User Manuals

Contract No. F175-BATURAJA CEMENT PROJECT

(PLANT II)

Sub-Contract No.
F175M021

Equipment Name Bag Filter

Sub-Supplier AAF Wuhan Co., LTD

 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

FOREWORD

The purpose of this manual is to clearly identify all the equipments supplied within
the kiln & raw mill dedusting system and to provide comprehensive information to
ensure the safe and efficient operation and maintenance of the plant.

The basic information contained within this manual provides clear and concise
written instructions on the operational functions of the equipment and identifies the
maintenance requirements of the system.

1
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

CONTENTS

CHAPTER DESCRIPTION

1 - ............................................ TECHNICAL SPECIFICATIONS.

2 - ............................................ CONTROL AND OPERATIONAL SPECIFICATIONS.

3 - .............................................. MAINTENANCE PROCEDURES.

4 - .. FILTER BAG TECHNICAL INFORMATION

5 -.. LIST OF RECOMMENDED SPARE PARTS

ANNEX DESCRIPTION

1- ............................................. INSTRUMENTS OPERATION & MAINTENANCE

MANUAL

2
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

INDEX

1. TECHNICAL SPECIFICATION

1.1. GENERAL DESCRIPTION

1.2. MECHANICAL SPECIFICATIONS
1.3. ELECTRICAL SPECIFICATIONS

2. CONTROL AND OPERATIONAL SPECIFICATIONS

2.0. DESCRIPTION OF THE OPERATION OF

THE INSTALLATION
2.1. FILTRATION PRINCIPLE OF FABRI-PULSE
XLC BAG FILTER
2.2. DESCRIPTION OF BAG FILTER CLEANING
SYSTEM
2.3. FIELD ELEMENTS
2.4. STARTING UP
2.5. EMERGENCY STOP
2.6. PLC CONTROL SYSTEM

3. MAINTENANCE PROCEDURES

3.1. GENERAL
3.2. PERIODICAL MAINTENANCE
3.3. FILTER BAG CHANGING PROCEDURES
3.4. REGULATION OF CLEANING CYCLE
3.5 COMMON PROBLEMS & SOLUTIONS

4. FILTER BAG TECHNICAL INFORMATION

3
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

1 - TECHNICAL SPECIFICATION

1.1. GENERAL DESCRIPTION

INDONESIA

B) Dedusting System in Kiln & Raw Mill Application

The AAF XLC Fabripulse Model fabric collector is designed for on-line maintenance and
on-line cleaning .

The pulse jet filter employs the principle of compressed air pulsing for bag cleaning. A
short pulse of compressed air is directed accurately downwards from a pulse pipe through
a venturi into a row of bags, causing the bags to flex and dislodging the dust cake from
the outside of the bag, the dust falls under gravity into the hopper where it is evacuated
by dust discharge system (by others).

There is access doors for each compartment to allow maintenance staff enter to carry out
maintenance work inside the compartment. The access doors have internal thermal
insulation and gasket for gas sealing. The gasket is pressed on the door frame by negative
pressure inside the collector, this provide an air-tight design and reduce false air entering
into filter which decrease the suction capability of the downstream exhaust fan..

In each compartment, there are bags mounted on split wire cages and suspended from a
tube sheet. The cage is galvanized for corrosion protection and more durable in high
temperature condition.

The filter bag is made of Fiberglass felt with PTFE membrane material. To ensure
effective cleaning of filter bag, diaphragm valve is selected to clean filter bags in a single
pulse pipe. Each pulse pipe is locked at the end with lock pin and the other end is
connected with quick release connection.

Compressed air manifolds runs along every compartments to supply compressed air. All
the manifolds are connected to a common compressed air pipe header, which provides
bigger compressed air reservoir and to ensure bag cleaning effectiveness.

The combined inlet and outlet plenum located at the center section of the collector, which
constitute an integral part of the filter would ensure a uniform distribution of gas to the
compartmented filter. The inclined plate inside the inlet and outlet plenum acts as a
separation wall between dirty gas chamber and clean gas chamber. There are steel walls
at two sides of this separation wall with the same height as the filter bag to prevent the
dusty gas going directly to filter bag before entering the bottom hopper.

4
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

The collector has been designed with adequate stiffening to withstand the high internal
negative pressure produced by the induced draft fan located downstream of the bagfilter.

A penthouse is installed at the top of the collector for weather protection of the collector.
The penthouse is a steel structure covered with corrugated plate and water drainage
system.

The collector is insulated with a layer of thermal insulation material made of mineral
rockwool to maintain the gas temperature inside the collector above the gas dew point to
avoid condensation and thus prevent any possible corrosion to the filter housing and
blinding of the filter bags.

Access by staircase.is provided from ground level to the top of the filter and
penthouse which require regular maintenance/inspection. Service platform and
access also provide at the filter gas inlet.

5
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

1.2. MECHANICAL SPECIFICATION

43BF21 Data sheet-Coal Mill
PT. SEMEN BATURAJA (PERSERO) - BCP PROJECT II BIDDER'S NAME
BIDDER DATA SHEET
Bag Filter (Process)
Equipment : JetPulse
Sheet :
43BF2
Equipment No :
1
COAL
Dept :
MILL
Technical Specification Unit Supplier Remarks
Description Data
GENERAL
Quantity # 1
Supplier AAF
Type / Design * XLC 3.6-3840
Housing dimensions:
width m 9
length m 18
Including
height 15.9 penthouse
m height
Number of compartments # 2
Compartment size (l x w) mxm 13.88x6.28
Number of Filter elements # 3840
Filtering area - gross m2 5646
- net
-
(during cleaning) m2
Center distance of bags - lengthwise /
~210,210
crosswise mm / mm
Minimum distance between bag and compartm.
80
wall mm
Hopper design - trough / inverse pyramidal T/P T
Hopper valley angle, outside against horizontal deg 70
No. of access doors/hopper 2
Access door dimensions mm x mm 610x610
Heated hopper discharge section yes / no no

CONSTRUCTION
Insulation thickness mm 100
Cladding type - galvanized steel sheet / aluminum
G
sheet G/A

Corrosion protection in clean gas plenum: yes

yes / no
Painting type -
Steel quality type/code -
Compartment housing:
material type Mild Steel

6
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

thickness mm 5
Hopper:
material type Mild Steel
thickness mm 5
Tubesheet:
material type Mild Steel
thickness mm 6
Inlet manifold:
material type Mild Steel
thickness mm 5
Outlet manifold:
material type Mild Steel
thickness mm 5

FILTER ELEMENTS
Supplier Needlefelt
Type of bag fixation * Snap Ring
Superfine
Antistatic PAN
Fabric quality fiber
Membrane quality (if applicable)
Fabric weight g/m2 600
Dimensions of bag:
length mm 3,600
diameter mm 130
Admissible temperature:
operation (continuous) C 120
maximum (peak) C 135
Bag cages
Single piece cages / number of pieces S/ # S
Cage finish SS304
Diam of longitudinal wire mm 3.2
No.of longitudinal wires # 12
Bag to cage size difference - circunferential mm 15-20
10
- longitudinal mm
Cage size 3600x125

CLEANING SYSTEM
Pulse pressure at header bar 4~6
Air consumption Nm3/h 340 On
Air quality class acc. To ISO 8573-1 2.2.1
(solids.moisture.oil)
Pulse air control by timer yes / no yes By PLC
Pulse air control by pressure difference yes / no yes By PLC
1 DP
Differential pressure gauge/switch type Transmitter
Transmitter
Solenoid valve size mm 1-1/2"
Blow pipe design - injector / double injector /
I
other I / DI / O
Number of bags per blow pipe # 14,16

7
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Qty of pulse valve 256

Air consumption per bag per hour Nm3/h 0.09
COMPRESSOR
Compressed air -from network / Supplied by
-
dedicated compressor N/C other
Type -
Supplier -
Motor Speed 1/min -
Power installed kW -
Air volume Nm3/h -
Compressed air tank volume l -
Static pressure bar -
Oil/Water separator
Pressure reducing valve
SPECIAL-DESIGN
Drop-out chamber Type / Design * NA
Type of plenum Walk-On
Upper walkway yes / no yes
Lower walkway yes / no yes
Stairs and ladders yes / no yes
Explosion vents yes / no Yes
Quantity per compartment 46
Type rupture disc
Make huali
Size mm x mm 910*910
bottom of bag and
Location
above hopper top
Pstat range bar - bar 0.1
Total filter venting area m2 39
Limit switches yes/no yes

