As a key equipment in fluid systems, the stable operation of online filters directly affects the efficiency of production processes and product quality. The following are the full process usage details from selection matching to long-term maintenance, covering core operational points and risk prevention strategies:

1、 Preparation before installation

1. Verification of adaptability to working conditions

-Select materials based on the characteristics of the medium (viscosity, corrosiveness, particle content) (stainless steel 316L is suitable for acidic and alkaline environments, PP material is suitable for weakly corrosive liquids);

-Confirm that the design pressure level (conventional 1.0-10MPa) should be 1.5 times higher than the maximum working pressure of the system;

-The selection of filtration accuracy follows the principle of "step-by-step progression": pre coarse filtration (50-100 μ m) protects the main filter (5-20 μ m), and precision terminal filtration (0.5-1 μ m) is used for high cleanliness demand scenarios.

2. Pipeline system optimization

-Installed downstream of the pump outlet, utilizing the back pressure effect to enhance impurity retention rate;

-Set up bypass pipelines and ball valves for easy maintenance without stopping the machine;

-Reserve at least 5 times the diameter of straight pipe sections upstream and downstream to eliminate the impact of eddy currents on filtration efficiency.

2、 Core operating procedures

1. Startup phase

-Slowly open the inlet valve and fully open it after the shell is filled with medium to avoid sudden pressure rise and impact on the filter element;

-Synchronous exhaust: Open the top exhaust valve until there are no bubbles continuously flowing out to prevent flow attenuation caused by air resistance;

-After 10 minutes of initial operation, close the drain valve and observe the basic reading of the differential pressure gauge (normal<0.1 bar).

2. Operation monitoring

-Differential pressure management: Set an alarm threshold (Δ P ≥ 0.3 bar), and immediately switch to the backup filter when the differential pressure reaches the warning value;

-Temperature control: The viscous medium needs to maintain a working temperature of ± 5 ℃ to prevent low-temperature solidification and blockage of the filter element;

-Vibration assistance: High viscosity materials can be equipped with pneumatic hammers, which automatically vibrate once every 30 minutes to loosen attached particles.

3、 Maintenance and upkeep

1. Filter replacement standard

-Regular replacement: Mandatory replacement according to the manufacturer's recommended cycle (such as monthly/quarterly);

-On demand replacement: Replace immediately when the pressure difference exceeds 3 times the initial value or the flow rate drops to 70% of the design value;

-Special operating conditions: Fluid containing colloidal/fibrous impurities needs to shorten the replacement cycle by 50%.

2. Cleaning and regeneration

-The metal sintered filter element can be cleaned using a combination of ultrasonic and back blowing (compressed air pressure ≤ 0.6MPa);

-The filter element is only allowed to be backwashed once and reused no more than 3 times;

-It is strictly prohibited to clean the pleated filter membrane with a hard bristled brush to avoid scratching the filter layer.

4、 Key points of risk prevention and control

1. Emergency response to sudden leakage

-When leakage is found on the flange surface, immediately close the front and rear shut-off valves, wear protective equipment for disassembly and maintenance;

-The replacement of sealing gaskets must use products of the same specifications from the original factory, and it is prohibited to mix gaskets of different materials.

2. Winter antifreeze measures

-Drain the residual liquid in the empty shell during shutdown, and inject ethylene glycol antifreeze if necessary;

-The electric heating belt winding needs to be covered with insulation cotton to maintain the shell temperature above 5 ℃.

3. Shutdown management

-Backwash before long-term discontinuation to remove residual impurities;

-Install blind plates at the entrance and exit to isolate the medium and prevent foreign objects from entering.