AGI Dust Collecting System Maintenance Manual

AGI
Brand
AGI
Model
Dust Collecting System
Type
Maintenance Manual
Read this manual before using product. Failure to
follow instructions and safety precautions can
result in serious injury, death, or property
damage. Keep manual for future reference.
Part Number: 8210-00038 R0
Revised: February 2023
Original Instructions
Dust Collecting System
System Balancing and Maintenance Instructions
1
FAX 402-245-5196 www.airlanco.com
AIR FILTRATION
SYSTEM
BALANCING
MANUAL
312 SOUTH HWY. 73, PO BOX 398
FALLS CITY, NE 68355-0398
800-500-9777
Revision date 06/05/2008
2 8210-00038 R0
DUST COLLECTING SYSTEM
DUST COLLECTING SYSTEM
8210-00038 R0 3
CONTENTS
1. Introduction ............................................................................................................................................ 4
2. Safety....................................................................................................................................................... 5
2.1 Safety Alert Symbol and Signal Words...................................................................................... 5
2.2 General Safety Information....................................................................................................... 5
2.3 Fan Safety .................................................................................................................................. 6
2.4 Drives and Lockout/Tagout Safety ............................................................................................ 6
2.4.1 Electric Motor Safety.................................................................................................. 7
2.5 Personal Protective Equipment................................................................................................. 7
2.6 Safety Equipment ...................................................................................................................... 8
3. Fundamentals of Dust Collecting System .............................................................................................. 9
3.1 System Components.................................................................................................................. 9
3.2 System Terminology ................................................................................................................ 11
3.3 Basic Calculations .................................................................................................................... 13
3.4 Field Test Sheet ....................................................................................................................... 14
4. System Balancing .................................................................................................................................. 15
4.1 Balancing the Aeration System ............................................................................................... 15
4.2 Measuring the Pressure Drop ................................................................................................. 16
5. Maintenance ......................................................................................................................................... 17
5.1 Maintenance Safety ................................................................................................................ 17
5.2 Dust Collecting Hoods and Air Flow Control Gates ................................................................ 17
5.3 Ductwork ................................................................................................................................. 18
5.4 Fans.......................................................................................................................................... 18
5.5 Dust Collectors ........................................................................................................................ 19
5.6 Contact Information ................................................................................................................ 19
6. Troubleshooting.................................................................................................................................... 20
4 8210-00038 R0
1. Introduction
The information presented in this manual is intended to familiarize operating personnel with the
fundamentals of dust collecting systems, operation and proper balancing to assure maximum
operating efficiency.
A dust collecting system comprises a number of components, each of which must function in
accordance with the original design criteria. A malfunction in any one part may cause the entire
system to become inoperable.
The following instructions detail these parts, function in the system and the procedure to use to
ensure efficient operation. Make sure original design data and drawings prepared when the systems is
available for reference. Study these to become familiar with the arrangement of duct work, hoods and
other equipment.
The system has been balanced after the original installation was completed. It is important that you
become familiar with “balancing” procedure and have the tools on hand to rebalance when necessary.
Read over all the instruction manuals to become thoroughly familiar with each piece of equipment and
keep recommended spare parts in stock.
1. INTRODUCTION DUST COLLECTING SYSTEM
8210-00038 R0 5
2. Safety
2.1. Safety Alert Symbol and Signal Words
This safety alert symbol indicates important safety messages in this manual. When you see
this symbol, be alert to the possibility of injury or death, carefully read the message that
follows, and inform others.
Signal Words: Note the use of the signal words DANGER,WARNING,CAUTION, and NOTICE with the safety
messages. The appropriate signal word for each message has been selected using the definitions below as a
guideline.
Indicates an imminently hazardous situation that, if not avoided, will result in serious injury or
death.
Indicates a hazardous situation that, if not avoided, could result in serious injury or death.
Indicates a hazardous situation that, if not avoided, may result in minor or moderate injury.
Indicates a potentially hazardous situation that, if not avoided, may result in property damage.
2.2. General Safety Information
Read and understand all safety instructions, safety decals, and manuals and follow them.
• Owners must give instructions and review the information initially and annually with
all personnel. Untrained users/operators expose themselves and bystanders to
possible serious injury or death.
• Use for intended purposes only.
• Do not modify the dust collecting system in any way without written permission from the manufacturer.
Unauthorized modification may impair the function and/or safety. Any unauthorized modification will void
the warranty.
• Follow a health and safety program for your worksite. Contact your local occupational health and safety
organization for information.
• Always follow applicable local codes and regulations.
DUST COLLECTING SYSTEM 2. SAFETY
6 8210-00038 R0
2.3. Fan Safety
• Keep away from fan impeller/blade; high suction can pull a
person toward the inlet. Contact with an unguarded
impeller/blade will cause severe injury.
• Keep the inlet screen in place at all times.
• Remove foreign material from the fan inlet before operating.
• Do not operate the fan if there is excessive vibration or noise.
• When the power is locked out, fans can still be dangerous
because of potential “windmilling.” Always block the
impeller/blade before working on any moving parts.
2.4. Drives and Lockout/Tagout Safety
Inspect the power source(s) before using and know how to shut down in an emergency.
Whenever you service or adjust your equipment, make sure you shut down your power
source and follow lockout and tagout procedures to prevent inadvertent start-up and
hazardous energy release. Know the procedure(s) that applies to your equipment from the
following power sources.
For example:
WARNING
• De-energize, block, and dissipate all sources of hazardous energy.
• Lock out and tag out all forms of hazardous energy.
• Ensure that only 1 key exists for each assigned lock, and that you are the only one that holds that key.
• After verifying all energy sources are de-energized, service or maintenance may be performed.
• Ensure that all personnel are clear before turning on power to equipment.
For more information on occupational safety practices, contact your local health and safety organization.
2. SAFETY DUST COLLECTING SYSTEM
8210-00038 R0 7
2.4.1 Electric Motor Safety
Power Source
• Electric motors and controls shall be installed and serviced by
a qualified electrician and must meet all local codes and
standards.
• Do not modify the magnetic starter. This component provides
overload and under-voltage protection.
• Motor starting controls must be located so that the operator
has full view of the entire operation.
• Locate main power disconnect switch within reach from
ground level to permit ready access in case of an emergency.
• Motor must be grounded.
• Guards must be in place and secure at all times.
• Ensure electrical wiring and cords remain in good condition;
replace if necessary.
