In harsh industrial manufacturing environments, dust collectors can be pushed beyond their design limits, negatively affecting production and profitability. Filtration can be complicated with all the variables found in a dust collection system. Filter air passages can easily become clogged with sticky dust - resulting in frequent change-outs and unscheduled maintenance. That's why it's more important than ever to use the most effective, reliable filtration available.
Parker has developed an innovative aftermarket replacement filter, BHA® TotalPleat™, to replace PowerCore® CP filter pack. Part numbers P032358-016-340 and P280356-016-340.
The BHA® TotalPleat™ is a proprietary MERV 15 filter offering numerous improvements and advantages.
This blog was adapted from the white paper, BHA® TotalPleat™ Delivers Long Filter Life. Download your copy today.
The innovative deep-pleated design is engineered to keep 92% of the filter face open to flow, yielding high efficiency, effectiveness, and long service life.
The filter is designed with larger airflow passages, creating 50% more open airways compared with OEM filter packs. The open-pleat spacing extends to the filter’s full height to maximize use of the media surface area. Strategically placed glue beads lock the pleatpack together so the air passages remain open throughout pulse cleaning.
The TotalPleat™ filter face is 28% more open compared with the OEM filter. TotalPleat™ has larger and fewer airflow passages, and this pleatpack is designed to minimize the number of glue beads or plugs to hold the pleatpack together - optimizing filter face availability.
Dust can be more fully ejected during pulse cleaning. The dust-laden air flows into TotalPleat™ at a 22% lower air velocity compared with the OEM filters. The TotalPleat™ filter’s higher percentage of available surface area and larger airflow passages prevent dust from getting trapped. The cleaning pulse can reach the full depth of the filter on the clean side. On the dusty side, the open pleat spacing gives improved dust ejection. The cleaning pulse is then better able to reach the full depth of the TotalPleat™ filter and effectively clean the filter media.
Parker engineers applied extensive computational fluid dynamics modeling during the research and design of TotalPleat™ to analyze the effects of the cleaning pulse as it strikes the filter’s top face. The cleaning pulse of the collector strikes the back half of the filter at an angle and typically is intended to flow unaided toward the front half. For more cleaning power, BHA® TotalPleat™ is designed with an inclined, louvered grid that deflects a portion of the cleaning pulse toward the front of the filter to evenly distribute it across the entire filter.
Energy savings are realized when dust is fully ejected from the filter during cleaning as a result of the even distribution of the cleaning pulse. Fewer pulses are required to keep the filters running at low dp and less energy is consumed. TotalPleat™ beta sites across the country demonstrate this innovation in pulse cleaning results, improved performance, and longer filter life.
At beta site test locations, the dust collectors vent a variety of applications that challenged the BHA® TotalPleat™ filters with different operating conditions, grain loads and dusts to be filtered.
At each beta test location, customers reported a longer useful life with BHA® TotalPleat™ filters than they experienced with the OEM filter packs. At several locations, TotalPleat™ filters have been running for longer than 12 months in applications where the OEM filters lasted only three to four months. At one beta site, the OEM filters plugged with dust in one week, requiring replacement; whereas TotalPleat™ was still running after 16 weeks.
Parker's R&D department conducted full-scale testing using our ASHRAE 199 test rig at our Industrial Filter Test Lab and Customer Experience Facility in Slater, MO, throughout the TotalPleat™ filter development project.
The ASHRAE 199-2016 test protocol defines a six-stage test procedure to measure the performance of industrial pulse-jet dust collectors and air filters. Our engineers collected data to compare filter differential pressure trends and the number of pulse-jet cleaning cycles required to maintain DP. Each stage of the ASHRAE 199 test has a defined duration, with the entire test being about 50 hours. While designed to be somewhat of a pass/fail test, the test is useful to compare the performance of various filters.
The greater percentage of open flow passages within the BHA® TotalPleat™ pleatpack that allow dust to be pulse cleaned more completely is key to outstanding performance. In combination with the louvered grid, the open flow passages on the clean side significantly improve the cleaning pulse’s penetration into the filter’s full depth. This keeps TotalPleat™ flow passages clear of dust accumulation; dust doesn’t become trapped in the filter. This innovative, new design minimizes pressure drop and results in extended useful filter life.
This blog was contributed the Filtration team, Parker Industrial Gas Filtration and Generation Division.
Powercore® is a registered trademark of Donaldson Company, Inc.