000

REV

20-Sep-11
DATE BY

ISSUE FOR INFORMATION DESCRIPTION

T.W.KIM CHKD.

G.B.BANG CERT.

S.H.YOON APPD.

Project Title

CONVERSION OF QURAYYAH OPEN CYCLE POWER PLANT TO COMBINED CYCLE POWER PLANT PROJECT C

Client

Consultant

Contractor

Document Title

O&M MANUAL FOR BACKWASH STRAINER

CREATED BY: DATE STARTED: OPR'G. DEPT.:

CHECKED BY: DATE COMPLETED: ENG. DEPT.: APPROVAL/CERTIFICATION INFORMATION DOC. NO. REV. NO.

THIS DOCUMENT IS NOT TO BE USED FOR CONSTRUCTION OR FOR ORDERING MATERIAL UNTIL CERTIFIED AND DATED

QURAYYAH JOB ORDER NO.

SAUDI ARABIA

1-0923053.01
JOB NO. PROJECT SUBDIVISION DOCUMENT TYPE CODE DOCUMENT NUMBER REV. NO.

30621127

000

3DT

00028

000

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AUTO STRAINER OPERATION AND MAINTENANCE MANUAL

2011.05.03

K. H. SHIN

S. P. CHU

K. H. YANG

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1. DESCRIPTION
1.1 GENERAL DATA
Filter Items : (1) Functional characteristics (each filter) - CODE & SPEC. - DESIGN PRESS. - DESIGN TEMP. - CORR. ALLOW - FLOW RATE - HYDRO. TEST PRESS. - PNEUM. TEST PRESS - RADIOGRAPHY (SHELL / HEAD) - MATERIAL (SHELL / HEAD) - THICKNESS (SHELL / HEAD) - WEIGHT (EMPTY / F.W) : ASME SEC. VIII DIV.1 2007 ED : 10 BarG : 38 : 0 mm : DN400 1191 /h,DN200 254 /h,DN550 2007 /h : 15 BarG : N/A : SPOT / FULL : S31803 : DN400(25/30mm),DN200(6/20mm),DN550(8/30mm) : DN400(1,650/2047kg),DN200(1250/1399kg), DN550(2150/3065kg) - VOLUME : DN400(0.424 ),DN200(0.166 ), DN550(0.959 )

(2) Dimensional characteristics (each filter) - Inlet and outlet flanges diameter - Discharge flanges diameter - Drain flange diameter - Filtration Rating - Number of venthole (DN20 dia.) - Number of DPIT hole (DN50 dia.) : DN400/DN200/DN550 150# SO.FF : DN80/DN65/DN100 150# SO.FF : DN50 150# SO.RF : 4 : 1 : 2

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1.2 DETAILED DESCRIPTION (SEE SECTION 4, DRAWING NO.)

Each filter consists mainly of the following : - One body shaped as a tank with vertical axis and supported by three legs bolted to the ground. The body is connected to the circuits through inlet, outlet and flushing flanges welded to the body. The cover flange if bolted to the main body, thus allowing the assembling or dismantling of the inner parts. The cover flange flattened top supports the drive unit. - AUTO SELF-CLEANING STRAINER :

Auto-cleaning strainer is an automatic, continuous self cleaning and the housing as vertical type and the element is wedged type design. During operation a differential pressure measuring system (DPIS) monitors the pressure change due to accumulating trash and controls the rotary brush cyclo drive and the motor actuator of drain line valve for cleaning of the wedged elements face. The wedged element is cleaned by the rotary brush operated by the cyclo drive. The accumulated trash on the wedged element face is gathered into a drain chamber for discharge. Flow into the drain chamber compartment area is blocked at the bottom of the wedged element to affect minimum loss of water required for draining.

- DIFTERENTIAL PRESSURE MEASURING SYSTEM (DPIS)

When a predetermind differential pressure across the strainer is reached, the DPIS initiates the cyclo drive of the rotary brush.

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The cyclo drive of the rotary brush if continued to operate untill the DPIS sense that the differential pressure across the strainer has returned to normal-completely switching the strainer. This system serve to provide assurance of continuous accurate DPIS readings and reliable strainer operation.

- CONTROL SYSTEM COMPONENT

The strainers is equipped with the rotary brush with cyclo drive and the drain line valves with motors actuator rotates sequentially by the DPIS. Valve motor is operable manually through the actuator handwheel or control panel. The control panel receives an electrical signal from the Brushing and draining Strainer operation.

- One loss of head detector.

- One junction box

1.3 INSTALLATION

(1) Tools requirements (out of JIMC supply) - 4 slings, load 10 tons each - 4 slings, load 10 tons each - 1 crane (or lifting device), load 15 tons - 1 level - 1 set of thickness gauges.

(2) Connection supply Electricity

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- Power (motor) : 0.2/0.4Kw 480V 3Phases 60Hz - Relays, electrovalves, limit switches : 120V 60Hz - Signalization (lamp)

(3) Scope of JIMC - One filter equipped with its inner parts. - One flushing valves including bolts and nuts (seals out of JIMC supply) - One ventvalve including bolts, nuts, seals and elbow. - One purge valve including bolts and nuts (seals out of JIMC supply) - One equipped loss of head detector and its support - One equipped junction box - One cyclo gear motor

(4) Erection procedure - Place the filter to its correct position, Filter handling is done by means of using slings and shackles attached to the two filter upper lugs. - Check the level in longitudinal and transversal directions. - Control the inlet and outlet flanges verticality. Wedge eventually the filter legs. - Place the four anchor bolts. Grout them.