SERVICE DISCONNECT
ON
OFF
Lockout
• The main power disconnect switch should be in the locked position during shutdown or
whenever maintenance is performed.
• In the event of unexpected fan shutdown, the fan can be reset using the main power switch
located on the fan or using a reset button when equipped.
2.5. Personal Protective Equipment
The following Personal Protective Equipment (PPE) should be worn when assembling, operating or maintaining
the equipment.
•Safety Glasses
Wear safety glasses at all times to
protect eyes from debris.
•Steel-Toe Boots
Wear steel-toe boots to protect feet from
falling debris.
•Coveralls
Wear coveralls to protect skin.
•Work Gloves
Wear work gloves to protect your hands
from sharp and rough edges.
•Dust Mask
Wear a dust mask to prevent breathing
potentially harmful dust.
•Hearing Protection
Wear ear protection to prevent hearing
damage.
DUST COLLECTING SYSTEM 2. SAFETY
8 8210-00038 R0
2.6. Safety Equipment
The following safety equipment should be kept on site.
•Fire Extinguisher
Provide a fire extinguisher for use in case
of an accident. Store in a highly visible
and accessible place.
•First-Aid Kit
Have a properly-stocked first-aid kit
available for use should the need arise,
and know how to use it.
2. SAFETY DUST COLLECTING SYSTEM
8210-00038 R0 9
3. Fundamentals of Dust
Collecting System
3.1. System Components
A typical system normally consists of the following major items:
Dust Collecting Hoods & Air Flow Control Gates
Dust is generated each time a granular product is disturbed, such as being dropped out of a bin onto a moving
belt, from one belt to another, from a truck or rail car into a hopper, or from an elevator leg into a bin, etc.
Properly designed hoods are installed at each of these points and equipped with an airflow control gate
(normally called a blast gate), which is adjusted to assure that each hood is handling the designed CFM (cubic
feet per minute) of air.
Ductwork
The ductwork collects the dust from a number of hoods and is sized to ensure proper carrying velocity.
When it is necessary to salvage the collected dust because of its value, only one type of dust can be handled per
system at one time. The ductwork may cover a fairly wide area as a result. The main duct gradually becomes
larger to accommodate the increased airflow and hold the air velocity to a reasonable level as each hood is
added. High velocity increases wear on the duct work and increases fan HP. Low velocity results in settling out
of larger particles which may eventually plug the line completely. Duct velocities in the range of 3,500 to 4,500
FPM are typical.
System ductwork is designed for use with a specific number of hoods. The branch line should be capped if a
hood is removed. If it is unlikely that another hood will be installed in the near future in the same general
location, then it may be desirable to remove the branch line all the way to the tee in the main duct and then
put a metal cap over the tee. Install a slide gate in the cap to bleed in sufficient air to maintain a minimum
conveying velocity. A velocity pressure reading should be taken to determine this.
If additional hoods are required at some other point in the system, a check of your ductwork drawing will
determine whether this is feasible. A change in ductwork might be necessary if the hood is to be installed near
the end of the system furthest from the fan. If it is to be installed near the fan, it is not so critical as long as an
airflow control gate is provided and proper balancing is utilized.
System Fan
The fan creates the vacuum necessary within the ductwork and hoods, which cause air to flow inward through
the hood, carrying dust particles with it. Fans are usually driven by an electric motor through a V-belt drive.
Dust Collector
This equipment is installed to separate the dust from the air stream, allowing the clean air to dissipate to the
atmosphere while confining the dust to a single discharge point.
Collectors today are usually assumed to be felt cloth or cartridge filters as opposed to the older cyclonic type of
collector. Filters operate at roughly 99.99% efficiency or better as compared to 80% to 90% for most cyclones.
Efficiency in this case means the percentage of dust removed from the air stream in the collector.
For example: 80% efficiency would mean that 20% of the dust is being emitted to the atmosphere.
DUST COLLECTING SYSTEM 3. FUNDAMENTALS OF DUST
COLLECTING SYSTEM
10 8210-00038 R0
Cloth filter Cyclones
Operates at a fixed efficiency and a fairly constant
pressure drop under normal operating conditions and
when properly maintained. If any malfunction occurs
in the filter that would cause added resistance to the
air flow, less air will be handled by the individual
hoods thus causing more internal dusting.
Normally operates at a fixed pressure drop, but with
varying efficiency that is dependent upon a number
of factors including:
• the size and weight of the dust particles
• velocity of the air inside the cyclone
• atmospheric conditions
A properly operating, self-cleaning filter is the heart of any dust collecting system, and the filter is usually the
first piece of equipment to check when a change is noticed in internal dust control. Selection of a filter with the
proper cloth area is based upon the air volume to be handled, the type of dust and atmospheric conditions. The
filter pressure drop, or differential pressure, will level off after the initial startup period. Differential pressure
readings will fall within a relatively small range unless trouble occurs. Filters are normally equipped with a
magnehelic gauge, which indicates the pressure drop across the filter bags. 2" to 5" is considered normal.
Rotary Valves
These serve as airlocks under the dust collectors to discharge collected dust and to minimize air flow either into
or out of the collector depending on whether the system fan is on the dirty or clean air side.
3. FUNDAMENTALS OF DUST COLLECTING
SYSTEM
DUST COLLECTING SYSTEM
8210-00038 R0 11
3.2. System Terminology
Manometer A manometer is an instrument used to measure pressure. It consists
of a clear “U” tube with a graduated scale between the two legs,
calibrated in inches. The zero point on the scale is at the mid-point
between the top and the bottom. In use, the manometer is filled with
water so that the level in each leg is at the zero point. The pressure
reading obtained is the difference between the two levels. The
difference is expressed as inches of water column (WC). As an
example, if the water rises 1.5" in the leg connected to the hood, it
will drop 1.5" from the zero point on the leg that is open to the
atmosphere, resulting in a total reading of 3" WC. Each manometer is
equipped with two rubber hoses, which can be of any length, usually
6" to 8" long each. However, in measuring static pressure, only one
hose is normally used. Today, electronic manometers are widely
available.
5
FAX 402-245-5196 www.airlanco.com
System Terminology
Manometer. A Manometer is an instrument used to measure pressure. It consists of
a clear “U” tube with a graduated scale between the two legs, calibrated in inches.
