Baghouse Accessories

Transcript

Energy Baghouse Accessories Designed to reduce maintenance, labor, and overall operating costs. Solving Challenges Solutions that solve problems in dust collectors and enhance system performance. GE Energy’s accessory products are solutions to real problems. Our products are designed to decrease maintenance time and labor costs, while adding value to your system. Our innovative accessories offerings include: • Neutralite® conditioning agent • Neutralite® SR (spark retardant) • Visolite® leak detection system • Conical spring • Tensionor® suspension system • AC Tensioning Tool® • U-Channel door seal • Clean-On-Demand™ • Photohelic® gauge Tensioning products applied properly in reverse air baghouses can increase filter life. Door seal keeps access doors sealed air-tight. Valves and valve kits optimize cleaning and conserve compressed air. Visolite® leak detection powder helps find leaks in the baghouse fast. GE is your is a complete resource for baghouse parts, accessories, and services. Clamps seal your filter bags and pleated elements to reduce leakage. Filter bag cages are designed to optimize filter performance and increase bag life. Neutralite® powder helps protect filters from moisture, hydrocarbons, and blinding problems. Efficiency Enhancers Transfer bulk materials easily with Vacutrans™ cleaning system. The Vacutrans system is an industrial strength tool specifically designed to convert your compressed air supply into a high powered vacuum and material transferring system. The benefits of the Vacutrans system include: • Reduced maintenance time - quick and easy cleanup • Extended bag life - reduces abrasion on the clean side of the fabric filter when used to remove particulate buildup from the clean air plenum • No manual handling of dust - dust flows directly into the collector’s hopper, eliminating the need to remove the bags for cleanup • Easy installation - simply attach the Vacutrans to the discharge hose and connect air • Virtually maintenance free - there are no moving parts to lubricate or wear out • Portable - can be easily moved between compartments or collectors • Uses the compressed air you have - operates in the 150-200 CFM (4.2m3/min–5.7m3/min) range at 100 psi (6.90 bars) Vacutrans Assembly Clean-On-Demand™ Baghouse Control Systems GE Energy offers a full line of baghouse control systems designed to achieve maximum ventilation and collection efficiency. Clean-On-Demand controls monitor the differential pressure across the filter bags. The user sets the high and low differential pressure set points (generally 1/2” w.c. (12.7mm w.c.) apart), whereby cleaning will start and stop. By operating the baghouse at a stable and optimum differential pressure, you are not over-or under-cleaning the filter bags. Benefits of Clean-On-Demand™ Controls • Maintains optimum dustcake for filtration efficiency • Helps protect bag fabric from blinding and bleed-through for better airflow and less emissions • Less flex cycles on the filter bag for increased filter bag life • Maintains stable ventilation at the process with no pickup of extra material caused by over ventilation or back puffing caused by under ventilation • Helps lower compressed air consumption and operating costs Standard Clean-On-Demand Controller • Solid-state construction • Digital input of pulse time, pulse duration, number of valves • Low profile Photohelic® gauge with high and low differential pressure set points • NEMA 4 (IP66) enclosure Differential Pressure Transmitter GE Energy’s Differential Pressure Transmitter includes a Magnehelic® gauge with 4-20 mA output housed in a NEMA 4X enclosure. The Magnehelic gauge gives local differential pressure indication, while the 4-20 mA output gives continuous remote indication of differential pressure. See back page for a complete listing of GE Energy’s baghouse products and services. Installation of timers can enhance baghouse performance. Cages Bag-to-cage fit is critical for proper performance and collection efficiency. Rounded edges Maximize Filter Bag Life The type of cage you buy will affect the life of your filter bags. Cages should be designed to optimize filter performance and promote longer bag life. Poorly manufactured cages allow over-flexing of the fabric, abrasion, holes, and eventually lead to filter failure. Avoid crimped or scalloped bottom pans, tapered or bowed cages, and cages that have wires welded on the outside of