Pulse Dust CollectorThe Installation Quality Directly Affects Its Dust Removal Efficiency, Operational Stability, And Service Life. It Is Necessary To Strictly Follow The Design Drawings And Specifications, And Adjust According To The On-site Working Conditions. The Following Are The Installation Process, Key Points, And Precautions:
1、 Preparation Before Installation
1. Basic Inspection
Flatness: The Horizontal Error Of The Concrete Foundation Is ≤ 3mm, And It Needs To Be Measured With A Level To Ensure That There Is No Tilt After Equipment Installation.
Bearing Capacity: The Basic Bearing Capacity Should Be ≥ 1.2 Times The Total Weight Of The Equipment (including The Full Load Weight Of Dust), And Load Verification Should Be Carried Out If Necessary.
Reserved Space: A 1.5-2m Maintenance Channel Is Reserved Around The Equipment, And A Space For Replacing Filter Bags Is Left At The Top (height ≥ Filter Bag Length+0.5m).
2. Equipment Inventory And Inspection
Component Verification: Clean The Box Body, Filter Bag, Pulse Valve, Spray Pipe, Control System And Other Components According To The Packing List, And Check For Any Damage Or Deformation (such As Cracking Of The Box Body Weld Seam And Scratching Of The Filter Bag Surface).
Material Confirmation: Check Whether The Material Of The Filter Bag (such As High Temperature Resistance And Anti-static) Is Consistent With The Design Requirements, And Whether The Thickness Of The Box Board Meets The Standard (generally ≥ 3mm).
2、 Installation Process And Key Points
1. Installation Of Base And Box
Base Fixation: Weld The Base Channel Steel Or Fix It To The Foundation With Expansion Bolts To Ensure Levelness (error ≤ 2mm). Rubber Pads Can Be Placed Between The Base And The Foundation For Shock Absorption.
Box Assembly: Segmented Boxes Need To Be Installed From Top To Bottom According To Their Numbers, With Clean Sealing Surfaces, Sealed With Silicone Or Asbestos Pads, And Evenly Fastened With Bolts (to Avoid Air Leakage). When Welding The Box, The Internal Welds Need To Be Polished Smooth To Prevent Dust Accumulation; External Welds Should Be Treated With Anti-corrosion Measures (such As Applying Anti Rust Paint And Topcoat).
Installation Of Ash Hopper: The Connection Between The Ash Hopper And The Box Is Tightly Sealed, With A Cone Angle Of ≥ 60 °. An Ash Discharge Valve Is Installed At The Bottom To Ensure Smooth Ash Discharge.
2. Installation Of Filter Bags And Bag Cages
Installation Sequence: First Install The Bag Cage, Then Cover The Filter Bag. Install From Both Sides Of The Dust Collector Inlet And Outlet Towards The Middle To Avoid Stepping On The Already Installed Filter Bag.
Key Operation: The Bag Cage Should Be Inserted Vertically Into The Flower Board Hole, With A Distance Of ≤ 5mm Between The Bottom And The Flower Board To Prevent Dust Accumulation; The Surface Of The Bag Cage Is Smooth Without Welding Slag Or Burrs To Avoid Scratching The Filter Bag. When Installing The Filter Bag, It Needs To Be Slowly Stretched To Ensure That The Elastic Ring Of The Bag Mouth Is Tightly Attached To The Flower Plate Hole (can Be Lightly Tapped And Compacted With A Wooden Mallet), To Avoid Wrinkles Or Looseness That May Cause Dust Leakage.
Attention: Installation Personnel Should Wear Clean Work Clothes And Gloves To Avoid Oil Stains And Sharp Objects From Contacting The Filter Bag; Moisture Proof Measures Are Required During The Rainy Season, And Temporary Storage Of Filter Bags Should Be Covered With Plastic Sheeting.
3. Installation Of Dust Cleaning System
Installation Of Pulse Valve Group: The Pulse Valve Is Fixed On The Airbag, And The Interface Is Sealed With Sealant Or O-ring To Prevent Compressed Air Leakage. Before Installing The Airbag, It Is Necessary To Remove Rust And Clean The Inside, Install A Drain Valve At The Bottom, And Regularly Discharge Condensed Water.