The zero point on the scale is at the mid-point between the top and the bottom. In
use, the manometer is filled with water so that the level in each leg is at the zero
point. The pressure reading obtained is the difference between the two levels. The
difference is expressed as inches of water column, or WC. As an example, if the
water rises 1.5” in the leg connected to the hood, it will drop 1.5” from the zero point
on the leg that is open to the atmosphere, resulting in a total reading of 3” WC. Each
manometer is equipped with two rubber hoses, which can be of any length, usually
6” to 8” long each. However, in measuring static pressure, only one hose is normally
used. Today, electronic manometers are widely available.
Velocity Pressure (Pv). Velocity Pressure is the difference between total pressure and static
pressure, and is used to calculate both FPM and CFM (refer to “Basic Calculations” on page 7).
Velocity pressure is measured through the use of a Pitot tube in conjunction with a manometer. A
velocity pressure of 1” WC to 1.5” WC is considered normal, equivalent to about 4,000 to 5,000 feet per
minute (FPM).
Static Pressure (Ps). Static pressure is measured in inches of water with a manometer, which is
described above.The word “pressure” is always used even
though in most cases we are talking about a dust control system
under a vacuum. This is the effect created by atmospheric
pressure due to movement of air created by a fan. Your vacuum
cleaner is a good example of this function. The fan does not
“suck” dust off the floor, it creates a vacuum inside the nozzle (or
hood), which causes outside
air to flow into the nozzle at
such a velocity that it picks up
and carries dust particles along
with it.
Total Pressure (Pt). Total
Pressure is the combination of static and velocity pressures, and is
expressed in the same units. It is an important and useful concept to
use because it is easy to determine and, although velocity pressure is
not easy to measure directly, it can be determined easily by
subtracting static pressure from total pressure. This subtraction need
not be done mathematically. It can be done automatically in the
manometer.
Pitot Tube. A Pitot tube is an instrument constructed as a tube within a tube. The inner tube is used to
measure total pressure, and openings in the outer tube allow measurement of static pressure.
Feet Per Minute (FPM). Term used to indicate the velocity of air in a duct. A velocity pressure of 1”
WC, as measured with a Pitot tube, results in a velocity of approximately 4,000 FPM, which is usually
sufficient to keep most dust in suspension in the duct.
Cubic Feet Per Minute (CFM). A term used to indicate the air volume from an individual hood or being
handled by the filter or fan. As an example, a fan may be selected to handle 10,000 cfm at 10” static
pressure. The 10,000 CFM is the total air to be handled by all hoods combined
and the 10” static pressure is that required to provide the desired airflow at the furthest
hood.
0
1
2
3
1
2
3
0
1
2
3
1
2
3
3" Ps
SIMPLE MANOMETER
Ps
Ps
Pt
AIR FLOW
PITOT TUBE
Ps
Pt
FLOW
Ps Pt
Pv
Velocity
Pressure (Pv)
Velocity pressure is the difference between total
pressure and static pressure, and is used to calculate
both FPM and CFM (refer to Section 3.3 – Basic
Calculations on page 13). Velocity pressure is
measured through the use of a Pitot tube in
conjunction with a manometer. A velocity pressure of
1" WC to 1.5" WC is considered normal, equivalent to
about 4,000 to 5,000 feet per minute (FPM).
5
FAX 402-245-5196 www.airlanco.com
System Terminology
Manometer. A Manometer is an instrument used to measure pressure. It consists of
a clear “U” tube with a graduated scale between the two legs, calibrated in inches.
The zero point on the scale is at the mid-point between the top and the bottom. In
use, the manometer is filled with water so that the level in each leg is at the zero
point. The pressure reading obtained is the difference between the two levels. The
difference is expressed as inches of water column, or WC. As an example, if the
water rises 1.5” in the leg connected to the hood, it will drop 1.5” from the zero point
on the leg that is open to the atmosphere, resulting in a total reading of 3” WC. Each
manometer is equipped with two rubber hoses, which can be of any length, usually
6” to 8” long each. However, in measuring static pressure, only one hose is normally
used. Today, electronic manometers are widely available.
Velocity Pressure (Pv). Velocity Pressure is the difference between total pressure and static
pressure, and is used to calculate both FPM and CFM (refer to “Basic Calculations” on page 7).
Velocity pressure is measured through the use of a Pitot tube in conjunction with a manometer. A
velocity pressure of 1” WC to 1.5” WC is considered normal, equivalent to about 4,000 to 5,000 feet per
minute (FPM).
Static Pressure (Ps). Static pressure is measured in inches of water with a manometer, which is
described above.The word “pressure” is always used even
though in most cases we are talking about a dust control system
under a vacuum. This is the effect created by atmospheric
pressure due to movement of air created by a fan. Your vacuum
cleaner is a good example of this function. The fan does not
“suck” dust off the floor, it creates a vacuum inside the nozzle (or
hood), which causes outside
air to flow into the nozzle at
such a velocity that it picks up
and carries dust particles along
with it.
Total Pressure (Pt). Total
Pressure is the combination of static and velocity pressures, and is
expressed in the same units. It is an important and useful concept to
use because it is easy to determine and, although velocity pressure is
not easy to measure directly, it can be determined easily by
subtracting static pressure from total pressure. This subtraction need
not be done mathematically. It can be done automatically in the
manometer.
Pitot Tube. A Pitot tube is an instrument constructed as a tube within a tube. The inner tube is used to
measure total pressure, and openings in the outer tube allow measurement of static pressure.
Feet Per Minute (FPM). Term used to indicate the velocity of air in a duct. A velocity pressure of 1”
WC, as measured with a Pitot tube, results in a velocity of approximately 4,000 FPM, which is usually
sufficient to keep most dust in suspension in the duct.
Cubic Feet Per Minute (CFM). A term used to indicate the air volume from an individual hood or being
handled by the filter or fan. As an example, a fan may be selected to handle 10,000 cfm at 10” static
pressure. The 10,000 CFM is the total air to be handled by all hoods combined
and the 10” static pressure is that required to provide the desired airflow at the furthest
hood.
0
1
2
3
1
2
3
0
1
2
3
1
2
3
3" Ps
SIMPLE MANOMETER
Ps
Ps
Pt
AIR FLOW
PITOT TUBE
Ps
Pt
FLOW
Ps Pt
Pv
Static
Pressure (Ps)
Static pressure is measured in inches of water with a
manometer, which is described above. The word
“pressure” is always used even though in most cases
we are talking about a dust control system under a
vacuum. This is the effect created by atmospheric
pressure due to movement of air created by a fan.
