From Clogged Filters to Clean Air: A Six-Year Maintenance Overhaul
From Clogged Filters to Clean Air: A Six-Year Maintenance Overhaul
The Challenge
After six years of continuous 24/5 operation, a client's air filtration systems had never undergone a complete filter maintenance.
The metal mesh filters were heavily saturated with particulate matter and solids, leading to compromised system performance.
This was evident in elevated fan speeds (up to 93%) and differential pressure readings over -0.10. In the Compounding area, excessive oil in the air and on nearby surfaces raised additional concerns from the maintenance team.
The Solution
Kogi Environmental Solutions conducted an on-site inspection and identified the primary cause of the performance issues: clogged mesh filters that had not been cleaned or replaced since installation.
We recommended:
• Soaking metal mesh filters in Simple Green solution and power-washing them to
restore airflow.
• Ordering a second set of filters for seamless changeovers without halting operations.
• Replacing aged tubing on the differential pressure sensor and cleaning the housing.
• Blowing out barbed fittings with compressed air to clear blockages.
• Semi-annual preventive maintenance on sensors and fittings moving forward.
We also noted a fault in the HMI caused by oil contamination in the pressure sensor line
and poor tubing fit, and provided guidance on restoring sensor accuracy.