Installation Of Spray Pipe: The Deviation Between The Spray Pipe And The Center Of The Flower Plate Hole Is ≤ 2mm. It Can Be Fixed With Positioning Fixtures To Ensure That The Spray Hole Is Aligned With The Center Of The Filter Bag. When Connecting The Spray Pipe To The Pulse Valve, The Pipeline Should Be Straight To Avoid Pressure Build-up And Displacement Of The Spray Pipe.
Compressed Air Pipeline: The Pipeline Material Is Galvanized Steel Pipe Or Stainless Steel, And The Pipeline Needs To Undergo A Pressure Test (0.6~0.8MPa) To Ensure No Leakage; The Pipeline Route Should Be Shortened As Much As Possible To Minimize Bends And Reduce Pressure Loss.
4. Installation Of Control System
Location Of Electrical Control Cabinet: Close To The Dust Collector But Away From High Temperature And Humid Areas For Easy Operation And Maintenance. The Cabinet Is Reliably Grounded (grounding Resistance ≤ 4 Ω).
Sensor Connection: The Pressure Transmitter Is Installed At The Inlet And Outlet Of The Dust Collector To Monitor The Resistance Of The Filter Bag; The Temperature Sensor Is Installed At The Air Inlet To Prevent Overheating And Damage To The Filter Bag.
Line Laying: Separate Signal Lines From Power Lines To Avoid Interference; The Cable Is Protected By Galvanized Steel Pipes, And The Interface Is Sealed And Waterproof.
3、 Commissioning And Acceptance After Installation
1. Single Machine Debugging
Dust Cleaning System Test: Turn On Compressed Air (pressure 0.4~0.6MPa) And Check Whether The Pulse Valve Is Blowing Normally One By One. The Blowing Sound Is Crisp And There Is No Air Leakage Sound; The Spraying Interval And Duration Are Set According To The Design Parameters (such As An Interval Of 30 Seconds And A Duration Of 0.1~0.2 Seconds). Observe Whether The Filter Bag Shakes Evenly During Spraying, And Whether There Are Any Blind Spots During Spraying (which Can Be Judged By The Accumulation Of Dust).
Ash Unloading System Test: Manually/automatically Start And Stop The Ash Unloading Valve, Run For 30 Minutes To Check The Motor Temperature Rise (≤ 60 ℃), Whether There Is Any Blockage, And Whether There Is Any Ash Accumulation In The Ash Hopper.
Fan Test: Jog The Fan To Confirm Correct Direction, Run It Without Load For 2 Hours, Monitor Vibration (≤ 2.5mm/s), Noise (≤ 85dB), And Current Stability.
2. Linkage Debugging
Load Operation: Connect To The Production Process System, Gradually Increase The Dust Concentration To The Design Load, Run For 4-8 Hours, Monitor The Inlet And Outlet Pressure Difference: Normal Resistance Is 800-1200Pa, If It Exceeds 1500Pa, Check The Dust Cleaning Effect Or Filter Bag Blockage.
Emission Concentration: Detected By A Dust Detector, In Compliance With Environmental Standards (generally ≤ 30mg/m ³).
Temperature Of Each Component: Bearing Temperature ≤ 70 ℃, Filter Bag Temperature ≤ Design Temperature Resistance Value (such As Normal Temperature Filter Bag ＜ 80 ℃, High Temperature Filter Bag ＜ 200 ℃).
Leakage Inspection: Apply Smoke Or Soapy Water To The Flange, Weld Joint, And Other Connections. If Any Leaks Are Found, Repair Welding Or Replace The Sealing Gasket In A Timely Manner.
3. Acceptance Criteria
Appearance: The Equipment Has No Obvious Deformation Or Rust, The Surface Paint Is Uniform, And There Is No Sagging Or Bubbles.
Performance Indicators: Dust Removal Efficiency ≥ 99%, System Resistance ≤ Design Value, Flexible Opening And Closing Of Each Valve, And Sensitive Response Of The Control System.
File Archiving: Provide Installation Records, Debugging Reports, Material Qualification Certificates, As Built Drawings, And Other Materials.