Your vacuum cleaner is a good example of this
function. The fan does not “suck” dust off the floor, it
creates a vacuum inside the nozzle (or hood), which
causes outside air to flow into the nozzle at such a
velocity that it picks up and carries dust particles
along with it.
Total
Pressure (Pt)
Total pressure is the combination of static and velocity pressures, and is expressed in the
same units. It is an important and useful concept to use because it is easy to determine and,
although velocity pressure is not easy to measure directly, it can be determined easily by
subtracting static pressure from total pressure. This subtraction need not be done
mathematically. It can be done automatically in the manometer.
Pitot Tube A pitot tube is an instrument constructed as a tube
within a tube. The inner tube is used to measure total
pressure, and openings in the outer tube allow
measurement of static pressure.
5
FAX 402-245-5196 www.airlanco.com
System Terminology
Manometer. A Manometer is an instrument used to measure pressure. It consists of
a clear “U” tube with a graduated scale between the two legs, calibrated in inches.
The zero point on the scale is at the mid-point between the top and the bottom. In
use, the manometer is filled with water so that the level in each leg is at the zero
point. The pressure reading obtained is the difference between the two levels. The
difference is expressed as inches of water column, or WC. As an example, if the
water rises 1.5” in the leg connected to the hood, it will drop 1.5” from the zero point
on the leg that is open to the atmosphere, resulting in a total reading of 3” WC. Each
manometer is equipped with two rubber hoses, which can be of any length, usually
6” to 8” long each. However, in measuring static pressure, only one hose is normally
used. Today, electronic manometers are widely available.
Velocity Pressure (Pv). Velocity Pressure is the difference between total pressure and static
pressure, and is used to calculate both FPM and CFM (refer to “Basic Calculations” on page 7).
Velocity pressure is measured through the use of a Pitot tube in conjunction with a manometer. A
velocity pressure of 1” WC to 1.5” WC is considered normal, equivalent to about 4,000 to 5,000 feet per
minute (FPM).
Static Pressure (Ps). Static pressure is measured in inches of water with a manometer, which is
described above.The word “pressure” is always used even
though in most cases we are talking about a dust control system
under a vacuum. This is the effect created by atmospheric
pressure due to movement of air created by a fan. Your vacuum
cleaner is a good example of this function. The fan does not
“suck” dust off the floor, it creates a vacuum inside the nozzle (or
hood), which causes outside
air to flow into the nozzle at
such a velocity that it picks up
and carries dust particles along
with it.
Total Pressure (Pt). Total
Pressure is the combination of static and velocity pressures, and is
expressed in the same units. It is an important and useful concept to
use because it is easy to determine and, although velocity pressure is
not easy to measure directly, it can be determined easily by
subtracting static pressure from total pressure. This subtraction need
not be done mathematically. It can be done automatically in the
manometer.
Pitot Tube. A Pitot tube is an instrument constructed as a tube within a tube. The inner tube is used to
measure total pressure, and openings in the outer tube allow measurement of static pressure.
Feet Per Minute (FPM). Term used to indicate the velocity of air in a duct. A velocity pressure of 1”
WC, as measured with a Pitot tube, results in a velocity of approximately 4,000 FPM, which is usually
sufficient to keep most dust in suspension in the duct.
Cubic Feet Per Minute (CFM). A term used to indicate the air volume from an individual hood or being
handled by the filter or fan. As an example, a fan may be selected to handle 10,000 cfm at 10” static
pressure. The 10,000 CFM is the total air to be handled by all hoods combined
and the 10” static pressure is that required to provide the desired airflow at the furthest
hood.
0
1
2
3
1
2
3
0
1
2
3
1
2
3
3" Ps
SIMPLE MANOMETER
Ps
Ps
Pt
AIR FLOW
PITOT TUBE
Ps
Pt
FLOW
Ps Pt
Pv
DUST COLLECTING SYSTEM 3. FUNDAMENTALS OF DUST
COLLECTING SYSTEM
12 8210-00038 R0
Feet Per
Minute (FPM)
Term used to indicate the velocity of air in a duct. A velocity pressure of 1" WC, as measured
with a pitot tube, results in a velocity of approximately 4,000 FPM, which is usually sufficient
to keep most dust in suspension in the duct.
Cubic Feet
Per Minute
(CFM)
A term used to indicate the air volume from an individual hood or
being handled by the filter or fan. As an example, a fan may be
selected to handle 10,000 CFM at 10" static pressure. The 10,000
CFM is the total air to be handled by all hoods combined and the 10"
static pressure is that required to provide the desired airflow at the
furthest hood.
5
FAX 402-245-5196 www.airlanco.com
System Terminology
Manometer. A Manometer is an instrument used to measure pressure. It consists of
a clear “U” tube with a graduated scale between the two legs, calibrated in inches.
The zero point on the scale is at the mid-point between the top and the bottom. In
use, the manometer is filled with water so that the level in each leg is at the zero
point. The pressure reading obtained is the difference between the two levels. The
difference is expressed as inches of water column, or WC. As an example, if the
water rises 1.5” in the leg connected to the hood, it will drop 1.5” from the zero point
on the leg that is open to the atmosphere, resulting in a total reading of 3” WC. Each
manometer is equipped with two rubber hoses, which can be of any length, usually
6” to 8” long each. However, in measuring static pressure, only one hose is normally
used. Today, electronic manometers are widely available.
Velocity Pressure (Pv). Velocity Pressure is the difference between total pressure and static
pressure, and is used to calculate both FPM and CFM (refer to “Basic Calculations” on page 7).
Velocity pressure is measured through the use of a Pitot tube in conjunction with a manometer. A
velocity pressure of 1” WC to 1.5” WC is considered normal, equivalent to about 4,000 to 5,000 feet per
minute (FPM).
Static Pressure (Ps). Static pressure is measured in inches of water with a manometer, which is
described above.The word “pressure” is always used even
though in most cases we are talking about a dust control system
under a vacuum. This is the effect created by atmospheric
pressure due to movement of air created by a fan. Your vacuum
cleaner is a good example of this function. The fan does not
“suck” dust off the floor, it creates a vacuum inside the nozzle (or
hood), which causes outside
air to flow into the nozzle at
such a velocity that it picks up
and carries dust particles along
with it.