collars or pans. Consistent diameter The GE Cage Difference GE Energy manufactures cages for use in most baghouses. Properly designed cages serve as critical baghouse components for optimum bag performance and durability. Our cages are constructed of the following materials: • Low carbon steel (bright basic wire) • Galvanized low carbon steel • Type 304 stainless steel • Type 316 stainless steel • Other specialty materials • Hastelloy® Cage top Cage bottom We also offer rigid wire cages with all bottom pans welded to the inside. Our cages offer the following benefits: • Rounded edges on top collars and bottom pans - The top collars and bottom pans are stamped from durable 20 gauge steel, with rounded edges to reduce abrasion. • Consistent spacing of rings and wires - The stringer wires in our cages are placed perpendicular to rings and consistently spaced so that the cage diameter is the same from top to bottom. This will promote a proper bag-to-cage fit. • Wires welded on the inside of collars and pans - The top collar and bottom pan are attached with the wires welded on the inside, helping to avoid premature bag failure. • Precision welding and polishing - Rings between the stringer wires are welded and polished to reduce burrs and sharp edges. We also use a weld bead at the top and bottom of the cage, allowing a point of contact weld that is much stronger than welding directly to the roll flange or pan. 3 Roll band low groove 1 Evenly spaced rings and wires Rounded bottom pan Two-piece roll flange top is designed for applications with low headroom in clean air plenum to simplify installation and removal. 5 Roll flange with built-in venturi Straight flange 2 Roll flange 6 Roll band high groove 7 4 Roll flange with venturi - The Omni cage top features a detachable top that allows removal of the cage top first. This allows the snapband to be snapped loose from the tubesheet, and the bag and cage body lift out easily. Visolite® Leak Detection One of the brightest leak detection products available for baghouses—we invented it! Locate Leaks in Your Baghouse Quickly and Easily The Visolite Leak Detection System reduces the time plant personnel spend identifying tears, holes, and bad seals in bags. Visolite is a lightweight fluorescent powder that is injected into the baghouse. The powder follows the path of least resistance, accumulating around the source of leakage, whether it is a weak area in the filter media or a bad seal. A monochromatic light is then used to pinpoint the exact location of air leakage and its severity. Visolite glows under the light to reveal air leaks in the baghouse. Visolite® Powder-Usage To determine the quantity of tracer compound needed to run one Visolite test, follow these guidelines: • For every 1,000 ft2 (93 m2) of filter cloth, one pound of Visolite is needed. To calculate filter cloth area in your system use the following formula: Total Cloth Area, ft2 (m2) = (Bag Diameter (in or mm) x 3.14 x Bag Length (in or mm)) x Total # of Bags 144 • If filter cloth square footage per compartment or baghouse is known, divide by 1,000 to obtain the number of pounds of Visolite powder to use. The powder quantity may vary depending on the length of ductwork between the fan and baghouse. Four Colors for a Variety of Industries Visolite is available in four different colors and incorporates a varying particle size distribution to minimize fabric bleedthrough. Straight pigment is also available for specific applications. It is important to choose the appropriate color for your specific application: • Pink - all industries • Orange - all industries except those where iron oxide is present • Green - aluminum, cement, and utility industries; good contrasting color for pink and orange • Yellow - all industries except cement, lime, asphalt, utility, and cogeneration plants where sulfur is in the dust Monochromatic Lights to Use With Visolite Powder GE Energy offers a variety of monochromatic lights to use with the Visolite leak detection powder. The Viso Wand and the Cordless Viso Wand are specifically designed for use in pulse-jet baghouses. The Super Wand is designed for use in reverse air and shaker baghouses, but can be used in pulse-jet systems. The Viso Big Light has a special high-intensity beam for brightly lit areas. Viso Big Light Portable LED Black Light Neutralite® Powder Creates a more efficient and porous dustcake. The Importance of Building a Protective Dustcake For