MODULE II PART C

Maintenance Engineering
Certificate Course

By Career Guidance Cell (CGC)

Department of Mechanical Engineering,
College of Engineering and Computer Science
 MODULE II
Plant Facilities Maintenance
 Maintenance in Air Purging Systems
AIR quality

Clean Air Act (CAA) , Occupational Safety and Health

Act (OSHA) - Importance of protecting the quality of
air in our atmosphere.

Contaminants - particulates, vapors, gases and/or

acid mists. Sources - manufacturing process or
industrial operation

Maximum allowable airborne concentrations of

contaminants -American Conference of Governmental
Industrial Hygienists (ACGIH) have established
threshold-limit values (TLVs) for airborne substances
with health hazard potential.
The advantages of installing air-purging equipment
include the following

1. Prevent contaminants from entering the working environment.

2. Increase quality of products manufactured or processes.
3. Meet the requirements of air pollution regulations.
4. Reduce maintenance downtime of process equipment.
5. Prevent local nuisance or damage to property.
6. Reclaim valuable materials.
7. Recover conditioned air.
8. Reduce or prevent fire or explosion hazards.
 Basic principles:

• Direct interception
• Centrifugal force
• Impingement
• Diffusion
• Gravity separation and settling
• Humidification
• Condensation
• Electrostatic attraction
• Absorption
TYPES OF EQUIPMENT
 Inertial or Dry Centrifugal

Simple cyclone. Multiple centrifugal. Dry dynamic

 Maintenance- Simple Cyclone and Multiple Centrifugal.
1. Emptying the storage hoppers at regular intervals to avoid re entrainment
2. Avoiding leakage at the dust-discharge point, especially if the unit is
under negative pressure
3. Routinely inspecting for buildup and extreme wear
4. Keeping uniform air volume to maintain constant efficiency
Dry Dynamic.
1. Keeping the dust-storage hopper vented back to the collector
2. Inspection of the impeller at scheduled intervals for accumulation and
wear on the blade tips
3. Emptying the dust-storage hopper regularly to avoid recirculation of
collected dust, which would reduce efficiency and cause extreme wear
4. Because this unit is a combination fan and dust collector, the preventive
maintenance outlined below under Fans regarding bearings and V-belt
drive should be followed
 Gas Absorbers
Gas absorption is a method of removing soluble and
chemically reactive gases from the airstream by
contacting them with a suitable liquid. This process
occurs when a soluble component of a gas stream
transfers to a liquid in contact with the gas. Absorbers
provide for intimate contact of the gas and liquid and
may vary widely in design and performance. Removal of
the contaminant may be by absorption if the gas
solubility and vapor pressure promote absorption
followed by chemical reaction. Gas absorption is a rate
process and therefore does not take place immediately
but rather at a rate depending upon several variables.
The most important of this process is the surface area of
contact. The absorption rate varies directly with
available surface area

Packed tower
 Maintenance in gas absorbers

Water rates of 5 to 10 gpm are typical for packed towers. Water is

distributed over V-notched ceramic or plastic weirs.

High-temperature deterioration is avoided by using brick linings,

allowing gas temperatures as high as 1600°F to be handled direct
from furnace flues.

The airflow pressure loss for a 4-ft bed of packing, such as ceramic
saddles, will range from 1.5 to 3.5 in WG. The face velocity
(velocity at which the gas enters the bed) will typically be 200 to
600 fpm.
 Particulate Scrubbers

Wet centrifugal. Wet dynamic.

Wet Centrifugal. Two types of wet centrifugal collectors are shown in Fig.
Collection relies on throwing the heavier particles against wetted collector
surfaces by centrifugal force. Water distribution can be from nozzles,
gravity flow, or induced water pickup by the airstream.

Wet Dynamic. The wet dynamic precipitator combines the dynamic and
centrifugal forces of a rotating fan wheel to cause the contaminant to
impinge on the numerous specially shaped blades, on whose surface a film
of water is maintained by spray nozzles at the inlet.
 Maintenance in wet centrifugal

1. Maintaining an adequate water supply at all times when fan is

operating.
2. When water is recirculated, use of adequate settling tanks providing
relatively clear water.
3. Continued water flow for 1/2 hr after fan is shut down to flush
equipment adequately.
4. Regular inspection of equipment for accumulations, and thorough
cleaning when required.
5. Inspection of spray nozzles, when used, at least once a week for
plugging.
6. Checking all drains for accumulations. A plugged drain may form a
water trap which could reduce the air volume
Orifice Type. Collection efficiency in
orifice-type wet collectors relies on
the pickup or delivery of large water
quantities to a collecting zone, where
centrifugal forces, impingement, or
collision causes capture of
contaminant before its removal from
the airstream. Water quantities in
motion are high, running from 10 to 40
gal per 1000 cfm. Much or all of this
water can be recirculated without the
use of distribution spray nozzles or
recirculation pumps.