Total Pressure (Pt). Total
Pressure is the combination of static and velocity pressures, and is
expressed in the same units. It is an important and useful concept to
use because it is easy to determine and, although velocity pressure is
not easy to measure directly, it can be determined easily by
subtracting static pressure from total pressure. This subtraction need
not be done mathematically. It can be done automatically in the
manometer.
Pitot Tube. A Pitot tube is an instrument constructed as a tube within a tube. The inner tube is used to
measure total pressure, and openings in the outer tube allow measurement of static pressure.
Feet Per Minute (FPM). Term used to indicate the velocity of air in a duct. A velocity pressure of 1”
WC, as measured with a Pitot tube, results in a velocity of approximately 4,000 FPM, which is usually
sufficient to keep most dust in suspension in the duct.
Cubic Feet Per Minute (CFM). A term used to indicate the air volume from an individual hood or being
handled by the filter or fan. As an example, a fan may be selected to handle 10,000 cfm at 10” static
pressure. The 10,000 CFM is the total air to be handled by all hoods combined
and the 10” static pressure is that required to provide the desired airflow at the furthest
hood.
0
1
2
3
1
2
3
0
1
2
3
1
2
3
3" Ps
SIMPLE MANOMETER
Ps
Ps
Pt
AIR FLOW
PITOT TUBE
Ps
Pt
FLOW
Ps Pt
Pv
Anemometer An instrument for measuring air velocity, used in system balancing to
measure face velocity for comparison to system design specifications.
Hot-wire and wind-vane
anemometers
Face Velocity Air velocity measured with an anemometer at the air inlet or exhaust.
Face velocity is expressed in feet per minute.
Air to Cloth
Ratio
A term indicating the ratio of the total amount of air in a filter divided
by the total cloth area. 10,000 CFM in a filter having 1,000 square
feet of cloth gives a ratio of 10:1.
Magnehelic
Gauge
An instrument usually furnished with a filter that provides a means of constantly monitoring
the operating static pressure drop, or differential pressure (DP) across the filter bags and
indicates if the filter is operating normally. A range of 0–10" WC is adequate on the dial. An
increase above the desired pressure drop allowed for in the system design would result in
decreased airflow and a resultant decrease in the efficiency of the entire system.
Cross
Sectional
Area
The area of the cross section of an air duct, usually expressed in square feet. Cross sectional
area is used in calculating CFM.
Traverse
Readings
Traverse readings are taken in the interest of accuracy, since the velocity of the air stream is
not uniform across the cross section of a duct. Friction slows the air moving close to the walls,
so the velocity is greater in the center of the duct. See Section 3.2.1 – Example of Traverse
Readings on page 12.
3.2.1 Example of Traverse Readings
To obtain the average total velocity in ducts of 4" diameter or larger, a series of velocity pressure readings must
be taken at points of equal area. It is recommended that at least 20 readings be taken along two diameters in
round ducts.
In rectangular ducts, a minimum of 16 and a maximum of 64 readings are taken at centers of equal rectangular
areas. The velocities are then averaged. These precautions should be observed for best accuracy:
1. Ensure the duct diameter is at least 30 times the diameter of the pitot tube.
2. Locate the pitot tube in a duct section providing 8½ or more duct diameters upstream and 5 or more
diameters down stream of the pitot tube. This length of duct should be free of elbows, size changes or
obstructions.
3. Provide an egg-crate type of flow straightener 5 duct diameters upstream of pitot tube.
4. Make a complete, accurate traverse.
3. FUNDAMENTALS OF DUST COLLECTING
SYSTEM
DUST COLLECTING SYSTEM
8210-00038 R0 13
6
FAX 402-245-5196 www.airlanco.com
Anemometer. An instrument for measuring air velocity, used in system balancing to
measure face velocity for comparison to system design specifications.
Face Velocity. Air velocity measured with an anemometer at the air inlet or exhaust. Face
velocity is expressed in feet per minute.
Air to Cloth Ratio. A term indicating the ratio of the total amount of air in a filter divided
by the total cloth area. 10,000 CFM in a filter having 1,000 square feet of cloth gives a
ratio of 10 to 1.
Magnehelic Gauge. An instrument usually furnished with a filter that provides a means
of constantly monitoring the operating static pressure
drop, or differential pressure (DP) across the filter bags and indicates if the filter is
operating normally. A range of 0-10” WC is adequate on the dial. An increase above the desired
pressure drop allowed for in the system design would result in decreased airflow and a resultant
decrease in the efficiency of the entire system.
Cross Sectional Area. The area of the cross section of an air duct, usually expressed in square feet.
Cross sectional area is used in calculating CFM.
Traverse Readings. Traverse readings are taken in the interest of accuracy, since the velocity of the
air stream is not uniform across the cross section of a duct.
Friction slows the air moving close to the walls, so the velocity is
greater in the center of the duct.
To obtain the average total velocity in ducts of 4” diameter or
larger, a series of velocity pressure readings must be taken at
points of equal area. It is recommended that at least 20 readings
be taken along two diameters In round ducts. In rectangular
ducts, a minimum of 16 and a maximum of 64 readings are taken
at centers of equal rectangular areas. The velocities are then
averaged.
These precautions should be
observed for best accuracy:
1. Duct diameter should be
at least 30 times the
diameter of the Pitot
tube.
2. Locate the Pitot tube in
a duct section providing
8½ or more duct
diameters upstream and
5 or more diameters down stream of the Pitot tube. This length
of duct should be free of elbows, size changes or obstructions.
3. Provide an egg-crate type of flow straightener 5 duct
diameters upstream of Pitot tube.
4. Make a complete, accurate traverse.
In small ducts or where traverse operations are otherwise impossible,
a fairly good degree of accuracy can be achieved by placing the Pitot
tube in the center of the duct. Determine velocity from the reading and
multiply by 0.9 for an approximate average.