a baghouse to operate efficiently, the fabric filters must capture and release particulate during the cleaning cycle. The effectiveness of this process depends on the development of the dustcake (initial control layer of dust) that protects the fabric interstices. A variety of particle sizes and shapes are needed to produce an efficient and porous dustcake. Particles that are similar shapes and sizes will form a very dense dustcake that restricts airflow. Neutralite® vs. Other Precoats/Conditioning Agents Neutralite consists of microscopic particles that vary dramatically in shape, while most other precoats only have one particle size. Neutralite is also lighter than lime and flyash and will not fall off the bags during cleaning. Don’t throw money down the hopper by using precoats that don’t work properly in a baghouse application. Lime Fly Ash Diatomaceous Earth • Alkaline by nature • Presence of sulfur can form gypsum, leading to plugging or blinding of filter bag • Similar particle size creates dense, compact dustcake • Generally abrasive • Typically used for wet • Varying pH from highly filtration applications acidic to very basic • Introduces moisture and • May require pretreatment hydrocarbons into the to alter hazardous gas stream material makeup • Moisture binds the diatoma• Material is heavy and ceous earth to the filter often falls off bag surface causing permanent blinding and loss of airflow NEUTRALITE® • No detectable free silica content for a safer work environment • Light density aluminum silicate powder • Varied particle size to prevent blinding of filters • Works in a variety of applications • Absorbs hydrocarbons, moisture, and sparks (Neutralite SR) • Proven to help lower DP, increase airflow, and lower emissions Neutralite® SR (Spark Retardant) If your operation has the potential for hot sparks in the gas stream entering the baghouse, Neutralite SR Powder can help protect your collector. It offers the same benefits as regular Neutralite powder, plus it: • Provides a protective barrier between the fabric and sparks in the gas stream • Helps extinguish sparks before they damage the bag • Absorbs up to 300% its weight in moisture and 250% its weight in oil and hydrocarbons to help prevent filter bag damage Independent testing by the Southern Research Institute showed that Neutralite® increased collection efficiency dramatically, while operating at a differential pressure 3 to 4 times lower than operation without an initial dustcake of Neutralite®. By injecting an initial dustcake of Neutralite powder, the fabric is protected from the particulate, while still allowing airflow to pass through the dustcake. The result is lower differential pressures and higher collection efficiency. Clamps Protection for your filter investment. When you buy new filters, buy new clamps. GE Clamps are Designed to Protect Your Filter Bags and Make Installation Easy Our clamps increase bag life by decreasing leakage and abrasion. Each clamp is designed specifically to ensure bag sealing and make filter installation simple. We offer a variety of designs and sizes engineered to meet your particular needs. They can be used with raw edge, cord, hem, or sleeve constructed bags and some 1 pleated filter elements. There are several reasons why clamps can fail: • Misapplication • Misplacement • Over-torquing • Reuse of old clamps • Corrosion Our dust collector experts recommend replacing clamps each time you change out your filter elements. 6 Clamp 2 5 4 3 Description 1 Worm Gear/ • Designed with a worm gear connection for tightening upon installation Latch Combination Clamp • Designed with a latch assembly for quick removal • Constructed of 300 series stainless steel and has a 9/16-inch (1.43 cm) band width 2 Quick Release Clamp • Swivel action locking of the screw to the band makes installation simple • Reduces downtime required during bag changeouts • Band and housing are constructed of 300 series stainless steel with no spot welds, reducing the possibility of rupture under stress • Clamp housing conforms to the round shape of the band, providing a stronger interlock 3 Worm Gear Clamp • Specifically designed with lower housing to be used in areas where room is restricted • Easy to tighten, which ensures a leak-resistant closure 4 T-Bolt Band Clamp • Used in high torque/clamp pressure applications where ordinary hose clamps fail • Available in general purpose and quick release styles depending on the