CONTROL - ELEMENTS
Pulse air control by timer yes / no yes by PLC
Pulse air control by pressure difference yes / no yes by PLC
Temperature control - (in/out) yes / no yes by T/T
Full-hopper level sensor yes / no yes by LS
Broken-Bag detector yes / no No

ACCESSORIES
Compressor / vessel / pipe included yes / no no
Exhaust air silencer yes / no

53BF02 Data sheet-kiln

PT. SEMEN BATURAJA (PERSERO) - BCP PROJECT II BIDDER'S NAME
BIDDER DATA SHEET
Bag Filter (Process)
Equipment : JetPulse
Sheet :

8
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Equipment No : 53BF02
Dept : KILN & RAW MILL
GENERAL
Quantity # 1
Supplier AAF
Type / Design * XLC 8-5376
Housing dimensions:
width m 19.7
length m 22.96
height m 23.6
Number of compartments # 8
Compartment size (l x w) mxm 5.74*7.35
Number of Filter elements # 5376
Filtering area - gross m2 21618 On
- net (during
20942 of
cleaning) m2
Center distance of bags - lengthwise / crosswise mm / mm ~230
Minimum distance between bag and compartm. wall mm 75
Hopper design - trough / inverse pyramidal T/P P
Hopper valley angle, outside against horizontal deg 60
No. of access doors/hopper 1
Access door dimensions mm x mm 610x610
Heated hopper discharge section yes / no NO

CONSTRUCTION
Insulation thickness mm 100
Cladding type - galvanized steel sheet / aluminum sheet G/A G
Corrosion protection in clean gas plenum: yes
yes / no
Painting type -
Steel quality type/code -
Compartment housing:
material type Mild steel
thickness mm 4
Hopper:
material type Mild steel
thickness mm 5
Tubesheet:
material type Mild steel
thickness mm 6
Inlet manifold:
material type Mild steel
thickness mm 4
Outlet manifold:
material type Mild steel
thickness mm 4

FILTER ELEMENTS
Supplier

9
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Type of bag fixation * snap ring

fiberglass+PTF
Fabric quality E membrane
Membrane quality (if applicable)
Fabric weight g/m2 746
Dimensions of bag:
length mm 8000
diameter mm 160
Admissible temperature:
operation (continuous) C 200
maximum (peak) C 260
Bag cages
Single piece cages / number of pieces S/ # 2
Cage finish galvanized
Diam of longitudinal wire mm 3
No.of longitudinal wires # 24
Bag to cage size difference - circonferencial mm 10--15
-
10
longitudinal mm
Cage size 8000x155
CLEANING SYSTEM
Pulse pressure at header bar <2
Air consumption Nm3/h 762
Air quality class acc. To ISO 8573-1 (solids.moisture.oil)
Pulse air control by timer yes / no yes by PLC
Pulse air control by pressure difference yes / no yes by PLC
Differential pressure gauge/switch type DP transmitter
Solenoid valve size mm 2.5 inch
Blow pipe design - injector / double injector / other I / DI / O I
Number of bags per blow pipe # 14
Qty of pulse vavle 384
Air consumption per bag per hour Nm3/h 0.142
COMPRESSOR
Compressed air -from network / dedicated
by others
compressor N/C
Type
Supplier
Motor Speed 1/min
Power installed kW
Air volume Nm3/h
Compressed air tank volume l
Static pressure bar
Oil/Water separator
Pressure reducing valve

SPECIAL-DESIGN
Drop-out chamber Type / Design *
Type of plenum
Static pressure range bar - bar

10
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

CONTROL - ELEMENTS
Pulse air control by timer yes / no yes by PLC
Pulse air control by pressure difference yes / no yes by PLC
Temperature control - (in/out) yes / no yes by T/T
Full-hopper level sensor yes / no yes by LS
Broken-Bag detector yes / no No

65.66BF36 Data sheet-Cement Mill

PT. SEMEN BATURAJA (PERSERO) - BCP PROJECT II BIDDER'S NAME
BIDDER DATA SHEET
Equipment : Bag Filter (Process) JetPulse
Sheet :
Equipment No : 66BF36
Dept : CEMENT MILL
GENERAL
Quantity # 1
Supplier AAF
Type / Design * XLC 8-2880
Housing dimensions:
width m 18.1
length m 17.22
height m 19.2
Number of compartments # 2
Compartment size (l x w) mxm 22.05x7.35
Number of Filter elements # 2880
Filtering area - gross m2 11581
- net (during cleaning) m2 10938 Of
Center distance of bags - lengthwise / crosswise mm / mm ~230/230
Minimum distance between bag and compartm. wall mm 75
Hopper design - trough / inverse pyramidal T/P P
Hopper valley angle, outside against horizontal deg 55
No. of access doors/hopper 2
Access door dimensions mm x mm 610x610
Heated hopper discharge section yes / no NO

CONSTRUCTION
Insulation thickness mm 100
Cladding type - galvanized steel sheet / aluminum sheet G/A G
Corrosion protection in clean gas plenum: yes
yes / no
Painting type -
Steel quality type/code -
Compartment housing:
material type Mild steel
thickness mm 4

11
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Hopper:
material type Mild steel
thickness mm 5
Tubesheet:
material type Mild steel
thickness mm 6
Inlet manifold:
material type Mild steel
thickness mm 4
Outlet manifold:
material type Mild steel
thickness mm 4

FILTER ELEMENTS
Supplier
Type of bag fixation * snap ring
Superfine
PE+PAN
Fabric quality fiber
Membrane quality (if applicable)
Fabric weight g/m2 600
Dimensions of bag:
length mm 8000
diameter mm 160
Admissible temperature:
operation (continuous) C 120
maximum (peak) C 135
Bag cages
Single piece cages / number of pieces S/ # 2
Cage finish galvanized
Diam of longitudinal wire mm 3.5
No.of longitudinal wires # 12
Bag to cage size difference - circonferencial mm 15-20
- longitudinal mm 10
Cage Size 8000x155
CLEANING SYSTEM
Pulse pressure at header bar ~2
Air consumption Nm3/h 650
Air quality class acc. To ISO 8573-1 (solids.moisture.oil)
Pulse air control by timer yes / no yes by PLC
Pulse air control by pressure difference yes / no yes by PLC
DP
Differential pressure gauge/switch type
transmitter
Solenoid valve size mm 2.5 inch
Blow pipe design - injector / double injector / other I / DI / O I
Number of bags per blow pipe # 16
Qty of pulse valve 180
Air consumption per bag per hour Nm3/h 0.225
COMPRESSOR
Compressed air -from network / dedicated N/C by others

12
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

compressor
Type
Power installed kW
Air volume Nm3/h
Compressed air tank volume l
Static pressure bar

SPECIAL-DESIGN
Drop-out chamber Type / Design *

CONTROL - ELEMENTS
Pulse air control by timer yes / no yes by PLC
Pulse air control by pressure difference yes / no yes by PLC
Temperature control - (in/out) yes / no yes by T/T
Full-hopper level sensor yes / no yes by LS
Broken-Bag detector yes / no No

1.3. ELECTRICAL EQUIPMENT SPECIFICATION

AAF have supplied electrical control instruments and PLC in a control panel.

13
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

2.0. DESCRIPTION OF THE OPERATION OF THE INSTALLATION

The purpose of the installation is to collect the kiln and raw mill dust and control the dust
emission less than 10 mg/m3 to achieve environmental friendly cement process.

2.1. FILTERATION PRINCIPLE OF FABRI-PULSE XLC BAG FILTER

Pulsejet bagfilters are the most universally applied dust collectors for the removal of dry
particulate from process and ventilation air, and for the recovery of product from
manufacturing processes.