R
.316 R
.548 R
.707 R
.837 R
.949 R
PITOT TUBE PLACEMENTS
AT CENTERS OF EQUAL
CONCENTRIC AREAS
TRAVERSE ON ROUND
DUCT AREA
PITOT TUBE PLACEMENTS AT
CENTERS OF EQUAL
RECTANGULAR AREAS
TRAVERSE ON RECTANGULAR
DUCT AREA
Hot-wire and wind-vane
anemometers
anemometers
In small ducts or where traverse operations are not possible, follow the steps below:
1. Place the pitot tube in the center of the duct.
2. Determine velocity from the reading and multiply by 0.9 for an approximate average.
3.3. Basic Calculations
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FAX 402-245-5196 www.airlanco.com
Basic Calculations
Velocity Pressure (Pv) = Total Pressure (Pt) - Static Pressure (Ps)
Pv = Pt - Ps
Feet Per Minute (FPM) = The square root of the Velocity Pressure (Pv) x 4004.4
FPM = 4004.4 Pv
Sq. Ft. of Cross Sectional Area (CSA) = (3.14) x Duct Radius (R)
÷
144 *
CSA = R²/144
Cubic Feet per Minute (CFM) = Cross Sectional Area x Feet Per Minute (FPM)
CFM = CSA x FPM
*Divide by 144 when duct radius is measured in inches.
DUST COLLECTING SYSTEM 3. FUNDAMENTALS OF DUST
COLLECTING SYSTEM
14 8210-00038 R0
3.4. Field Test Sheet
8
FAX 402-245-5196 www.airlanco.com
FIELD TEST SHEET
FAN OWNER
FAN MFR.
FAN NAMEPLATE DATA
DATE BY
FAN RPM APPX BHP
MOTOR NAMEPLATE DATA
SKETCH OF INSTALLATION
SHOWING POINTS OF READING
READINGS SP
(OUTLET)
SP
(OUTLET) V P V P
TOTAL
AVERAGE
XXXXX
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20 PROBE POINTS IN A RECTANGULAR DUCT
L/8 L/4 L/4 L/4 L/8
W/8
W/4
W/4
W/4
W/8
L
W
R
PROBE POINTS IN A ROUND DUCT
.316R
.548R
.707R
.837R
.961R
Density = .075 530
460 + °F
Barometric Pres.
29.92
= lbs. per cu. ft.
"k" = .075
Density =
"k" times
SP = " SP
VP = " VP
BHP = " BHP
at st'd. density
average duct velocity = 4000
= 4000
VP
= fpm.
CFM = velocity x duct area
= x = CFM
Add to the SP any loss due to duct friction
between pints of readings and fan due to
poor inlet and outlet connections.
Add to the SP any loss due to duct friction
Between points of readings and fan due to
poor inlet and outlet connections.
3. FUNDAMENTALS OF DUST COLLECTING
SYSTEM
DUST COLLECTING SYSTEM
8210-00038 R0 15
4. System Balancing
Balancing is the procedure of directing airflow to the pickup points through the use
of blast gates. This is accomplished with the aid of a manometer (either clear tube
or electronic) or a 0–3” magnehelic gauge.
System balancing is important and every operator should be aware of how it is
done and be familiar with the terminology used.
9
FAX 402-245-5196 www.airlanco.com
System Balancing
System balancing is very important and every operator should be aware of how it is done and be
familiar with the terminology used.
Fan speed is selected to provide the required static pressure at the furthest hood; therefore the hoods
nearest the fan will have a higher available pressure unless the air flow control gates are adjusted so
that only the calculated static pressure is provided.
See “Industrial Ventilation, A Manual Of Recommended Practice For Design” by ACGIH for a
comprehensive discussion of exhaust system design procedure.
Balancing is the procedure of directing airflow to the pickup points through
the use of blast gates. This is accomplished with the aid of a manometer
(either clear tube or electronic) or a 0-3” magnehelic gauge.
Start at the hood closest to the dust collector. Drill a small hole in the duct
between the hood and the blast gate. Usually, a 1/8” hole will suffice,
unless it is desired to install a permanent tap. Place the free end of the
hose attached to the vacuum side of the manometer. Adjust the gate until
the manometer shows 1” WG. If an anemometer is available, check the
face velocity of the hood, and compare to the design specifications.
Proceed to the next hood on this branch and repeat this procedure.
Continue this process with each hood until the hood farthest from the collector has been adjusted. Start
over at the first hood and check each one in order again. Some adjustments will probably be required.
By adjusting the gate, the desired conditions can be established at which point the gate should either
be locked or at least marked for future reference.
When determining the total differential pressure
(DP) across the filter from the air inlet to the air
outlet side, the same technique can be used. Drill a
1/8” hole in the inlet and outlet ducts and measure
the pressure at each point. The static pressure
reading on the clean air side will be higher than on
the dirty air side if the filter is on vacuum. The
pressure drop is the difference between these two
readings.
In the following example, the procedure is outlined with the hoods numbered in the order in which they
should be balanced.
1
3
2
4
5
6
7
8
9
10
11
12
13
14
FREE AIR IF
REQUIRED
MAGNEHELIC
0
1
2
3
ADJUSTABLE BLAST GATE
1/8" HOLE
INCHES OF WATER
(TYP 1")
4.1. Balancing the Aeration System
1. Select a fan speed to provide the required static pressure at the furthest hood.
Note
Hoods nearest the fan will have a higher available pressure unless the air flow control gates are
adjusted so that only the calculated static pressure is provided. See “Industrial Ventilation, A Manual
Of Recommended Practice For Design” by ACGIH for a comprehensive discussion of exhaust system
design procedure.
2. Starting at the hood closest to the dust collector, drill a small hole in the duct between the hood and the
blast gate. Usually, a 1/8” hole will suffice, unless it is desired to install a permanent tap.
3. Place the free end of the hose attached to the vacuum side of the manometer.
4. Adjust the gate until the manometer shows 1” WC. If an anemometer is available, check the face velocity of
the hood, and compare to the design specifications.
9
FAX 402-245-5196 www.airlanco.com
System Balancing
System balancing is very important and every operator should be aware of how it is done and be
familiar with the terminology used.
Fan speed is selected to provide the required static pressure at the furthest hood; therefore the hoods
nearest the fan will have a higher available pressure unless the air flow control gates are adjusted so
that only the calculated static pressure is provided.
See “Industrial Ventilation, A Manual Of Recommended Practice For Design” by ACGIH for a
comprehensive discussion of exhaust system design procedure.
Balancing is the procedure of directing airflow to the pickup points through
the use of blast gates. This is accomplished with the aid of a manometer
(either clear tube or electronic) or a 0-3” magnehelic gauge.
Start at the hood closest to the dust collector. Drill a small hole in the duct
between the hood and the blast gate. Usually, a 1/8” hole will suffice,
unless it is desired to install a permanent tap. Place the free end of the
hose attached to the vacuum side of the manometer. Adjust the gate until
the manometer shows 1” WG. If an anemometer is available, check the
face velocity of the hood, and compare to the design specifications.
