As industrial environmental standards become increasingly stringent, the stable operation of baghouse dust collection systems has become a critical factor in ensuring safe production for enterprises. As the core actuator in air-cleaning systems, the performance of electromagnetic pulse valves directly impacts dust removal efficiency and equipment lifespan. Recently, in response to the frequent pulse valve failures encountered in industrial settings, technical experts from SMCC have developed a systematic approach to fault diagnosis and preventive maintenance. This solution aims to help enterprises reduce the risk of unplanned downtime.
I. Impact of pulse valve failure on the operation of the dust removal system
Pulse valve failure is the primary cause of dust removal system malfunction. The malfunction of this component will directly lead to abnormal equipment operation. As the core actuator component of a bag filter, the pulse valve, once failed, will immediately interrupt the dust cleaning function. The filter bag will quickly experience dust blockage, resulting in increased equipment operating resistance and excessive flue gas emissions. Relevant industrial cases show that enterprises that fail to promptly address pulse valve failures can be subject to administrative penalties by environmental protection departments and listed as key environmental monitoring targets. At the same time, it can cause significant damage to a large number of filter bags, leading to a significant increase in direct and indirect economic losses.
II. Common fault types and cause analysis of pulse valves
The fault types of pulse valves can generally be classified into three categories: mechanical component damage, air source contamination, and electrical control abnormalities.
Mechanical component damage
Diaphragm damage: As the core sealing component of the pulse valve, the diaphragm is prone to fatigue aging or mechanical damage due to long-term high-frequency operation. Typical symptoms include valve air leakage and weak blowing force. Data shows that diaphragm damage accounts for over 60% of pulse valve failure cases.
Spring failure: The valve core reset spring may experience fatigue fracture or decreased elasticity after prolonged compression, resulting in the valve failing to close properly and causing continuous air leakage.
Seal aging: The valve body sealing ring or rubber gasket may harden and crack due to material mismatch or extended use, leading to air pressure leakage and affecting the blowing pressure.
Air source pollution and blockage
Valve core jamming: Oil, water, and particulate impurities contained in the compressed air can enter the interior of the valve body, causing the valve core to be obstructed in its movement. This manifests as either no action or slow action after being powered on.
Orifice blockage: The orifice is a key component for controlling the pressure relief rate. Dust backflow or scaling of condensate water can cause it to lose its throttling function, resulting in the pulse valve acting but without dust removal effect.
Abnormal electrical and control system
Coil burnout: The electromagnetic coil is damaged due to unstable voltage, moisture-induced short circuit, or overload, manifesting as an alarm from the controller and no response from the valve body.
Temporal disorder: Disorder in control procedures or incorrect parameter settings can lead to abnormal ash removal cycles, resulting in ash accumulation on some filter bags or damage due to excessive blowing.
III. Quick troubleshooting method for pulse valve malfunctions
Fault diagnosis is the prerequisite for achieving rapid maintenance, and the location can be determined on the industrial site through a three-step method.
Firstly, by judging the operating sound, a normal pulse valve should exhibit regular air-ejecting actions. If there is no sound or abnormal noise, it can be determined that the corresponding valve body is abnormal;
Secondly, according to the air pressure monitoring, an abnormal decrease in compressed air pressure usually indicates a valve body leak;
Thirdly, through visual inspection, it can be determined that diaphragm deformation, valve body heating, and continuous exhaust from the pressure relief port are all typical fault characteristics.
IV. 10-Minute Emergency Manual Dust Removal Procedure
Emergency response measures can restore the basic operational capability of the dust removal system within a short period of time, thus avoiding a complete production shutdown.
The first step is to cut off the power supply and compressed air source of the equipment to eliminate potential safety hazards during maintenance;
The second step involves performing a manual triggering operation, utilizing a manual button or lever to achieve forced blowing and dust removal, thereby quickly restoring the permeability of the filter bag. The third step involves implementing pressure regulation based on on-site conditions. If necessary, the bypass valve can be temporarily opened to reduce system load, thereby gaining time for maintenance operations.
V. Replacement specifications and selection requirements for pulse valve accessories
The replacement of accessories must strictly adhere to model matching and installation standards to reduce the occurrence of secondary failures. During the selection phase, it is necessary to verify key parameters such as the diameter of the pulse valve, working pressure, and working voltage, while selecting corresponding materials and seals based on the working environment. During the disassembly process, impurities on the installation surface must be cleaned, and the sealing performance must be ensured during the installation process. In the commissioning phase, it is necessary to test the blowing effect and changes in the pressure difference of the dust collector to confirm that the equipment has returned to normal operation.
VI. Solutions for six or seven types of high-frequency faults
Fault maintenance should be carried out in a one-to-one correspondence of phenomenon, cause, and disposal measure to improve maintenance efficiency.
The damage of the spring is manifested as continuous air leakage. It can be replaced with a corrosion-resistant spring and equipped with a high-precision filter;
The damage to the diaphragm manifests as weak blowing force. It can be replaced with a high-temperature resistant fluororubber diaphragm and inspected regularly;
The valve core may become stuck due to dirt, resulting in malfunction. It can be cleaned and the air source drying and filtering system can be optimized;
The blockage of the throttle hole manifests as ineffective injection, which can be gently cleared and a check valve installed;
The coil burnout manifests as no action from the valve body. The resistance can be detected, and voltage stabilization and moisture-proof equipment can be installed;
The seal failure is manifested as insufficient air pressure, and the sealing components can be tightened and lubricated according to the standard torque;
The time sequence disorder manifests as uneven ash removal. The control program can be reset and the blowing parameters calibrated.
VII. Preventive maintenance and lifespan enhancement plan for pulse valve
Routine maintenance can effectively reduce the probability of malfunctions and extend the overall service life of the pulse valve.
Enterprises should upgrade the purification of their compressed air systems and control the indicators of oil content and water content;
Install intelligent monitoring modules to achieve real-time monitoring and abnormal alarming of pressure and motion status;
Establish a regular maintenance mechanism, inspect vulnerable parts such as diaphragms and coils monthly, and clean the dust inside the valve body quarterly.
Meanwhile, a common spare parts reserve system will be established to ensure the rapid supply of key components such as diaphragms, springs, and seals.
VIII. Conclusion
The stable operation of electromagnetic pulse valves is a crucial guarantee for bag filters to achieve emission standards and continuous operation. By standardizing fault diagnosis procedures, implementing rapid emergency response plans, regulating accessory replacement, and institutionalizing preventive maintenance, enterprises can significantly reduce the risk of sudden downtime, minimize economic losses caused by environmental penalties, equipment damage, and production interruptions. Continuously optimizing the quality of air supply and monitoring methods can further enhance the operational reliability of the dust removal system, providing stable support for industrial production to comply with environmental regulations.
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