The Fabri-Pulse XLC on-line cleaning bagfilter is based on a downflow air principle
pioneered by AAF and proven in hundreds of installations world-wide. An understanding
of the design and operating principle of the Fabri-Pulse is essential for effective operation
and maintenance. Knowledge of the collector nomenclature is necessary so that parts can
be easily identified and located.

Principle of Operation
1. Dust laden air is drawn against the inlet inclined separation plate and changing
direction enter into hopper and allowing the heavier dust fall directly into hopper result
of gravity force.

2. The air is drawn through the fabric tubes with the dust collecting on the outside of the
bags. The collected dust forms a cake which enhances filtering efficiency.

3. Cleaned air flows upwards from the bags to the clean air plenum and is discharged.
The unique cleaning system has been designed to minimize compressed air
consumption for any given application, but with enough cleaning reserve for the most
challenging applications.

4. The filter bags are periodically clean with pulses of compressed air initiated by the
PLC based on differential pressure across filter bags. This low volume pulse of high
pressure air is directed from the manifold via the pulse pipe to a venturi located at the
top of the bag. The pulse induces an additional large volume of clean air through the
venturi into the bag, expanding the fabric rapidly. When the bag reaches its maximum
extension, it stop abruptly and the filter cake is thrown clear and the dislodged dust
falls to the hopper below.

14
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

5. Hoppers are designed to receive the dust and not for the storage. The
recommended pratice is to continuously empty the hopper by means of a
conveyor and/or rotary air lock valve, or by some other discharge device to
attain a seal. Any dust reintrainment will decrease collector efficiency,
reduce bag life and result in increased operation pressure.

2.2. DESCRIPTION OF BAG FILTER CLEANING SYSTEM

2.2.1 Field Instrument

One differential pressure transmitter installs locally to control pressure drop
across bag filter. 4-20mA signal from transmitter will be sent to PLCs analog
input (AI) continuously for bag cleaning control.

2.2.2 Operation Mode

From operation panel (OP) it is possible, manually, make a filter cleaning test.
Automatically, through signals sent via OP screen, the user can choose the
cleaning mode:

A) DIFFERENTIAL PRESSURE/ TIMER CLEANING MODE

B) TEST MODE (only though OP panel)

In DIFFERENTIAL PRESSURE MODE, when a set value (adjustable and

programmable) is reached the system will begin the cleaning, finishing at
reaching the set low value and completing a cleaning cycle in the entire
compartment.

In TIMER MODE the cleaning process is made continuously, independent of the

pressure drop across the filter.

Note: PLC will keep in its memory the last compartment cleaned and it will
begin the cleaning cycle with the next output in the preset sequence when the
preset CLEANING START value reached.

15
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Mode 1: Differential Pressure Cleaning

16
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Mode of Cleaning
Mode 1 DP Mode

SPPT = 1000Pa
Send confirmation to PLC

Compartment Compartment
(1, 2, 3, 10) (11, 12, 13, 20)

Row 1 & 8 Row 1 & 8

Row 5 & 12 Row 5 & 12

Row 9 & 16 Row 9 & 16

Row 3 & 13 Row 3 & 13

> 800Pa
Row 7 & 10 Row 7 & 10

Row 2 & 14 Row 2 & 14

Row 6 & 11 Row 6 & 11

Row 4 & 15 Row 4 & 15

Row 17 & 18&19 Row 17 & 18&19

Send confirmation to PLC

SPPT

<800Pa+10s delay

STOP CLEANING

17
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Mode 1 Adjustable Parameters

Blowing time 150m.sec

Interval between blowing 15sec
Cleaning start value 1000 Pa
Cleaning stop value 800 Pa
High pressure 1500 Pa (alarm)
Very high pressure 1800 Pa
Low pressure 600 Pa

Mode 2: Timer Cleaning

18
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Mode of Cleaning
Mode 1 TM Mode

START
Send confirmation to PLC

Compartment Compartment
(1, 2, 3, 10) (11, 12, 13, 20)

Row 1 & 8 Row 1 & 8

Row 5 & 12 Row 5 & 12

Row 9 & 16 Row 9 & 16

Row 3 & 13 Row 3 & 13

NO
Row 7 & 10 Row 7 & 10

Row 2 & 14 Row 2 & 14

Row 6 & 11 Row 6 & 11

Row 4 & 15 Row 4 & 15

Row 17 & 18&19 Row 17 & 18&19

STOP Send confirmation to PLC

STOP CLEANING

Mode 2 Adjustable Parameters

19
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Blowing time 150m.sec

Interval between blowing 15sec
Cleaning start value 1000 Pa
Cleaning stop value 800 Pa
High pressure 1500 Pa (alarm)
Very high pressure 1800 Pa
Low pressure 600 Pa

Mode 3: Test Mode

20
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

This mode is selected only for checking of the functionality of solenoid valve and
diaphragm valve. Each compartment shall be able to be selected and test individually by
OP Panel install on the PLC Control Panel.

2.3 FIELD INSTRUMENTS

21
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

2.3.1 TEMPERATURE MEASUREMENT

There are two temperature probes at the inlet of the filter and two at the outlet which are
communicated with DCS.If the temperature at the inlet of the filter is higher than a
predefined value, a warning alarm will be generated by DCS. But if this value continues
going up we could reach the emergency stop value.As there are two temperature probes
at inlet, the highest value will be chosen, generating an alarm if the difference between
these two values exceeds a 15% of the highest value.

2.3.2 PRESSURE MEASUREMENT

Two differential pressure transmitter are installed to measure the differential pressure
across filter continuously(one at each filter of the twin) and the signal are used for
bag cleaning system.

2.3.3 HOPPER LEVEL DETECTOR (if application)

One detector installed at each pyramid hopper and give alarm when the dust in the hopper
accumulate until the predefine level.

2.3.4BAG LEAK DETECTOR (if application)

Two bag leak detectors are installed at outlet piping (one at each outlet) to detect high
emission due to broken bag and give alarm when emission higher than preset value.

STARTING UP

2.4.1 GENERAL

22
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

An essential knowledge of the filter and its operation will be useful for the person
responsible for its operation and maintenance.

We recommend that this person familiarizes himself with the description of the
filter in such a way that he can identify and locate its different parts without
difficulty.

THE PURPOSE OF DUST HOPPERS ARE NOT FOR DUST STORAGE. ONLY
IN THE CASE OF AN EMERGENCY IN THE DISCHARGE CONVEYOR MAY
THEY BE USED FOR THIS PURPOSE.

The hoppers will be emptied continuosly through the rotary valve and discharge
conveyor.

IT IS NECESSARY TO ENSURE THAT THE HOPPERS ARE EMPTIED

REGULARLY.

2.4.2 PRESTART CHECK

A final inspection must be made for the interior and exterior of the filter before
start up.

a) Power supply is healthy to the PLC control system. When PLC power on, a
signal will be to DCS system.
b) Compressed air supply is available at <3.5 barg at the compressed air
manifolds on the filter. Check and make sure no leaks at all the joints of the
valves and connectors.
c) Press test mode button and check that all solenoid valves is operates correctly.
d) No fault signals are present.
e) Dust discharge system is required to run
f) Fan starter is ready to run with isolator on, stop released and fault free.

2.4.3 START-UP AND RUNNING

The PLC can be start and put on run operation. Once the fan has started the
differential pressure across the filter bags will begin to rise after a period of time.
The differential pressure across the filter bag will be measured at field and
feedback to PLC . The DCS can obtain the reading of differential pressure across
the filter bag via PLCs Profibus DP. The pulse cleaning system will be started
after the differential pressure reach the preset value.

AT DEFAULT, AT STARTING THE PULSE CLEANING MODE OF

PRESSURE MODE WILL BE AUTOMATICALLY CHOSEN BY PLC.

23
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Whenever the filter put in stop operation, the pulse cleaning system shall be
stopped before the stop of dust discharge system, this is to ensure the dust in
hopper is empty.

2.5 EMERGENCY STOP

The system designed to provide two (2) Emergency stops signals, executed by
the users system, to protect the XLC Filter.

Emergency stop (1)

When the air flow, at the inlet of the filter, reach a VERY HIGH temperature,
which could damage the filter bags.

Emergency stop (2)

When the filter reaches a VERY HIGH pressure drop, which could damage the
filter bags.

