Maintenance & Reliability · SOP

Dust Collector Bag Leak Detection And Sealing

A definitive technical procedure for identifying failed filter bags in a pulse-jet dust collector, isolating the breach via row-by-row differential pressure testing, and temporarily sealing the bag to maintain emissions compliance and protect downstream rotating equipment.

Estimated Time

45 min

Difficulty

Advanced

Regulation

CSA Z432 / BC OHS 3.13

Version

1.0

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Purpose

To provide a stringent, repeatable procedure for locating leaking bags in a pulse-jet dust collector, temporarily isolating them to meet regulatory emission limits, and logging the fault for planned replacement. This minimizes downtime, extends bag life, and reduces environmental risk from fugitive particulate emissions.

Scope

This procedure applies to all cartridge and baghouse dust collectors in the facility. It covers clean-air side visual inspection, row-by-row differential pressure trending, temporary plug installation, and documentation. Permanent bag change-out is covered under SOP-PM-047. All maintenance technicians and reliability engineers are required to follow this procedure when a bag leak is suspected or a stack plume is observed.

Safety Precautions

LOTOLockout/tagout the main fan, rotary airlock, and compressed air header. Insert personal padlock and tag. Verify zero energy state (0 dP) on the Magnehelic gauge before opening any access doors.
PPEWear N100 or P100 full-face respirator (based on dust toxicity), cut-resistant gloves, safety glasses, and disposable Tyvek coveralls to avoid dermal exposure to accumulated hazardous dust.
CONFThe clean-air plenum may be classified as a confined space. A confined space entry permit, continuous gas monitoring, and a standby attendant are mandatory if entry is required.
EXPLIf the dust is combustible (e.g., wood, metal, food starch), ensure the system is fully purged of any explosive atmosphere. Use only non-sparking tools. No hot work is permitted inside the collector.

Required Tools & Materials

Magnehelic gauge (0–10" w.c.) with silicone tubing
Explosion-proof LED inspection light
Expandable bag plugs (4", 6", 8" diameters)
High-temp RTV silicone gasket maker (rated to 500°F)
Utility knife / snips
LOTO hasp, padlocks, and tags
P100 / N100 full-face respirator
Tyvek coveralls
ServiceGrid mobile app for digital checklist completion

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Procedure: Step-by-Step

1 Initiate LOTO. Lock out the main fan, rotary airlock, and compressed air header. Insert your personal padlock and tag. Verify zero energy state on the Magnehelic gauge.

2 Stabilize and baseline. Allow 5 minutes for complete dust cake stabilization. Record the static pressure drop (dP) on the Magnehelic gauge across the entire collector.

3 Visual clean-side inspection. Open the clean-air plenum access doors. Using the explosion-proof inspection light, scan every bag from the clean-air side. Flag any bag showing light penetration, torn pleats, or detached collars.

4 Isolate the leaking row. If no obvious visual breach is found, perform an isolation sequence. Pulse one row at a time and watch the pressure spike on the gauge. A row with a weak or missing spike is the leaking row.

5 Install the sealing plug. From the clean-air side, insert the appropriately sized expandable bag plug into the tube sheet opening. Tighten the wingnut until the rubber cup seals firmly against the tube sheet collar.

6 Apply a positive seal. Apply a continuous ¼" bead of high-temp RTV silicone around the entire circumference of the plug base. Smooth the bead with a gloved finger to guarantee a zero-emission seal. Allow 10 minutes for skin-over.

7 Document in ServiceGrid. Log the event in the maintenance system. Record bag row, position number, date of installation, plug serial number, and technician ID. ServiceGrid will automatically schedule the bag replacement for the next outage window.

8 Re-energize and verify. Remove all tools and debris from the plenum. Close and latch all doors. Remove LOTO tags and padlocks. Re-energize the system. Bring the fan up to 25%, 50%, 75%, then 100% speed over a 5-minute ramp. Verify the dP returns to baseline. Visually confirm zero visible emissions from the stack.

Dust Collector Bag Leak Detection And Sealing

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