application • More sealing pressure for bottom load collectors collecting fine particulate 5 Tool-Less Clamp • Designed for easy attachment to Norblo style bags • No tools required for installation or removal • Has a 6-inch (15.24 cm) diameter and 1/2 inch (1.27 cm) band width 6 Lined Clamp • Designed for our patented PulsePleat® filter elements • Constructed of 316 stainless steel • The liner protects the filters from extruding or shearing through the band notches on the clamp as it is tightened Tensioning Provides proper support to filter bags. Tensioning is Critical to Reverse Air Baghouse Operation Improper tensioning is one of the main causes of bag failure in reverse air baghouses. Excessive tensioning causes harmful stress on the fabric yarns and sewing threads and also prohibits movement necessary for dustcake release. We have developed many tensioning assemblies to best fit your application. The assemblies are available in chrome silicon steel for moderately elevated temperatures or 17-7 PH stainless steel for high temperature applications. Conical Spring Unlike a linear spring, which compresses equal amounts for equal pounds of load applied to it, the conical spring becomes harder to compress as heavier loads are applied. In this manner, it acts as a shock absorber, preventing the fabric from total collapse while under the reverse air cycle. It also reduces any “popping” effect on the bags when returning to service. This spring is used in the I-Bolt and Double Draw Bar Assembly and the Pre-Loaded Rod and Draw Bar Assembly. I-Bolt Assemblies I-Bolt and Double Draw Bar Assembly Features and Benefits • Hitch-pin design allows for ease of maintenance when re-tensioning • Easy adjustment and installation reduces labor that is normally associated with threaded bolt assemblies • Provides the necessary tensioning to maintain proper collection efficiency • Prevents bag-to-bag abrasion • Features a patented cup washer centering the spring on the bolt, which resists spring buckling and abrasion • Provides non-linear compressibility, supporting both the bag and dustcake, allowing fabric the necessary movement to clean while preventing bag collapse • Provides the required pre-load and travel for proper tensioning Tensionor® Suspension System Our Tensionor® Suspension System adjusts the filter bag/cap assembly to the proper tension, providing the following benefits: • Prevents abrasion caused by improperly tensioned bags that droop into thimble • Easily installed in shaker or reverse air without the use of hand tools • Helps reduce fan horsepower requirements due to lower pressure across the filters • Increases filter bag life by minimizing flex fatigue and abrasion at bottom of filter Tensionor® Suspension System AC Tensioning Tool® System The AC Tensioning Tool® System is a precision tensioning device used with our I-bolt and double drawbar tensioning assemblies providing accurate, consistent bag tension significantly faster than conventional methods. Additional Tensioning Products Pre-Loaded Rod and Drawbar Assembly is designed for use in tight spaces. The TRAP Control System is designed to reduce bottom bag abrasion in shaker baghouses. It features a self-cleaning torsion spring and anti-collapse rings. Hanging Assemblies include Tubehook, Double-D Hanger, and Strap Clip hanging assemblies, available in both carbon and stainless steel. AC Tensioning Tool® Valves/Valve Kits Improve your baghouse cleaning system. The Efficiency of Your Pulse-Jet Cleaning System Relies on Proper Valve Operation Diaphragm and solenoid valves work together for efficient operation of the baghouse cleaning system. GE Energy can provide technical support, complete rebuild instructions, and an in-house engineering staff to assist your crews with site-specific valve problems. We supply a a wide variety of valves to accurately fit your application. • For extremely corrosive applications, valves can be coated in a variety of finishes • Integral solenoid valves are mounted directly on the diaphragm valve • Remote solenoids are mounted in a separate NEMA enclosure • Valves available for high volume/low pressure applications Inside view of double diaphragm valve. Diaphragm valve kit includes: • Diaphragm • Spring Solenoid valve kit includes: • Plunger Assembly • O-Rings • Hardware • Retaining Clip • Clip Retainer Simplified valve troubleshooting guide Problem Cause Solution Valve will not open • No power to timer or