2.6. PLC CONTROL SYSTEM

24
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

2.6.1HMI Operation

Operators can control the coal mill filter on KTP1000 operator panel, such as
Operators logon/logoff, cleaning mode selection, cleaning operation, system alarm,
trends, ect.

2.6.1.1 Operator Logon/Logoff

KTP1000 panel has 1 group for authorization level. When the power on, the LOGON
screen display. 1 authorized level:Admin. The operator who not logon cannot operate
and change the parameter.
Button Exit: softkey: exit runtime;
Button Status: Turn to Status screen;
Button Parameter: Turn to Paremeter screen;
Button Alarm: Turn to Alarm screen;
Button DP trends: Turn to DP trends screen;
Button Next: Turn to next screen;
Authorization:
Admin: change the running parameter/start & stop filter/exit runtime/
When logon, the username and password would display, administrator can change the
username and password.

25
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

2.6.1.2 Filter Status Screen

Filter status screen display the status of the filter: running parameter, actual
cleaning mode, status of blowing valves.
Button Logon: Turn to Logon screen;
Button Parameter Turn to Parameter screen;
Button Test: Turn to Test screen;
Button Alarmr Turn to Alarm screen;
Button Trends Turn to Trends screen;
Button Next Turn to next screen;

Local operation:
Switch the LOCAL/REMOTE selector on the door to the LOCAL position, the
operation button will enabled, select the mode you needed in Symbolic IO Field,
and the mode name will show in the field when the mode had been selected,
then depress the START button to start cleaning filter. The status of SPV
groups will display by changing the colour of corresponding compartment and
block.

Remote operation:
Switch the LOCAL/REMOTE selector on the door to the REMOTE position,
the operation button will disabled, the filter will be controlled by DCS.

26
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

2.6.1.3 Parameter Setting Screen

Set running parameter of DP MODE and TM MODE. The Administration
authorized level is necessary.
Button Scaling: Turn to Scaling screen ;
Button Logon: Turn to Logon screen ;
Button Status:Turn to Status screen;
Button Test: Turn to Test screen;
Button Alarm: Turn to Alarm screen;
Button Trends:Turn to Trends screen;
Button Next: Turn to next screen;

27
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

2.6.1.4 Test Screen

When selected TEST mode, operators can test running

Choose which COMP. to be tested.Input the SPV group you want to

test,depress SingleSpray Start ,then the SPV group you selected will be active,
depress SingleSpray Stop button, the SPV group you selected will be
deactivate.Input the Blowing time and Interval time,depress the CyclicSpray
Start button, the SPV group you selected will be activate automatic.

2.6.1.5 Alarm Screen

Display alarm messages.

28
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

2.6.1.6 Trends Screen

Display analog trends.

29
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

2.6.1.7 Analogue Scaling Screen

To adjust the scaling of analogue signals.

1 Differential Pressure Transmitter 0-4000Pa 4-20mA

2 Temperature Transmitter 0-300 4-20mA

2.6.1.8 Software Requirement

To program the PLC and SIMATIC KTP1000 panel, the following software is
required:
STEP7 V5.4+SP3 or later
WINCC flexible 2007 v1.2.0 standard or later(English version)

30
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

3 - MAINTENANCE PROCEDURES

3.1. GENERAL

READ THESE INSTRUCTION FIRST

USE THE CORRECT TOOLS
ALWAYS CHECK THAT THE APPROPRIATE MANDATORY AND
VOLUNTARY SAFETY PROCEDURES ARE OBSERVED
ENSURE THAT GUARDS ARE FITTED BEFORE OPERATING ANY
EQUIPMENT
ISOLATE AND DISCONNECT ELECTRICAL AND PNEUMATIC
SUPPLY WHERE APPLICABLE BEFORE SERVICING
OBTAIN PERMIT TO WORK

WE RECOMMEND THAT ALL SERVICING MAINTENANCE IS

RECORDED

CAUTION

All necessary steps have been taken to ensure, as far as is practical, that
equipment is designed and manufactured to be safe when used properly.

These instructions are however, general and it is important that the user observes
all statutory plant and other safety requirements.

It is further assumed that the equipment will be maintained and used by

appropriately qualified, experienced and competent people, for whom these
instructions have been written.

Maintenance Personnel

Before carrying out any maintenance it is recommended that familiarisation with

the equipment which is to be worked upon, is undertaken by reading each of the
proprietary equipment manufacturers literature in Annex 2.

Before undertaking any work on equipment a PERMIT TO WORK should be

obtained.

Equipment must be isolated from its source and a notice which states the
equipment is NOT to be made live because someone is working on it must be
secured to the Isolated Switch.

ALL PERSONNEL MUST BE AWARE THAT EQUIPMENT CAN START

AUTOMATICALLY WITHOUT WARNING AND HENCE MUST BE

31
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

ISOLATED ELSEWHERE PRIOR TO MAINTAINNING OR REMOVING

GUARDS.
If lowering equipment from its operating position for ease of maintenance, always
use approved and certified lifting equipment. Item such as Dust Disposal Items
should only be removed from their location by means of a hoist.

When lowering equipment from its operating position always ensure that there are
no projections which will prevent the item being rested in a safe position. If items
are being lowered onto the floor ensire that the floor areas are clear and that
equipment can be released from the lifting-gear without danger to personnel.

Always depressurize or isolate compressed air lines prior to undertaking any

Maintenance.

The collector is designed to handle dust from kiln and raw mill and must be
checked prior to personnel entry via any access door.

ABOVE ALL REMEMBER SAFETY IS OF PARAMOUNT IMPORTANCE IN

OPERATING AND MAINTAINING THE PLANT AND PERSONNEL
SHOULD AT ALL TIMES FOLLOW THE MAINTENANCE INSTRUCTIONS
PROVIDED BY THE EQUIPMENT SUPPLIERS WHEN CARRYING OUT
ANY MAINTENANCE OR REPAIR ACTIVITIES.

Procedures for Reducing Hazards During Maintenance

It cannot be stressed too strongly that only qualified personnel, familiar with the
construction, operation and the hazards involved, should be permitted to have
access to machines and equipment, especially for inspection and maintenance, or
for adjustments to control and protective equipment.

Electricity

A well-planned and executed maintenance schedule is essential to the satisfactory

and safe operation of electrical equipment. The user should establish a
maintenance programme giving due consideration to the installation and
maintenance instructions. Rules and regulations for operations and safety should
be formulated and made known to personnel who will be associated with the
equipement. Similarly, personnel should be made aware of particular risks which
they may different or changing circumstances. During normal operation of
electrical equipment all doors, covers and protective guards must be secured in
their proper positions. Whenever possible maintenance should be performed with
the equipment not in operation and disconnected from the line. When maintenance
is being carried out, suitable warning signs should be prominently displayed and
all appropriate precautions taken to reduce hazards involved, particularly that of
having power restored to equipment while work is still proceeding or is
incomplete.

32
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

REMEMBER TO ISOLATE AND CHECK

Compressed Air

Certain equipment on the plant is operated by means of compressed air and prior
to undertaking any maintenance on equipment so operated it is essential that the
compressed air pressure is either relieved or isolated by closing upstream valves
and draining where applicable by opening intermediate drainage valves.

MAINTENANCE PERSONNEL SHOULD BE AWARE OF THE CONDITION

OF ANY ITEM OPERATED BY COMPRESSED AIR PRIOR TO
UNDERTAKING ANY SERVICING COMPRESSED AIR IS A DANGEROUS
MEDIUM IF INCORRECTLY UTILISED.

Hot Surfaces

The plant is designed to operate continuosly at the elevated temperatures detailed

within the design specification. The plant must be suitably protected (by others) to
safeguard personnel should be made fully aware of the temperature of operation
of the plant to avoid personal injuiry.

Access to Confined Spaces

Access ladders and platforms are provided to certain areas of plant to gain access
to certain ares/items of equipment.

