface.
vii. Install the new filter bags correctly and properly with bag collar
snapped in with the tube sheet.
viii. Insert the bag cages gently into the filter bags.
ix. When all filter bags and bag cages are installed, vacuum clean the
nozzle house once again.
x. Replace the top covers.
xi. Open the inlet and outlet dampers.

1.5.2 MAINTENANCE OF PULSE VALVES

The function of the Fabric Filter pulse system is in general

controlled by the FF control system. The FF control system
controls that a pulse is given within a certain time. An alarm
triggers if there is a problem in the compressed air pressure.

The best way to control the function of individual valves is to listen

to the valve when it is pulsing. A good working valve should have a
sharp hard pulse. The pulse valves should be checked regarding
any damage and abnormal wear at regular intervals. The following
steps are to be followed while checking the pulsing system:
i. Disconnect the supply voltage to the valve. Check that the air
manifold pressure is released.
ii. Take out the valve assembly.
iii. Replace the valve assembly in the manifold.
iv. Supply voltage line is reconnected to the valve. Then check the
valve function by starting the electronic control unit.

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1.5.3 MAINTENANCE SCHEDULE

Object/Action Frequency
Ductwork
 remove dust assemblies. Once a year
 check for corrosion signs. Once a year
 check compensators Once a year

Fabric Filter
 check cleaning system regarding pulsing Once a day
frequency, pulse tank pressure, pulse
valve operation.
 check sealing of inner cover Once a month
 check operation of in- and outlet damper Once a month
 check inside of nozzle house, signs of Once a month
penetrated dust, fixation of nozzle tubes.
 check hopper, dust assemblies, level Twice a year
indicator, signs of condensation, filter
bags hanging
Conveying system
 conveyors in general Once a week
 stuffing boxes tightness and lubrication Once a week
 chain or belt stretching Once a week

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1.6 TROUBLE SHOOTING
Sl. No. Incident Remedial Action
1 Low pressure of Check the comp. air system
compressed air to the for leaks, valve positions etc.
cleaning system. Check the pressure switch.
Check for leaking pulse
valves.
2 Pulse valve has not opened Check pulse valves.
mechanically, cleaning
pulse too short.
3 Tank pressure hysteresis Check hysteresis.
is too high in relation to
pulsing.
4 Fault in the Sequential Power failure/Master switch/
Timer. PLC may be in OFF position -
turn to ON.
5 Low current consumption Blown fuse or faulty element -
by the heating elements at replace as required.
the bottom hopper outlet.
6 High dust level in bottom Check the dust discharge
hopper. System is working properly.
Check the heating in the
hopper is turned on.
Inspect, clean and empty
hopper as required.
8 High-High temperature at Open dilution damper, if any.
the fabric filter inlet. The
fabric filter is going to by-
pass operation.
9 Sequential Timer is not Check for blown fuse.
working, when power is
switched on.
10 Sequential Timer does not Check the selector switch for
recycle at the point set by loose connection.
selector switch or open
connections.
11 Sequential Timer is Either the display or display
working fine but display driver IC may be faulty.
gives faulty reading. Replace them.

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12 Sequential Timer Display The IC or power supply may
changes cycle but output be faulty.
states do not work.
13 One output channel of Corresponding driver
Sequential Timer does not transistors may be faulty.
work.
14 Worn gaskets causing
Regularly inspect all gasketed
leakage joints and replace if required.
15 Damaged bearings Replace with available spares.
16 Unwanted vibrations
Check all machines for
causing damage. abnormal noise and
vibrations.
17 Over-heating of rotating Check all drives and motors
equipment. for abnormal heat. An
overheating motor or conveyor
gearbox may point to
accumulation of dust.
18 Pneumatic cylinders for Check all air operated pistons
actuation of dampers are (dampers) for leakage.
not working properly.
19 Too high/too low pressure Check all pressure vessels for
in Air receiver. abnormal pressure.
High Outlet Emission caused by:
20 Bag Rupture a. Initiate a short shutdown
for inspection of filter bags.
b. If it is observed that dust
layer exists on the “CLEAN
SIDE” around some bags, it
indicates that those bags
are damaged.
c. Replace the damaged bags
with new filter bags.
d. If more than 10% of bags
are found worn out it is
advised that all bags
should be replaced.
e. Check the temperature of
incoming gas whether it is
within the specified range
for the fabric of bag.

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High Pressure Drop caused by:
21 Inadequate Bag cleaning. Check the pulsing sequence in
the PLC/DCS/Timer Panel.
22 Longer Pause time between Reduce pause time (Range 5
successive Pulsing. sec to 30 sec) or increase
Pulsing time (100 milliseconds
23 Pulse duration may be too to 400 milliseconds) on trial
low. basis and continue changing
until acceptable DP is
achieved.
24 Pulse valves are not working Check the pulse valves
properly. particularly the diaphragm to
ensure that it is in perfect
working condition.
25 Solenoids are not getting Check whether the power and
power/signal. control cable connections of
the pulse valves are in perfect
order.
26 Compressed air pressure and Check the compressed air
volume is not adequate. pressure and fluctuation of
the same with the pressure
gauge mounted on the air
manifold and ensure that it
never goes below 4 bar.
27 Compressed air may contain Check whether the Air Drier
moisture and oil which could and oil filters installed up-
be blinding the filter bags. stream of the bag filter is
working perfectly and the
compressed air which is
coming to bag filter is dry and
oil free.
28 Leakage of comp. air in the Check the Pulse Piping
Pulse piping system. connections (Air manifold,
Pulse Valves, Blow tubes,
Quick Coupling, Unions, and
Sockets etc.) are without any
leak as this is a very leak-
prone area.
29 Flue gas may contain high Check with process regarding
dust load which is developing the trend of the dust load for

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 of thicker dust cake within a
very small period.
30 Bag filter might have gone
into the Dew point regime
during fluctuation in the
process parameters which
might have caused
condensation inside the bag
filter and choked the bags in
the recent past.
31 Flue gas volume may have
increased which in turn
increases the CAN velocity
inside the filter.
32 There may be leakages in the
ducting at upstream of the
bag filter or leakages in the
bag filter casing or hopper
which allows ingress of
moisture inside the bag filter
and chokes the filter bags.
33 The hopper may be full of
dust, which is being churned
due to turbulent gas flow at
filter inlet which is re-
entering the stream and
increasing the apparent dust
load.
34 The filter bags may be
partially or fully clogged by
moist dust.
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past few weeks.
Check with process regarding
the trend of the flue gas
temperature and look for any
excursion in the dew point
regime.
Check with process regarding
the trend of the flue gas
volume for past few weeks.
Check the ducting upstream
of the bag filter for any
leakage due to corrosion,
erosion, or abrasion. If found,
seal the same with patch
welding. Also, double check all
the flanged joints. If required,
re-gasket all the flanges.
Check whether the RAV/
Screw Conveyor or any other
dust discharge equipments
are functioning normally and
the level switches are
providing accurate signal
regarding the dust level in the
hopper.
Inspect all filter bags and look
for any clogging in the filter
media. If the clogging is less
severe, cleaning with comp.
air jet will be able to restore
the bags. However, if it is
severe (cemented due to oil,
moistures etc.) replacing the
filter bags will be only option.