Proceed to the next hood on this branch and repeat this procedure.
Continue this process with each hood until the hood farthest from the collector has been adjusted. Start
over at the first hood and check each one in order again. Some adjustments will probably be required.
By adjusting the gate, the desired conditions can be established at which point the gate should either
be locked or at least marked for future reference.
When determining the total differential pressure
(DP) across the filter from the air inlet to the air
outlet side, the same technique can be used. Drill a
1/8” hole in the inlet and outlet ducts and measure
the pressure at each point. The static pressure
reading on the clean air side will be higher than on
the dirty air side if the filter is on vacuum. The
pressure drop is the difference between these two
readings.
In the following example, the procedure is outlined with the hoods numbered in the order in which they
should be balanced.
1
3
2
4
5
6
7
8
9
10
11
12
13
14
FREE AIR IF
REQUIRED
MAGNEHELIC
0
1
2
3
ADJUSTABLE BLAST GATE
1/8" HOLE
INCHES OF WATER
(TYP 1")
5. Proceed to the next hood on this branch and repeat this procedure. Continue this process with each hood
until the hood farthest from the collector has been adjusted.
6. Start over at the first hood and check each one in order again. Adjust as necessary.
Note
By adjusting the gate, the desired conditions can be established at which point the gate should
either be locked or at least marked for future reference.
DUST COLLECTING SYSTEM 4. SYSTEM BALANCING
16 8210-00038 R0
In the following example, the procedure is outlined with the hoods numbered in the order in which they should
be balanced.
9
FAX 402-245-5196 www.airlanco.com
System Balancing
System balancing is very important and every operator should be aware of how it is done and be
familiar with the terminology used.
Fan speed is selected to provide the required static pressure at the furthest hood; therefore the hoods
nearest the fan will have a higher available pressure unless the air flow control gates are adjusted so
that only the calculated static pressure is provided.
See “Industrial Ventilation, A Manual Of Recommended Practice For Design” by ACGIH for a
comprehensive discussion of exhaust system design procedure.
Balancing is the procedure of directing airflow to the pickup points through
the use of blast gates. This is accomplished with the aid of a manometer
(either clear tube or electronic) or a 0-3” magnehelic gauge.
Start at the hood closest to the dust collector. Drill a small hole in the duct
between the hood and the blast gate. Usually, a 1/8” hole will suffice,
unless it is desired to install a permanent tap. Place the free end of the
hose attached to the vacuum side of the manometer. Adjust the gate until
the manometer shows 1” WG. If an anemometer is available, check the
face velocity of the hood, and compare to the design specifications.
Proceed to the next hood on this branch and repeat this procedure.
Continue this process with each hood until the hood farthest from the collector has been adjusted. Start
over at the first hood and check each one in order again. Some adjustments will probably be required.
By adjusting the gate, the desired conditions can be established at which point the gate should either
be locked or at least marked for future reference.
When determining the total differential pressure
(DP) across the filter from the air inlet to the air
outlet side, the same technique can be used. Drill a
1/8” hole in the inlet and outlet ducts and measure
the pressure at each point. The static pressure
reading on the clean air side will be higher than on
the dirty air side if the filter is on vacuum. The
pressure drop is the difference between these two
readings.
In the following example, the procedure is outlined with the hoods numbered in the order in which they
should be balanced.
1
3
2
4
5
6
7
8
9
10
11
12
13
14
FREE AIR IF
REQUIRED
MAGNEHELIC
0
1
2
3
ADJUSTABLE BLAST GATE
1/8" HOLE
INCHES OF WATER
(TYP 1")
4.2. Measuring the Pressure Drop
To determine the total differential pressure (DP) across the filter from the air inlet to the air outlet side:
1. Drill a 1/8” hole in the inlet and outlet ducts.
2. Measure the pressure at each point.
3. Get the difference between static pressure reading on the clean air side and on the dirty air side.
Note
The static pressure reading on the clean air side will be higher than on the dirty air side if the filter is
on vacuum. The pressure drop is the difference between these two readings.
4. SYSTEM BALANCING DUST COLLECTING SYSTEM
8210-00038 R0 17
5. Maintenance
Before continuing, ensure you have completely read and understood this manual’s
Safety section, in addition to the safety information in the section(s) below.
5.1. Maintenance Safety
• Keep components in good condition. Follow the maintenance
procedures.
• Ensure the service area is clean, dry, and has sufficient
lighting.
• Do not modify any components without written authorization
from the manufacturer. Modification can be dangerous and
result in serious injuries.
• Shut down and lock out power before maintaining
equipment.
• After maintenance is complete, replace all guards, service
doors, and/or covers.
• Use only genuine AGI Airlanco replacement parts or
equivalent. Use of unauthorized parts will void warranty. If in
doubt, contact AGI Airlanco or your local dealer.
5.2. Dust Collecting Hoods and Air Flow Control Gates
Dust is generated each time a granular product is disturbed, such as being dropped out of a bin onto a moving
belt, from one belt to another, from a truck or rail car into a hopper, or from an elevator leg into a bin, etc.
Properly designed hoods are installed at each of these points and equipped with an airflow control gate
(normally called a blast gate), which is adjusted to assure that each hood is handling the designed CFM (cubic
feet per minute) of air.
Hoods/Gates Maintenance
Hoods positioned over a belt or a bin Require little attention other than occasionally checking to
make sure the blast gate is functional and set at the desired
point.
Hoods installed under a belt pulley, for
example at the discharge end
Check more frequently to make sure that an excessive
amount of dust has not accumulated which would restrict the
air flow.
Note
If allowed to continue, it would cause the hood to fill
up and eventually spill over. An accumulation of dust
in the bottom of one of these hoods might be caused
by trash such as paper, cloth, etc. or an obstruction in
the branch line from this hood to the main duct.
Clean the hood before restarting the belt. Check to make sure
that the air control gate is not accidentally closed off.
DUST COLLECTING SYSTEM 5. MAINTENANCE
18 8210-00038 R0
Hoods/Gates Maintenance
Note
Occasionally a belt will stop while still carrying
product, which will cause an abnormal flow of
product into the hood.
Other types of hoods (that may be required
to suit specific dust producing areas)
Keep clean and free of an accumulation of trash.