PLEASE NOTE THE PLANT IS DESIGNED TO HANDLE HOT AND DUSTY

GASES, PRECAUTIONS MUST BE TAKEN PRIOR ENTERING THE AREA
SUCH AS SURROUNDING VENTILATION. IT IS RECOMMENDED THAT
ANY PERSON ENTERING SHOULD BE ACCOMPANIED BY A SECOND
PERSON POSITIONED OUTSIDE THE AREA.

33
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

3.2. Periodical Maintenance

3.2.1. Initial Daily or Weekly Maintenance.

Record the collector pressure drop daily for at least the first 30 days of operation.
Adverse operating conditions can be detected by a change in pressure drop. A differential
pressure transmitter is provided by AAF to measure the pressure drop reading across the
dust cake and fabric. After start-up, the pressure drop will gradually rise to its normal
operating level which will be in the range 100 150 mm W.G.

The filter cleaning cycle is automatically controlled from the control panel with either the
pressure switching points or the interval between pulses being set to maintain a steady
pressure drop across the filter in the range 100 to 150 mm W.G.

Do not be alarmed if cleaning pulses cause momentary spikes in the pressure readings.

NOTE:
The interval between pulses is set during commissioning and is very much dependent
upon the application and reliant upon pulse pressure to ensure effective cleaning.
The pulse duration is pre-set and should not be altered without first consulting an AAF
Ltd. Representative.

3.2.2. Monthly Maintenance

The access doors should be open for a monthly inspection of the filter bags.
Any faulty or worn tubes must be replaced to prevent damage to the collector.
The compressed air line regulator, dryer and filter should be checked for proper
operation.
Also inspect the dust discharge device on the hopper outlet for proper operation.

NOTE:
Before entering a compartment ensure that the compartment pulse sequence is inhibited.

34
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

3.2.3. Six Monthly Maintenance

Ducts leading to and from the collector should be inspected for dust build up during each
planned maintenance or every six months. In addition the following inspection should be
made:
a) Examine the fabric tubes for any wear or damage with special attention to seams
and stitching.
b) Examine internal steel components for wear or corrosion, if any structure beams
thickness decrease as compare to its design thickness due to corrosion,
abrasionetc, this structure shall be reinforced (if any doubt arise, please consult
AAFs engineering department)
c) Inspect all joints for evidence of air or dust leakage.
d) Check for evidence of moisture or dust build up within the collector.
e) Check all electrical apparatus for proper operation.
f) Check to see if the diaphragm and solenoid valves are pulsing when energised by
the control panel.
g) Check inlet and outlet ductwork for signs of dust. Make sure no dust is settled in
the center plenum of the filter, mainly over the sloped panel. Gas velocity above
or below the sloped pannel is relatively small (to minimise total system pressure
drop). If any bag is broken and dust enter the clean gas area, this dust may settle
over the sloped panel. Sloped panel is designed to withstand only a small
quantity of dust, in case dust is settled on sloped panel it is necessary to remove it
out immediately.
h) Check all safety & warning labels are intact and eligible and secure.

3.3 Filter Bag Changing Procedure

Bag changing/inspection requires attention to full safety procedure/checks (see
previously)
Bag changing/inspection is carried out with the plant off, the area requires good
ventilation and should be checked for the presence of noxious gases before entering.
Hopper should also be checked for the presence of noxious gases prior to removing the
compartment lid.
In order to avoid the possibility of inhaling dust particles which have been deposited in
the AAF Fabri Pulse bag filter it is recommended that the following procedure is adopted.
Where filter bags are being removed, they should be placed into a polythene sacks for
ultimate disposal.

a) Obtain a Permit to Work on the plant ensuring that the Permit states the
identification number of the equipment which is being worked upon.
b) Ensure that protective clothing is not worn, i.e. Overalls, Anti-Dust Masks,
Headgear, Gloves and ensure that a sufficient quantity of polythene sacks is
available at the Access Door Level.

35
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

c) Isolate the collector and attach a Warning Notice to the isolation switch which
warns personnel that the system is not to be switched on.
d) Close the outlet hopper outlet valve if fitted and attach a warning notice.
e) Climb access ladder to top of the Fabri Pulse. Open and secure the plenum access
door this gives access to the pulse pipes in the clean air plenum.
f) Check the internal atmosphere.
g) Remove the Pulse Pipes by loosening the retaining peg and withdrawing the pulse
pipe from its bulkhead fitting, lifting the Pulse Pipes clear of the compartment.
Lay the Pulse Pipes out in the sequence in which they are re removed.
h) Remove the Filter Sleeve Cage. The cage may be of split construction so that it
can be removed within a limited headroom.
Note: Take care not to damage or bend filter cages.
i) Remove the Filter Sleeve from the Tube Plate and allow it to drop into Hopper.
j) Remove and allow six Filter Sleeves to drop. Allow one minute for any dust
displaced from the Filer Sleeves to settle.
k) Open the Hopper Access Door and check the internal atmosphere. Reach inside
the Hopper and pull a Filter Sleeve towards the door so that it can be put into a
Polythene Sack in such a manner that the Sleeve does not come outside of the
Hopper and the sack does not go inside the Hopper and thus become
contaminated with dust on its external surfaces. It may be necessary to use a rod
to pull Filter Sleeves to the Access Door if they are too far away. It is not
necessary to climb inside the Hopper to carry out any of the activities described
above.
Ensure that a good foothold in maintained whilst carrying out all of the Filter
Sleeve removal, and packing into polythene bags, activities.
l) Tie off the top of the polythene bags and lower it to ground level for removal
from site
m) Repeat activities j to m inclusive until the required number of filter sleeves
have been removed from the compartment.

Note: Inspect new bags and cages for damage from shipping, storage or handling
prior to installation. ONLY SMOOTH CAGES MUST BE USED DO NOT USE
DAMAGED BAGS OR CAGES.
n) Insert closed end of the bag through tube sheet hole until bag cuff is near tube
sheet.
o) Collapse bag cuff into half moon shape and insert as shown.
p) Snap bag cuff into position making sure centre groove of cuff seals properly at the
tube sheet.
q) Insert cage assembly into the installed bag ensuring that the cage top fits snugly
on top of the bag cuff.

36
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

Note: The cages is a split construction to allow them to be installed in a limited

headroom in which event the bottom portion should be lowered into the bag leaving
the final 300-600 mm proud of the filter bag and the upper portion is then snapped
into position prior to lowering into the bag as previously identified. It is imperative
that both halves of the cage snap together before the cage is fully lowered.

Repeat steps n to q until all bag assemblies are installed.

r) Re-fit the Pulse Pipes ensuring that each pipe is fitted into its original position
ensuring pulse holes are pointing down and centred over the bags.
s) Gently replace the roof door and secure wedge clamps ensuring foreign objects or
personnel items are not located below the door whilst it is located and that it seats
correctly.
t) Close and secure the Hopper Access Door.
u) De-isolate the collector and remove warning notice.
v) Cancel the Permit to Work

NOTE: It may be necessary to take a dye test or or pre-coating of the filter bags as
previously identified.

3.4 Regulation of Cleaning Cycle

The regulation of the GENERAL CLEANING time, INTERVALS BETWEEN AIR

PULSES and the DURATION OF AIR PULSES, all of these being adjustable at will,
is directly linked to the depression which is created through the bag material. With
use, the bags age and provoke a greater pressure drop. Consequently, the cleaning
action will become more energetic by varying the cleaning times appropriately. When
maximum cleaning times become necessary, this is a sign that the bags must be
changed.

Proprietary Equipment
For details of any necessary maintenance on proprietary equipment for example
diaphragm and pilot valves, instrumentetc please refer to manufacturers standard
literature.

37
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

3.5 Common Problems & Solutions

PROBLEM: High Pressure Drop Reading

Cause Solution

Improper pulse cleaning Check the wiring, fuses, and setting of pulse duration
operation and interval. DO NOT ADJUST THE PULSE
DURATION WITHOUT CONSULTING AN AAF
REPRESENTATIVE

Check the air supply to be sure the compressor is

Insufficient compressed providing 2-4 barg. Check for a plugged filter in the
air compressed air line

Check operation of diaphragm valve by removing pilot

Diaphragm valve line to simulate operation. Clean and / or repair
malfunction diaphragm if necessary

Solenoid pilot valve Listen to be sure the solenoid are firing. Check for
malfunction momentary air venting each time it fire. Clean or replace
if necessary.