Orifice type.
 Two types of orifice mode

Nozzle type Venturi scrubber.

Nozzle Type. High-pressure nozzles normally are installed in tower
types of centrifugal collectors. A large number of small nozzles is
involved, using water pressure of 250 to 600 psi and water volumes of 5
to 10 gal per 1000 cfm. Distribution of the droplets must be such that
dispersion increases the chances of impact between water droplet and
contaminant particle, rather than droplet against droplet to form
larger, less effective droplets. The use of small nozzle orifices makes
recirculation of water impractical for most industrial operations.

Venturi Scrubber. In the venturi design the shear stresses of the

airstream traveling at velocities of 12,000 to 20,000 fpm or higher are
used to break up water introduced through open supply pipes in the
venturi throat. The turbulence in the venturi occurs within a short time
interval.
 Maintenance in orifice type
1. The baffles or orifices that force the air to travel through the water
should be checked regularly for wear, corrosion, and accumulation.
2. A high-pressure water jet should be used periodically for hosing down the
interior.
3. Moisture entrainment baffles should be removed and cleaned. They must
be replaced properly, by having the hooked lips opposite the direction of
airflow.
4. Water overflow pipe should always be open to prevent reduced air volume
resulting from excessive water in the collector.
5. Water level control device should be regularly inspected for proper
operation. Improper water level will affect efficiency, air volume, and
performance of the unit.
6. Orifice-type collectors incorporating sludge ejectors for removal of the
collected dust should be inspected regularly.
Fabric Filtration

The filter media may consist

of cellulose (paper),
polyester, acrylics, nylon,
polypropylene, Teflon, glass,
cotton, woven metals, and
woven ceramics. The filter
media can be arranged in
many configurations such as a
mat, multiplied mats,
envelope, cartridge, or a
tubular shape (bag).
The collection mechanism is a
combination of impaction, direct
Conventional fabric collector, intermittent-duty.
interception, and diffusion.
 Fabric Type

Conventional fabric collector, continuous-duty Reverse-pulse fabric collector.

 Maintenance in Fabric type

1. Dust leakage through holes in the filter media

2. Unusual wear, or holes in the baffle plates, if used
3. Unusual wear in the spark screens, if used
4. Excessive buildup or accumulations in the dust storage hoppers
5. Leaky or inoperative dust discharge valves
6. Routine inspection of the fabric cleaning mechanism
 Electrostatic Precipitators
Precipitators are commonly classified in two groups,
low-voltage and high-voltage. The low-voltage,
small-dust-holding capacity, low-dust-loading
designs are used for indoor ambient air filtration.
The high-voltage precipitator is used to collect
particulate-laden air and gases in high-capacity
situations. The principle of collection is defined as
using electrical forces to impart a negative charge
to either liquid or solid particulate matter in a dirty
air or gas stream, collecting the charged particulate
matter to a positively charged collecting surface.
15,000 V for the low-voltage precipitator and
100,000 V for the high-voltage precipitator are used.
Cleaning uses a vibratory mechanism.
Electrostatic precipitator.
 Maintenance in precipitator type

All grounding procedures should be followed whenever maintenance

personnel:

1. Clean the line insulators.

2. Clean precipitator insulators.
3. Contact any high-voltage part.
4. Enter the rectifier screened enclosure.
5. Perform work inside the precipitator chamber.

Even with the current turned off, it is not safe to enter the equipment until the static
electricity has been dissipated by grounding. Proper grounding procedure consists of
connecting a heavy wire to the grounded steel work and then hooking it to the
disconnected high-voltage point.
After all the precautionary measures have been taken, normal maintenance
inspection includes:

1. Checking for excessive accumulations on the discharge and electrodes and

collecting surfaces.
2. Checking inoperative dust outlets and storage hoppers.
3. Checking performance of the electrical system for good ionization.
4. Maintain electrical clearances inside the precipitator in accordance with
manufacturer’s tolerances.
5. Inspect and ensure rapping (cleaning) mechanisms are in proper operating
condition.
 Sludge Settling Tanks.