* NOTE : During handling, caution not to damage coated surfaces.

- Make sure that the rotary brush shaft is fixed on the motor shaft end. - Install the ventvalve on the filter upper part. Do not forget to place the supplied seals.

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- Connect the purge piping to backwashing pipe (seal out of JIMC. supply) - Connect the purge valve to the piping - Connect the inlet and outlet pipes to the filter - Connect the flushing piping to the filter. Assemble the flushing valves with the piping. - Connect the piping from the filter tappings to the differential pressure indicator switch. - Wire the electrical cables : Drive unit motor (packing gland) Actuators electrovalves (packing gland) Differential pressure detectors (terminal block) Electrical cabinet power supply (terminal block)

2. OPERATING INSTRUCTIONS
2.0 PRECOMMISSIONING INSTRUCTIONS
- Inspect imperatively the cleanness of the upstream circuit. - Open the flushing valves. - Open the ventvalves and close the purge valve. - Close the two way block valves (Differential pressure indicator switch)

2.1 COMMISSIONING INSTRUCTIONS

2.1.1. Filter out of operation - Empty filter body. Open flushing valves.

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- Open vent valve - Close purge valve

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- Open the two way "block valve". Avoid stagnant crude oil in instrumentation piping - Put selector switch on position "STOP". Power off the junction box

2.1.2. filter commissioning (start up) - All feeding networks available. Power on the junction box - Verify that the purge valve is closed. Flushing valves are opened. - Open the "block valves" to differential pressure indicator switch. - The vent valve is opened. - Let the raw oil enter the body filter gradually. - After a short while (roughly 5 minutes), close successively the flushing valves. - Close the vent valve when oil shows out. - Close the "block valves" to differential pressure indicator switch. - Put the selector switch on position "Start" - Check the normal operating cycles, opening and closing of flushing valves. - Filter is then automatically controlled ; normal operation. 2.1.3 Normal Operation

Filter is under the control of automatic orders coming from a clock or from differential pressure indicator switch.

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(1) Clock control

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- One clock impulse every 3 to 4 hour generates a complete washing cycle - Loss of head detectors prevail on the clock control cycle. See hereafter (2.1.3-(2)) (2) Loss of head detector control - Loss of head first level ; > 60 mm H2O - Loss of head first level ; > 120 mm H2O

First level - Complete washing cycles are performed as long as the first level signal is generated. - Rotary brush rotation is operated while flushing valves are successively opened. - Washing cycles and after the loss of head first level disappearance.

Second level - Complete washing cycles are performed as long as the first level signal is still generated. - High pressure alarm is on.

3. MAINTENANCE
3.1 SPECIAL TOOLS AND HANDLING DEVICES

See in 1.3-A. Out of JIMC supply.

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3.2 SPARE PARTS STORAGE REQUIREMENTS

Use original packing when supplied.

3.3 PREVENTIVE MAINTENANCE

(1) Weekly maintenance - Drain out the eventual debris deposit at the filter bottom, through the purge valve.

(2) Quarterly maintenance - Control the bolts tightness - Inspect the filter vibration absence while screening drum is rotating - Verify the motor insulation

(3) Annual or shut down equipment maintenance instructions - Check the filter closely - Replace every seal when dismantling. - Inspect the inner coating, Make sure of rust stain absence. Check the outside coating. - Inspect the screening drum. Verify the sieves and their tightness (absence of holes, surface permanent deformation, broken wires, etc..) - Control the legs fastening.

3.4 CORRECTIVE MAINTENANCE

(1) Forward

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Inside inspection of the filter can be achieved through the inlet and outlet pipes. Replacing inner parts or repairing inner coating involve carrying the filter away. Parts concerned are : - Elements - Seals (shaft seals) - Speed reducer - Eventually inner bolts All other parts can be reached from outside, no filter carrying away is necessary.

(2) Precautions to be taken before maintenance

- Power off current. - Apply all appropriate safety measure, especially when parts are carried on or when working in some unusual positions. - Secure parts that could fall over while working. - Take a great care of coated surfaces. - Inner parts assembly is based on wedge beams. - Taking off cover flange. - Disconnect all electrical wires. - Inner parts maintenance implies to empty the body filter, to drain out oil, to carry the drive motor out and to disconnect the inlet and outlet flange, the flushing flanges, the purge pipe and the legs fastening.

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3.5 AUTO STRAINER OPERATION FLOW CHART

SYSTEM READY
(DCS OPERATING : LCP REMOTE,AUTO) READY CONDITION : NOT FAULT SIGNAL DP < H DISCHARGE MOV CLOSE

* H : Set Pint #1 (System Start)

YES

DP > H (10sec delay) or 24H timer on (DP<H)

YES

DISCHARGE MOV OPEN GEAR MOTOR RUN (Run time : 1~3min)

YES

DP < H
NO YES

DISCHAGE MOV CLOSE GEAR MOTOR STOP

YES

END (System Ready)

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