A leaking rotary lock, screw conveyor, slide gate, etc.,

Leaky dust discharge can overload a Fabri Pulse by preventing dust discharge.
device This will cause high pressure drop. Excessive bag wear
and reduced air volume.

High humidity will create blinded bags which results in

excessive pressure drop. Run the cleaning mechanism
Condensation with the fan off and program timer on to release the dust
cake. If condensation is a recurring problem, pre-
processing warm-up and post-processing purge periods
of 15 to 30 minutes each may help. Exterior insulation
may also be necessary. Sources of moisture may come
from leaky process ductwork, moisture in the process gas
stream, or moisture in the compressed air system.

38
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

PROBLEM: High Pressure Drop Reading Contd.

Cause Solution

Static electricity In extremely rare instances a static electric build-up can

cause a high pressure drop. Increase the humidity if
possible, using discretion to avoid causing condensation.
Grounded bags may also be required

Too much air or too much dust will create high pressure
Collector overloads drops across the collector. Check the fan speed, system
design, pre-cleaners and the damper position. Also be
sure the dust load and air volume are those the system
was designed to handle by undertaking a volumetric
check immediately up or down stream of the collector

39
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

PROBLEM: Visible Discharge

Cause Solution

Incorrect installation or Check for holes or rips in bags. Replace damaged bags.
damaged bags Reseal bags as necessary.

Insufficient dusk cake The unit could be pulsing too often resulting in over
cleaning. Check to see if the pressure drop is at least
100mm. Increase pulse interval until the unit is operating
stably at 100mm pressure drop minimun.
DO NOT ADJUST PULSE DURATION WITHOUT
CONSULTING AN AAF REPRESENTATIVE.

The Fabripulse collects material via interception of

particles within the gas stream via a filter media. By its
Extremely fine fume very nature there exists pores in the media through which
extremely fine fume may pass. Inject filtration aid to
block off pores. (Dependent upon application this may be
a continuous requirement).
PLEASE CONSULT AN AAF REPRESENTATIVE
FOR ASSISTANCE IN CHOOSING A FILTRATION
AID.

40
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

PROBLEM: Visible Discharge Contd.

Cause Solution

Over temperature The Fabripulse collects material via interception of

operation particles within the gas stream via a filter media. Some
materials vapourise into a gaseous form as the
temperature and / or pressure of operation may vary. The
Fabripulse is not directly able to collect particles in
the gaseous form. Check temperature and pressure for
correct operation. Inject absorption agent for collection
of gaseous media.
PLEASE CONSULT AN AAF REPRESENTATIVE
FOR ASSISTANCE IN CHOOSING A FILTRATION
AID.

41
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

PROBLEM: Insufficient Extraction

Cause Solution

Incorrect fan rotation The incorrect rotation of the fan will mean that the
system will not provide the system static pressure or air
volume required.
Check fan rotation and correct as appropriate.

Tighten the V-belts if necessary. Replace broken or

Fan v-belt slippage stretched belts (refer to manufacturers standard literature
for maintenance/installation procedure)

Collector high pressure See earlier

Leaks Leaking ductwork, access doors, explosion vents, dust

discharge devices, or housing will cause insufficient
suction at the pick-up point. Seal any leaks with an
appropriate media.

Clogged ducts, closed dampers or closed gates will shut

off the air flow. Remove blockage making sure that the
Closed air passages system design is not compromised.

42
 XLC SERIES FILTER
OPERATION & MAINTENANCE MANUAL

PROBLEM: Insufficient Extraction Contd.

Cause Solution

Undersize ducts Undersize ducts will create excessive pressure losses for
which the fan may not have been sized. Duct size should
be reviewed considering the design specifications and
fan selections.

43
 EWEKORO NIGERIA BAGFILTERS
OPERATION & MAINTENANCE MANUAL

PROBLEM: Fabric Bags Problems

Cause Solution

Over temperature Operating temperatures should be not exceed specified

maximum.

Humidity can blind bags. Moisture will result in denser

Humidity
dustcake build-up or will adhere dust to the bag.
Drawing dry air through collector may dry the dust
enough to allow the collector to clean with the fan off. If
this doesnt work the bags must be dry cleaned or new
bags installed.

Each bag material is selected for specific physical and

Dust discharges chemical characteristics which are compatible with the
gas stream composition and temperature.

Dust build-up into the bag area will result in excessive

abrasion on the bags. The build-up may be caused by a
Dust build up within malfunction of the discharge device or condensation in
hoppers the hopper heaters with insulation may have to be added
to the hoppers.

Dirt on the clean side of bags will wear the bags out from
the inside. This could be the result of a broken bag, or
incorrect bag installation or an improper tube sheet seal.
Bag wear on the inside Vacuum the clean air side and replace the bag. Do not
blow dirt inside the bags. If the bags have dust inside
them, vacuum them out.

44
 EWEKORO NIGERIA BAGFILTERS
OPERATION & MAINTENANCE MANUAL

4. FILTER BAG TECHNICAL INFORMATION

General Performance Guarantee Provision

1. The start-up of this plant must be advised immediately to AAF International by

written notice.
2. Filter bags and cages must be correctly installed and maintained.
3. There must not be:
temperature and chemical conditions inconsistent with bags fibres nature
vapour condensation and/or incrustations on bags and felt clogging
incandescent particles in the gas flow
abrasion due to abnormal gas flow stream
4. Bag must be properly stocked, handled and installed.
5. During the start-up, bags precoating must be assured.
6. Correct and documented monitored data of the working conditions during the
entire guarantee period must be at free disposal of AAF International and must be
prove to be in accordance with working conditions advised to AAF International
with your inquiry.
7. Personnel appointed to by AAF International is fully authorized to inspect bags
8. Compressed air quality to be maintained with the quality of water content <4 g/m3
and oil content <1mg/m3
9. Preheating of the filter unit during shutdown and start-up to avoid condensation.

(For details please refer to Bags Warranthy Condition provided)

Temperature of intake gas into the filter

Bags are designed for a maximum temperature 280 deg C in short period of time.
Intake gas temperature into the filter must be always below the maximum
temperature in order to avoid bag damage.

Operator must make sure no gases will enter into the filter exceed maximum design
temperature, the solution will be considered to install some injection of dilution air or
some inlet gases cooling tower etc.

If filter intake gases goes up the maximum design temperature, bag guarantees will
extinguish automatically.

Chemical composition of intake gases into the filter

Bags quality material is established according to gases intake chemical composition.

Intake gas chemical composition into the filter must be maintain within design
parameters in order to avoid bags degradation.

45
 EWEKORO NIGERIA BAGFILTERS
OPERATION & MAINTENANCE MANUAL

If gas intake chemical conditions are going to be changed, customer must report to
AAF about the new conditions. In that case AAF will reconsider a new bag life
performance guarantee, or even may recommend to change to a different bag quality
material to suit the new condition.

Fiberglass PTFE membrane filter bag Installation Instructions

Protect the membrane Use installation sleeve!

1) Tubesheet

2) Put in installation sleeve in order to prevent damaging the membrane

3) Install filterbag with care

46
 EWEKORO NIGERIA BAGFILTERS
OPERATION & MAINTENANCE MANUAL

4) Put in the total length of filter assembly

5) Finally remove installation sleeve and fix snap ring

6) Repeat procedure with next filterbag!

47
 EWEKORO NIGERIA BAGFILTERS
OPERATION & MAINTENANCE MANUAL

GENERAL CONDITIONS

1. This guarantee offering is good if signed at the same time the contract is signed.

2. The collector shall be operated in accordance with the specifications and conditions
contained herein. Deviations from the conditions will void the guarantee only if
such deviation causes bag failure.

3. Bag failure is defined as:

Emissions in excess of the guaranteed level.

Greater than 5% of the bags in a compartment or a whole filter develop wear

holes, rips or tears due to loss of strength, prior to reaching the minimum life.

Remedy for bag failure in the event of emission in excess of guaranteed level is
for AAF to supply replacement bags on a bag-by-bag basis until the emission
level is met.

