Stop Leaks to Recover Operating Costs on Dust Collectors

Diaphragm and solenoid valves are often the last item on your Pulse Jet Dust Collector that is maintained or serviced. While most operators focus on filter performance, in terms of emissions and ventilation, the pulse jet system valves are leaking operational dollars.

The moving parts (springs, media, and plungers) within a solenoid and diaphragm valve have a limited life span. Dust collector valves are often culprits of uncaptured expenses due to internal failures.

Most notable valve manufacturers admit their moving parts are suitable for a finite number of cycles. But, what does that parameter mean in terms of everyday usage? Let us assume your dust collector is a crucial piece of the ventilation system of your facility working 24/7/365. Those valves are cycling 100,000 times a year or more. When was the last time that you have rebuilt your diaphragm and solenoid valves?

A healthy pulse jet valve, operating in proper sequence, makes a crisp and clean pop, much like a pistol. If the valves are compromised, then valve actions sound weak or always hiss with leaking compressed air.

Leaking valves not only reduce filter cleaning effectiveness, but they also waste compressed air resources. When filters do not clean efficiently due to reduced compressed air volume in the manifold tank, over time, those filters become overwhelmed and eventually blind. Blinded filters reduce collection draft, consume more fan amperage, and require more frequent replacement. Small valve leaks can quickly amass increased operating costs.

Within a typical diaphragm valve, you find two moving parts, a flexible media diaphragm, and coiled spring. In some cases, larger-sized pulse jet valves can have two diaphragms. Either one or both items can fail over time. Similarly, in a solenoid valve, you typically find two moving parts, a magnetic plunger and spring. Coincidental repetitive failures can be found with these as well.

Along with a preventative maintenance inspection plan, one can prolong diaphragm and solenoid life by ensuring the plant compressor system is delivering clean and dry air. Oil and debris-free compressed air prevent the fouling of the valves. Furthermore, instituting pulse on-demand vs. time protocol will not only foster longer parts and filters life; but also reduce the compressed air consumption by up to 67%.

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