Blast gates Check blast gates. If they are damaged in any way or if the
blast gates do become inoperable, repair immediately.
Only authorized personnel are allowed to
re-adjust the blast gates.
5.3. Ductwork
The primary things to watch for are:
• worn areas in elbows
• leaking flanges
• dented sections which restrict air flow
• hoods no longer in use but still connected to the system
Note
An accumulation of small leaks has the same result as adding another hood without changing the duct
sizes, fan RPM or motor HP.
If cleanouts are not used, open up the longer horizontal runs for periodic inspection when necessary.
Check ductwork that is installed outdoors for leaks and moisture accumulation to minimize the plugging
problem in the duct as well as in the filter.
Important
Use proper tool to clean out plugged duct work.
5.4. Fans
Fan Blades
• Check the blades for wear.
Note
Fans are subject to wear when they are installed on the dirty air side of a collector. Excessive wear
on the blades will cause an unbalanced condition which will be noticeable in excessive vibration and
reduced efficiency. Worn bearings will result in overheating and a change in the fan’s sound. Once
an operator becomes familiar with the normal sound of a properly functioning fan, any abnormal
sound will become apparent and should be checked immediately. Spare bearings and a spare wheel
are good insurance against an extended down period.
5. MAINTENANCE DUST COLLECTING SYSTEM
8210-00038 R0 19
Bearing
Use right bearing lubricant at the correct intervals. Be careful not to over-lubricate. Refer to the manufacturer’s
maintenance manual.
V-belts
• Check the V-belts for correct tension regularly.
1. Place a straight edge over the complete set of
belts.
2. Push the belts downward so that the same
pressure is exerted on each belt. A deflection
of approximately 1" at the midpoint between
sheaves is considered normal.
Note
Belts that are too loose will result in belt
slippage, causing overheating. Belts that
are too tight will cause the bearings to
overheat.
• Refer to your belt manufacturer’s guidelines for
correct tensioning procedure.
• Never replace only one belt. Always replace the
entire set.
• Be sure the fan is operating in the correct
rotation after performing any work that requires
removing or disconnecting the motor. A switch in
lead wires is easy to overlook.
11
FAX 402-245-5196 www.airlanco.com
If additional hoods are required at some other point in the system, a check of your ductwork drawing
will determine whether this is feasible. A change in ductwork might be necessary if the hood is to be
installed near the end of the system furthest from the fan. If it is to be installed near the fan, it is not so
critical as long as an airflow control gate is provided and proper balancing is utilized.
A more common problem occurs when additional hoods are added with no change in duct sizes, fan
RPM or motor HP. The fan will normally handle a fixed amount of air at designed total static pressure;
therefore, adding hoods merely robs other nearby hoods. This may not be serious if the resultant dust
control is still adequate. However, in most cases you end up with only partial dust control at an
increased number of points rather than adequate dust control on the original hoods.
The primary things to watch for are worn areas in elbows, leaking flanges, dented sections which
restrict air flow and hoods no longer in use but still connected to the system. An accumulation of small
leaks is the same as adding another hood with the results as outlined above. In any event, the worst
possible thing to do when ductwork becomes plugged is to use a hammer to clean it out. This only
aggravates the problem.
Fans
Fans are usually driven by an electric motor through a V-belt drive. Normal maintenance consists of
proper use of the right bearing lubricant at the correct intervals. Be careful not to over-lubricate. Refer
to the manufacturer’s maintenance manual.
Fans are subject to wear when they are installed on the dirty
air side of a collector. Excessive wear on the blades will
cause an unbalanced condition which will be noticeable in
excessive vibration and reduced efficiency. Worn bearings
will result in overheating and a change in the fan’s sound.
Once an operator becomes familiar with the normal sound of
a properly functioning fan, any abnormal sound will become
apparent and should be checked immediately. Spare
bearings and a spare wheel are good insurance against an
extended down period.
Be sure the fan is operating in the correct rotation after
performing any work that requires removing or disconnecting
the motor. A switch in lead wires is easy to overlook.
V-belts should be periodically checked for correct tension.
Belts that are too loose will result in belt slippage, causing overheating. Belts that are too tight will
cause the bearings to overheat. Never replace only one belt. Always replace the entire set. Correct belt
tension can typically be determined by placing a straight edge over the complete set of belts and
pushing downward so that the same pressure is exerted on each belt. A deflection of approximately 1”
at the midpoint between sheaves is considered normal. Refer to your belt manufacturer’s guidelines for
correct tensioning procedure.
5.5. Dust Collectors
1. Remove excessively caked bags. Replace with new bags. See the dust collector operating manual for
replacement instructions.
Important
Never replace only one bag. Always replace the entire set of bags.
2. Rebalance the system after a complete set of filter bags is replaced.
Note
Filter bags are made of a variety of materials, with synthetics most commonly used now.
3. Check the magnehelic gauge after bag replacement.
The initial differential pressure should be quite low, under approximately 1" of water.
5.6. Contact Information
If you have any questions regarding the material in this manual, please contact your AGI Airlanco representative
at 800-500-9777.
DUST COLLECTING SYSTEM 5. MAINTENANCE
20 8210-00038 R0
6. Troubleshooting
Shut down and lock out all power sources before diagnosing any of the causes or
attempting any of the solutions below.
In the following section, we have listed some causes and solutions to some of the problems you may
encounter.
If you encounter a problem that is difficult to solve, even after having read through this section, please
contact your local dealer or distributor. Before you contact them, please have this operation manual
and the serial number from your machine ready.
Problem Cause Solution
Appearance of more dust
floating in the atmosphere
Filter not working properly 1. Check the mechanical operation of
the filter, see instruction manual.
2. If there is no mechanical malfunction,
then check the appearance of the
filter tubes.
Note
Filter bags normally operate
with a coating of dust. If the
dust becomes caked due to
moisture or for any other
reason, the automatic cleaning
mechanism will not be able to
clean down the tubes as
effectively. Caking will cause a
rise in the differential
pressure, which in turn causes
a drop in the total air flow
with a resultant increase in
float dust inside the plant.
Inadequate dust control Additional hoods added
without changing duct
sizes, fan RPM or motor
HP.
Increase duct sizes, fan RPM or motor HP
6. TROUBLESHOOTING DUST COLLECTING SYSTEM
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AGI Dust Collecting System Maintenance Manual

AGI
Brand
AGI
Model
Dust Collecting System
Type
Maintenance Manual
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