Bag failure in terms of differential pressure is defined as operational P across

the tube sheet in excess of the maximum guaranteed P of 1500Pa when the
system is operated within the specified performance conditions and with an
optimized cleaning cycle as determined by AAF.

Remedy for bag failure in the event of differential pressure in excess of the
guaranteed level is for AAF to supply replacement bags on a bag-by-bag basis
until the pressure drop guarantee is met.

4. Remedy for bag failure is as follows:

Supply replacement bags on a bag-by-bag basis until the emission level is met.

If bag defect found >5% of total bags in a compartment, all the bags of the entire
compartment shall be replaced free of charge; if bag defect found <5% of total
bags in a compartment, the bag shall be replaced on one to one basis free of
charge.

In the event that AAF supplied filter bags are not suitable for the application in
the environment and condition specified in this contract (as determined by AAF),
AAF will supply replacement bags of conventional material.

48
 EWEKORO NIGERIA BAGFILTERS
OPERATION & MAINTENANCE MANUAL

Replacement shall be on a one-time basis only if the defect is not attributed to

the Supplier. Credit toward replacement = (guaranteed months of life - months
after installation) (guaranteed months of life) times the original purchase
price.

During the bag warranty period, bag replacement shall be on a full basis.

5. The Purchaser shall notify AAF immediately should bags fail to perform as specified.
The Purchaser shall allow 36 hours for AAF to respond.

6. Failed bags must only be replaced with AAF supplied filter bags unless otherwise
agreed to by AAF.

7. AAF shall not, under any circumstances, be liable for any incidental, consequential,
or special damages, including but not limited to the loss of business or profits based
on any alleged negligence, breach of warranty, strict liability, or any other theory,
arising out of the use and/or handling of these products and any replacements or
reorders. The maximum liability of AAF shall not exceed the purchase order price.

8. Terms and conditions on the quotation form apply to this sale. If conflict with terms
and conditions and general conditions exist, the general conditions shall apply.

9. Withholding payment of invoice shall void guarantee unless otherwise agreed to in

writing by AAF except The purchaser withhold the payment due to problems caused
by AAF or its products.

10. The Purchaser shall allow AAF to examine, at AAF's manufacturing/laboratory

facilities, any AAF supplied filter bags which may have been removed due to
questionable operation. The Purchaser must indicate to AAF in writing the reason
and specific location of any/all bags which are removed, due to questionable service,
from the baghouse during the guarantee period.

11. The Purchaser shall make all test results pertaining to or affecting the performance
of the AAF supplied filter bags available to AAF when such results are obtained.

49
 EWEKORO NIGERIA BAGFILTERS
OPERATION & MAINTENANCE MANUAL

TECHNICAL CONDITIONS

1. Prior to installation:

a. Bags must be stored in clean, dry conditions. Bags damaged prior to

installation shall not be installed.

b. AAF shall be allowed to conduct an inspection to ensure that the collector meets
the specified design criteria.

c. All extraneous material (i.e., welding slag, rust, dirt, etc.) must be removed from
the collector.

d. Inspect cages/thimbles/caps to ensure they are not damaged or defective.

2. AAF shall be allowed to witness the bag installation and to specify reasonable
procedures.

3. The Purchaser shall conduct a fluorescent dust leakage test prior to start-up and
properly seal all leaks that are identified. A second test shall be conducted if
necessary. AAF shall be allowed to witness the test and specify reasonable
corrective procedures.

4. The Purchaser shall cooperate with and assist AAF in determining the optimum
cleaning cycle and any other reasonable adjustments or corrections which may be
necessary to optimize the performance of the AAF supplied filter bags.

5. Temperature excursions shall not exceed 260oC for more than 10 minutes per day as
measured at the collector inlet and shall never exceed 288oC.

6. Purchaser shall be responsible for proper distribution of airflow. Examples of flow

distribution problems include, but are not limited to damper failure, hopper fill-up,
or duct pluggage.

7. Purchaser shall ensure the bags are not subjected to external mechanical damage
(i.e., bag-to-bag or bag-to-collector abrasion, impingement by high velocity dust; lift
velocity <1.2 m/sec, inlet velocity < 10 m/sec).

8. Pulse pressure shall be regulated to 2 - 4bar. The pulsing air must be dry and free of
contaminants and pulse pipes properly aligned.

9. The backing material selected must be compatible with the application with regard
to temperature rating and chemical resistance. The collector must be operated

50
 EWEKORO NIGERIA BAGFILTERS
OPERATION & MAINTENANCE MANUAL

above the acid dew point.

10. Failed bags must be promptly replaced, plugged or tied off.

11. Purchaser shall be responsible for replacing bags damaged as a result of sparks or
fires.

12. Proper start-up and shut-down procedures must be followed. Purchaser is

responsible for replacing any bags failed due to hydrocarbon blinding.

13. The baghouse shall be bypassed or pre-coated during start-up and during oil firing.

14. Purchaser shall be responsible for vacuuming any/all dust which accumulates on
tube sheet due to any potential failed bags, leaking welds on tube sheet, and/or bags
removed for routine analysis.

TESTING

1. All testing is to be performed by an agreed upon method within 90 days after

successful installation of the filter bags. AAF shall have the option to witness testing
and participate in a pretest conference with the testing company.

2. Particulate matter is defined as front half catch obtained during EPA methods 5 or
17 emission testing or VDI2066 methods.

3. AAF shall not be responsible for particulate/pseudo-particulate generated from

vapor condensation in the flue gas after the baghouse.

4. Recording of the heated probe temperatures throughout each emission test run is
required.

5. Emission sampling volume and/or time must be sufficient to achieve 10 mg

particulate catch.

6. The Purchaser shall be responsible for providing a procedure to determine the

amount of leakage around the filter bags.

For enquiry, kindly contact AAF Wuhan office

Tel: +8627 84236609/84236630
Fax: +8627 84236620
Email: enquiry@aafwuhan.cn

51


-1-

1

-2-


30-50%

33-50% 50%

MT600

MT800MT1000MT1200MT1400MT1600MT1800MT2000

80 t/h650 t/h 0-27 r/min

-3-


-4-
-5-


1.

2.

3.

-6-


2 MOBIL630

4 1L 0.9KG

2#

5 NAS 6-7 ISO12-15

-20-----120

15-25

-7-
 100012001400
632628013058

160018002000
633234016068

38

-8-
 CONTENTS

1Structure outlined1

2Technical performance

3Schematic diagram and Type Selection

4Installation

5Operating and maintenance

6Wearing parts

-9-
1Structure outlined
1This rotation unloader is specifically for vertical

mill of the company with the a dosing of large and medium-sized

air lock feeding devices, and with positive pressure and

negative pressure to transport and drying functions

2 rotation unloader its simple structure, reliable

performance, good sealing performance, with a replaceable wear

liners and checking doors, its structural features can be

resolved into the grinding particulate material is stuck problem

in the long-term use has been highlights the the characteristics

of the product - small, compact structure, has been used widely

in home and abroad. The company has a rotary unloader and

self-cleaning Tipper two structures.

3 rotation unloader comprises a rotation impeller

structure, the fixed shell and the drive devices, most of the

impeller blades have a resistant liner inlaid improves the life

of the impeller; from the inlet port to the center of the

centerline of of the housing certain deviation is to applicable

to materials into larger particles, but also added a dam plate.

Most shell lined with abrasion-resistant layer; impeller is

supported by the bearings at both ends, can ensure a gap between

- 10 -
the impeller and the casing uniformly, leaving a gap between the

impeller and the corresponding shell. Sealed at both ends are

sealed with asbestos packing, simple, good sealing, easy repair

and replacement.

This rotation unloader features a hot air channel, when

feeding humidity, impeller may stick to the bottom of powdered

materials have a certain thickness, then they should pass into

the high temperature gas, drying the material at the bottom, so

that its difficult to bond at the bottom of impeller, does not

affect feeding capacity, when not in use hot air to the inlet

and outlet the blind dead. (Except for self-cleaning)

rotation unloader in the housing opened one to two side

access door can be opened, if necessary, check the internal

situation. When the impeller using six months or more, open the

small access door on the impeller end plate repair welding fray

can not cause impeller card material. Also in the top with

inspection hole, usually occurs when the debris into the

impeller or blocking materials and other incidents affecting the

normal operation of the feeder, you can open the access door to

clean up, or observe their specific usage. When the rotation

unloader fill rate is generally between 30-50%, can not feed too

- 11 -
much, if there is the phenomenon of sticky material can be

readily cleaned. Design of the equipment is also 33-50% by

feeding the hopper feeding quantity greater than 50% is prone

to jammed, so that the drive device is damaged, it should be added

overload electrical control design on the drive.