solenoids, or faulty steps in timer • Solenoid coil continuity • Buildup of debris (oil, dirt, etc.) in solenoid plunger sleeve • Tubing between solenoid and pulse valve blocked • Tubing ID too small (< 0.167” or 0.42cm) or tubing too long (> 8’ or 2.44m) • Solenoid plunger worn • Holes in diaphragm • Blocked exhaust ports • • • • • • • • Valve will not close • Solenoid leaks air (leaks air) • Tubing between solenoid and pulse valve leaks • Solenoid energized continuously • Insufficient air supply • Blocked bleedports in pulse valve housing • Bad seal on diaphragm or broken diaphragm spring • • • • Check wiring, may need new timer board Replace coil Clean or replace plunger Unplug lines - replace if needed Install correct tubing Rebuild with solenoid repair kit Replace diaphragm Remove blockage Rebuild or replace solenoid Replace tubing and/or connectors Check power - replace timer board Check compressor supply lines, and the header is properly sized • Lightly tap housing near bleedport to release blockage or disassemble valve and clean out bleed port • Replace with diaphragm kit Door Seal/Access Doors Help prevent outside air from leaking into the system. Avoid Corrosion, Emissions, and Production Loss by Keeping Access Doors Sealed Properly A door seal is one of the most overlooked issues in dust collector maintenance. If your doors are not sealed properly, many problems can occur within your system, including: • Corrosion of doors and walls • Fugitive emissions • Production losses • Maintenance problems • Reduction of airflow across filters due to condensation and blinding 1 2 3 GE Energy has developed a variety of door seals to prevent leakage of outside air into your air pollution control (APC) equipment. Helpful Maintenance Tips 6 • Replace old door seal • Make sure the door is not warped and seals tightly • Avoid repeated opening of access doors, which often moves the seal 5 GE Energy has the Perfect Access Door for Your Dust Collector 4 Need custom made doors for your baghouse, electrostatic precipitator (ESP), or selective catalytic reduction (SCR) system? GE Energy supplies access doors to fit all typical OEM applications, whether you need a stamped, round precipitator door with a key interlock, an insulated center-pivot baghouse door, or a large rectangular moisture-proof scrubber or SCR access door. All our doors are custom-manufactured to suit your needs. Many are preassembled, and are on-the-shelf. Other, less-common styles are assembled and welded using jigs to ensure a precise fit for your unit. 7 Material Size Part No. Max.Temp. Specifications 1 Solid Silicone U-Channel 3/4 in. (1.9 cm) x 1 in. (2.54 cm) 5/8 in. (1.59 cm) x 7/8 in. (2.22 cm) 821-0003 821-0007 450° F (232° C) • Excellent high-temp • General resistance to oxidizing chemicals, ozone, and alkalies • Poor resistance to solvents, oils, concentrated acids, and abrasion 2 Sponge Neoprene 3/16 in. (0.48 cm) x 1/2 in. 820-0358 (1.27 cm) 820-0359 3/8 in. (0.95 cm) x 1 in. (2.54 cm) 250° F (121° C) • Good resilience, abrasion resistant • Moderate chemical resistance • Generally affected by strong oxidizing acids 3 Sponge Silicone 3/16 in. (0.48 cm) x 1/2 in. (1.27 cm) 3/8 in. (0.95 cm) x 1 in. (2.54 cm) 820-0070 350-0898 450° F (232° C) • Excellent high-temp • General resistance to oxidizing chemicals, ozone, and alkalies • Poor resistance to solvents, oils, concentrated acids, and abrasion 4 “Rope” Style Inconel Core* 1 in. (2.54 cm) Bulb 816-0026 600° F (316° C) 5 “Rope” Style Glass Core* 1 in. (2.54 cm) Bulb 816-0022 6 “Tadpole” Style Inconel Core* 1/2 in. (1.27 cm) Bulb 1 in. (2.54 cm) Bulb 816-0024 816-0019 600° F (316° C) • Excellent high-temp • General resistance to oxidizing chemicals, ozone, and alkalis • Poor resistance to solvents, oils, concentrated acids, and abrasion 7 “Rope” Style Zetex™ 3/4 in. (1.9 cm) square 128 ft. (39.01 m) per roll 1 in. (2.54 cm) square, 86 ft. (26.21 m) per roll 821-0125 821-0102 1500º F (815º C) *Glass Core and Inconel Core Door Seals are Teflon® impregnated for chemical resistance. • Excellent high-temp • Good resistance to most acids, alkalies, and solvents • Abrasion resistance • Superb tensile strength Gauges Small changes now can mean big savings in the long run for your operation. Keep Differential Pressure in Check with Pressure Measurement Gauges High differential pressure in the baghouse can cause damage to filter bags, decrease airflow in your baghouse, and increase