Operating a dust collector efficiently can save a lot of money on energy costs and consumables. But how do you know it is operating efficiently without constantly doing pressure readings and visual checks of equipment status? And how do you know when its filters need replacing? Cartridges are expensive, but running them too long eats excess electricity and hurts collector performance. Remote filter monitoring can give production engineers, facility managers and other plant personnel confidence that the dust collector is doing its job so they can focus their attention on the critical production processes.
Monitoring differential pressure
Most quality brand industrial dust collectors have pulse cleaning systems that continually blow the dust off the filters to keep pressure drop low. Pulse cleaning helps the cartridges last longer, and premium-quality filters can last twice as long. But even quality filters will eventually run inefficiently and need to be replaced when the collected dust particles becomes too deeply embedded to pulse off. Also, unforeseen incidents can occur that hurt performance and cause a surge in pressure drop.
By monitoring filters remotely 24/7, you are alerted when your high differential pressure set points are hit. Then you can troubleshoot issues that you probably wouldn’t have noticed. Filter monitoring systems like Camfil’s GoldLink™ system are good preventive maintenance tools that optimize dust collection and reduce overall downtime costs.
Here are some situations that would be quickly discovered by a filter monitoring system:
- Someone forgot to turn on the cleaning system or the compressed air, and the filters haven’t been cleaning.
- The hoppers/dust bins are full and loading over the filters, causing high differential pressure.
- The filters have become too loaded to work effectively and require a change-out.
How filter monitoring works
The Camfil Gold Link device is a small box fitted with a 4-20mA differential pressure sensor that is installed in the control panel of any new or existing dust collector. When powered up, the device begins measuring overall dust collector readings. The pressure data is transmitted to the Cloud via a secure cellular modem where it is monitored by Camfil personnel at the Jonesboro headquarters. All data sent through the cellular network is fully encrypted end to end. This provides a fully isolated cloud connection without going through plant Ethernet networks.
Camfil stores the data in its database, where “out of range” readings trigger an alarm notification. Camfil views the data and alerts you to any issues that may require attention. Most often, high pressure readings signal that it is time to change out the filter cartridges.
In addition to getting alerts, the current status of your filters is always viewable via Camfil’s dashboard. If you have multiple dust collectors across multiple locations, all data can be viewed at the same time for comparison purposes and analysis of performance trends.
Remote filter monitoring systems like this provide peace of mind. Facility managers can focus on more important things, knowing they will be alerted if there is a dust collector issue that needs to be addressed. Also, you get operational insights and performance data that can reduce unplanned downtime.
Advantages of filter monitoring
- Eliminate manual performance checks
- Reduce downtime
- Reduce filter changeout
- Proactive maintenance
- Reduce energy usage
- Automatically capture performance data required for regulatory compliance reports
- Monitor operator exposure risks