1. Periodic removal of the sludge before the tank becomes completely filled
2. Removing the silt from the bottom of the clean water chamber
3. Checking drag-type chain sludge conveyors, if used, for broken links and
bent paddles
4. Checking for accumulations in the hopper bottom to avoid binding of the
conveyor
5. Periodically inspecting automatic timers normally used with sludge ejectors
to permit operation for 2 hr after the fan has been turned off
6. Routine inspection of chain guides and hopper wear plates for excessive
wear
7. Removal of chain links whenever proper tension is lacking in the conveyor
8. Checking pumps handling water from sludge settling tanks for abrasion
 Fans.
One of the most important items of any exhaust system is the fan. Most fan
troubles are caused by:
1. Abrasive cutting of the fan impeller and housing
2. Improper maintenance of V-belt drive and bearings
3. Accumulations causing vibration
Routine maintenance
1. Bearings for proper operating temperature (greasing on an established
schedule)
2. Bearings and/or housing for excessive vibration
3. Belt drives for proper tension and minimum wear
4. Correct coupling alignment
5. Fan impeller for proper alignment and rotation
6. Wear or material accumulation on impeller
 Maintenance of heavy duty air discharging units

1. Vibration caused by accumulations or improper mounting on a platform of light

construction.
2. Abrasive wear and corrosion of the blades, rivets, and bolt heads. This usually
will appear near the impeller disk.
3. Proper rotation. Most fans will discharge some air when running backward; so
air movement is not an adequate test for correct fan rotation. Most
manufacturers mark direction of rotation on the housing.
4. Proper tension on belts. In the event of a belt break in a multiple belt drive, all
the belts should be changed at the shutdown period. Multiple V belts should
have matching numbers to avoid having a few of the belts carry all the load.
5. Routine schedule for greasing the bearings. Follow the schedule and methods
outlined by the bearing manufacturer. Remember that overg reasing can be as
detrimental as lack of greasing.
 Maintenance of duct systems
Troubleshooting and maintenance procedures in duct systems

1. Location of the system indicated by bay, column, machine, or department

numbers. Manufacturer’s equipment, operating, and installation instructions
recorded or filed for reference in maintenance and ordering spare parts.
2. Operating data. Recorded design volume on each hood, branch, and
connection, as well as total volume, pressure, horsepower, and rpm.
3. System characteristics. Pressure readings taken at all checkpoints after the
system has been balanced. These figures are used for comparison when
checking performance at future scheduled dates.
4. Operating voltages and currents of equipment as compared with design
conditions.
5. A daily log of the air-purging system operation parameters.
 Don’ts in AIR PURGING SYSTEMS

Don’t hope to provide a dust collector by tying a burlap bag over a

discharge pipe.

Don’t put two collectors of the same order of efficiency in series. the
second collector will not remove enough material to alter discharge
appearance

Don’t visualize discharge appearance based on efficiency data. Appearance

of effluent air will be governed by efficiency of the collector, particle size
of the contaminant, and concentrations of the solid particles.
 Don’ts in AIR PURGING SYSTEMS
Don’t expect dust-collection equipment design to be more advanced than
production machine design.

Don’t wait for dust collectors to fail before ordering replacement parts.

Don’t visualize discharge appearance based on efficiency data. Appearance of

effluent air will be governed by efficiency of the collector, particle size of the
contaminant, and concentrations of the solid particles.

Don’t attempt to recirculate cleaned air from dust collectors handling toxic
material without careful investigation of the policing required to be assured of
maintaining effectiveness.

Don’t install unit collectors on heavy-duty production operations without careful

evaluation of the frequency of servicing required
 MAINTENANCE OF AIR PURGING EQUIPMENT

1. Cleaning the storage hoppers at regular, predetermined intervals

2. Definite scheduling of inspection for preventive maintenance

3. Repairing, replacing, and cleaning all parts where indicated by the

regular inspection
 References
Maintenance Engineering Handbook 7th Edition by Keith Mobley (Author),
Lindley Higgins (Author), Darrin Wikoff (Author), Publisher : McGraw-Hill
Professional; 7th edition (March 21, 2008), ISBN-10 : 0071546464, ISBN-13 :
978-0071546461
Thank You
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