operating costs. You can monitor differential pressure with one of our pressure measurement gauges, and even allow your collector to clean on demand! Magnehelic® Gauge for Continuous Pressure Measurement The Magnehelic gauge is used to measure the differential pressure between the clean gas side and the dirty gas side of the baghouse, which is the bag’s resistance to the airflow. A sudden drop in pressure denotes a leak in the system. A sudden or sharp rise in pressure denotes that the filter bags are becoming blinded or “caked” with particulate. The Magnehelic gauge is the best indicator of your baghouse’s current operating status, and offers critical information when troubleshooting. Photohelic® Gauge to Incorporate Clean on Demand The Photohelic gauge is a Magnehelic gauge with the capability to allow a collector to clean on demand. In addition to measuring differential pressure between the clean and dirty sides, the Photohelic gauge allows you to set high and low pressure points. When the actual differential pressure reaches the high point, a relay signals the pulse system to activate cleaning. While cleaning, the differential pressure will fall to the low pressure point and a relay signals the pulse system to stop cleaning. Surge Valve Provides Fast and Easy Cleanout of Gauge Lines The Surge Valve is a three-way valve that allows fast and easy cleanout of Magnehelic and Photohelic lines without disconnecting the lines to manually clean. The ball valve is designed to protect the gauges from breaking under high pressure cleaning. The benefits of the surge valve include: • Simple to operate – close the valve and a push of a button cleans the entire line in seconds, making it a fast, easy way to keep the lines clean. • Can be connected to a timer for automatic cleaning. • Withstands temperature ranges from 32° F (0° C) to 200° F (93° C). • Heavy duty construction makes it suitable for service up to 150 psi (10.34 bars) pressure. A surge valve can eliminate plugged lines. Diaphragm Valve Blowpipe Auto Purge Valves Help Prevent Corrosion and Agglomeration in the Baghouse GE’s automatic purge valves are designed to help eliminate water buildup in the compressed air header of a pulse-jet system. Without the purge, water from the compressed air can enter the baghouse and cause corrosion to filter bags and an agglomerated, hard-to-clean dustcake. The valve is installed at the bottom of the air header assembly and is connected to a pulse valve. When the pulse valve fires, the valve opens the purge valve discharge port on the air header assembly, removing excess moisture. Venturi Header Purge Valve Your Complete Resource A system-wide approach to optimize your APC system. Baghouse Filters BHA-TEX* Expanded PTFE Membrane Filters* Cartridges - Paper and Spun Bonded Media * Filter Bags and Cages* STS* SpiroTube Filter System* PulsePleat* Pleated Filter Elements * ThermoPleat* Pleated Filter Elements * Baghouse Parts and Accessories Access Doors AC Tensioning Tool* Bag Cups/Venturis/Thimbles/Clamps Dampers/Ductwork / Fans Diaphragm/Solenoid Valves/Valve Repair Kits Differential Pressure Monitors and Magnehelic*/Photohelic* Gauges Door Seal Gauge Line Cleaners - Surge Valve Neutralite* Conditioning Agent Pressure Transducers PureLine* Filter System Tensioning Assemblies* Tubesheets/Blowpipes Vacutrans* Vacuum Cleaning Systems Visolite* Leak Detection System* GE Energy 8800 E. 63rd Street Kansas City, MO 64133 Phone: +1.816.356.8400 Fax: +1.816.353.1873 Toll-Free: 800.821.2222 Email: [email protected] For international customer support: Brazil +55.48.3225.6601 China +86.21.6357.7100 Acoustic Cleaners Germany +49.201.76026.0 Acoustic Horn Replacement Parts BHA Powerwave* Acoustic Cleaning Systems* India +91.20.256.38.500 Monitors and Electronics Japan +81.3.5544.38.22 Clean-on-Demand* Controllers CPM* Particulate Detection System* Systems and Services Technical Services Installations/Refurbishings/Inspections Maintenance Programs Max-9* Electrostatic Fabric Filter Rebuilds/Conversions/Upgrades Troubleshooting and Maintenance Seminars Evaporative Gas Conditioning Vaporfect* Evaporative Gas Conditioning Systems/Nozzles/Lances/Engineering Mexico Toll free: 01.800.522.4768 01.800.821.2222 Philippines +63.2.877.7422 Spain +34.93.553.0850 Switzerland +41.62.386.7777 United Kingdom +44.1254.268.900 www.ge-energy.com/airquality ©2008 General Electric Company. 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