Note the direction of rotation of the impeller, accordance

the rotation direction given to the device indicated on the

drawings and wiring, not the opposite direction to the material,

otherwise there will stuck phenomenon, the impeller or impeller

abnormal overload, the impeller shaft can be determined by the

end of the proximity switches situation impeller rotating and

signals, both on the the functioning of the implementation of

rotation unloader line monitoring.

2Technical performance
We rotation unloader vertical mill is designed with the

following specifications: MT600, MT800, MT1000, MT1200, MT1400,

MT1600, MT1800, MT2000, etc., feeding capacity from 80 t/h-650

t / h, the number of revolutions 0-27 r / min, both large and

small volume using a torque reducer.

Rotation unloader overhaul time is generally 8 months, when

overhaul or replacement of wear plate welding according to the

- 12 -
actual situation, time is usually once a week for maintenance,

overhaul, not exceeding one year, or it may not be repaired due

to excessive wear. The Company proposes to less than a year when

the best use of re-ordering a spare device to facilitate device

when there is a serious problem, replace the spare up, the

removed Depot repair, do not delay production, most of the

current user With this approach.

- 13 -
3Schematic and Type Selection

- 14 -
- 15 -
4, the installation instructions
This machine is the overall structure, the upper case under
flanges are installed, you can directly and non-standard items
direct related the composition of a closed unloading or Feed System,
in order to strengthen the seal sealant can be applied in the the
docking flanges surface or add asbestos rubber mat seal.
Please note that when installing the Rotation unloader read the
installation requirements:
1) Note that materials flow direction and the direction of
rotation of the rotor to be consistent, use of such best use of
blanking, as shown below.

(2) when adjusting the transmission, the machine can move the
situation then start to look to see whether the the steering is
consistent with our starting marked direction, the direction
indicator device end plate cards.
- 16 -
 (3) When the unloader constrained installation position can be
adjusted by yummy treats the tube; If the material flow direction
of the rotor in the opposite direction, the impeller blades and
the shell will soon be worn, which affects the productioncaused
heavy economic losses.

5Operation and Maintenance

1, the motor connection to ensure impeller rotates in the same
direction as the direction of the left cover red arrow signs.
2 , before use to add MOBIL630 gear reducer oilreducer
maintenance should be strictly in accordance with the requirements
of the reducer for maintenance. For example: oil, grease
3, the seal gland refueling, open the lid every three months,
plus exchange of graphite sealing filler, and put grease.
4, bearing injection volume 1L about 0.9KG (former factory fill)
once every two weeks plus 2 # lithium grease, check the bearing
cap open for three months, to replace one. Has its own bearing
housing oil cup.
5, grease cleanliness NAS reach 6-7 ISO12-15
Temperature range -20 ----- 120
6.When the local environment humidity and hot summer rainy
season must be added, resulting in the bottom of the impeller can
not caking and harden without affecting the feeding amount. (If
the equipment adopts for the self-cleaning impeller feeder, do not

- 17 -
pass hot air, but it must always back gear overhaul connection with
the shaft.) Open manhole door conducted maintenance workers
cleaning up the bottom of the impeller every 15-25 days .

6Wearing parts
(1), Oil asbestos packing or graphite packing.
(2), bearing
1000, 1200, 1400 unloader: (6326) 280 130
58
1600, 1800, 2000 unloader: (6332) 340 160
68
(3), the impeller and shell antiwear plates with antiwear
plates: 8 months should repair and replacement, different
environments very different use of time, but will causing excessive
wear throughout the equipment can not be repaired, one of the most
important spare, back after the plant maintenance equipment as new.
Alternate use for a long time will not be scrapped.

- 18 -

---------------------------------------1

---------------------------------------------1

-------------------------------------1

---------------------------------2

-------------------------------------------------2

-------------------------------------------3

Contents
The scope of work

The requirements of Installation

Adjustment

Operating process

Lubrication

Maintenance


2.1 20

2.2

2.3
2.4

3.1
3.2


A
B 40
C
D 85dB
E 0.05DkwD
m
3.3

A
B 50
C

4.1
4.2
4.3
4.4

5.1
90 150 SY1172-77S


60 80
5.2
ZL1SY141275
2/3

6.1
A
B
C
D
6.2

A
B
6.3

A
B 0.5M

2
C

D

3
1.Features and Applications

Horizontal screw conveyor for conveying machinery, basic dimensions of

two parts, as part of the drive, the corresponding dimensions shown in Figure.

Conduct on-site inspections in accordance with the appropriate size for the

selected device, further confirmation of construction.

2.Installation Requirements

2.1 20 days before the screw conveyor installation, you should pour a good

foundation, the foundation should ensure that the screw conveyor is in

operation with sufficient stability.

2.2 Screw conveyor should install all parts before inventory is complete, and

all kinds of dirt cleaned inside and outside.

2.3 All coupling bolts should be tightened to reliability.

2.4 Dust port inlet, the discharge port should avoid housing flange and cover

lap. Generally take spot welding.

3.Adjustment

3.1 screw conveyor installation, respond to lubricate all lubrication points,

prepare commissioning.

3.2 first start the application jog mode, jog for a few test to observe the part

of the action that can be carried out after the normal load test run. Load test

run should be continued for more than two hours, if found not to comply with

the following conditions should be immediately shut down, correct operation

after the line until it is in good operating condition.

A, screw conveyor running smoothly, no loose fasteners.

4
B, each bearing temperature of not more than 40 , lubrication, sealing

well.

C, reducer no oil leakage, no abnormal sound, electrical equipment,

couplings safe and reliable.

D, no-load operation noise should not exceed 85dB.

E,No-load operation per meter length of the screw conveyor power

consumption should not exceed 0.05Dkw (D units of m).

3.3 load test run after passing can load test run. Commissioning of the

material should be required to transport materials, and shall comply with the

following conditions:

A, the actual motor power should not exceed the rated power.

B, each bearing temperature is not greater than the ambient temperature plus

50 .

C, load test run should be carried out after eight hours, during operation if

unusual circumstances, should immediately stop inspection, can not be

forcibly run.

4.Screw conveyor rules

4.1 load start screw conveyor, after stable operation can only feed.

4.2 stop off before feeding device, material handling has finished before

being shut down.

4.3 It should be uniform continuous feed.

4.4 abnormal situation, immediately turn off the feeder, then stop, can

continue to run after troubleshooting.

5
5.Lubricating

5.1 reducer lubrication

Selection of 90 ~ 150 industrial gear oil (SY1172-77S) or neutral level

pressure gear oil. New reducer twenty days after use, to be replaced with new

oil. For long-term continuous work reducer must change the oil once a month,

for the daily working time does not exceed eight hours reducer, the first oil

change should be six months. If found using temperature over 60 or oil

temperature exceeds 80 , the lubricant must be replaced before use.

5.2, tail bearing box lubrication

Use lithium grease ZL-1 (SY1412-75) generally filling a month, accounting

for about two-thirds of the amount injected into the bearing housing space is

appropriate.

6.Care and Maintenance

6.1 Routine maintenance

A, keeping the work environment clean, regularly wipe the body.

B, tighten fasteners.

C, add a little oil, grease.

D, ensure that the circuit is intact.

6.2 a maintenance

After three months of continuous use of the screw conveyor, level should be

maintained.

A, cleaning drives, replace oil.

B, bearing housing if the oil spill, oil seals should be replaced.

6
 Mounting for Level Switch
Please make sure the socket thread size the same as level switch thread

size.

Welding the socket with the side wall as per drawings required.

(refer to below capture, degree 20 should be ensured)

Mounting protecting angle should be above level switch probe (

Angles length =500mm