Recordkeeping and Routine Maintenance

Every operation and maintenance manual ever written states that "good recordkeeping is the
key to an effective operating system." In the real world, recordkeeping practices range from
none to extensive computerized logging and retrieval systems. As stated previously, it is very
important to develop a baseline for both the baghouse operation and the process that it controls
to evaluate future performance and maintenance trends.

Although most operators agree that recordkeeping is imperative, the specifics on what parameters
are monitored and at what frequency are very site-specific. A number of performance
parameters were listed in the previous section. In addition to these parameters, the baghouse
vendor will generally provide some checklists for performing routine inspections. These
checklists should be used as templates to develop forms for the operators to fill out when making
their rounds.

In addition to documenting the routine inspections, the operator should document all maintenance
performed on the baghouse; especially bag replacement. A majority of the larger plants
have computerized work order systems that should be used to develop a special file for baghouse
maintenance. In addition, since the most common and expensive failures are for bag
replacement, maintaining a trend of bag failures is imperative. A typical bag replacement
record as shown in Figure 1 should be used. Using this type of tool can help identify failure
patterns due to design or operating practices.

Figure 1. Bag failure location record

Inspection frequencies of all baghouse components should be established by maintenance
engineers. Vendors' recommendations of an inspection schedule should be followed. A listing
of typical periodic maintenance follows.

Daily Maintenance 

1. Check pressure drop.
2. Check pressure drop.
3. Monitor gas flow rate.
4. Observe stack outlet visually or with a continuous monitor.
5. Monitor cleaning cycle, pilot lights, or meters on control panel.
6. Check compressed air on pulse-jet baghouses.
7. Monitor discharge system; make sure dust is removed as needed.
8. Walk through baghouse to check for normal or abnormal visual and audible conditions.

Weekly Maintenance

1. Check all moving parts on the discharge system including screw-conveyor bearings.
2. Check damper operation; bypass, isolation, etc.
3. Spot check bag tensioning for reverse-air and shaker bags.
4. Check compressed air lines including line oilers and filters.
5. Blow out any dust from manometer lines.
6. Verify temperature-indicating equipment.
7. Check bag-cleaning sequence to see that all valves are seating properly.
8. Check drive components on fan.

Monthly Maintenance

1. Spot check bag-seating condition.
2. Check all moving parts on shaker baghouses.
3. Check fan for corrosion and blade wear.
4. Check all hoses and clamps.
5. Spot check for bag leaks and holes.
6. Inspect baghouse housing for corrosion.

Quarterly Maintenance

1. Thoroughly inspect bags.
2. Check duct for dust buildup.
3. Observe damper valves for proper seating.
4. Check gaskets on all doors.
5. Inspect paint on baghouse.
6. Calibrate opacity monitor.
7. Inspect baffle plate for wear.

Annual Maintenance

1. Check all welds and bolts.
2. Check hopper for wear.
3. Replace high-wear parts on cleaning system