ouinn' rnent - epaauthorities and flsmidth. all references to design standards are given in the ec...

. I

Ms. Ann Marie Donlon,

Office of Licence and Guidance,

Environmental Protection Agency,

PO Box 3000,

Johnstown Castle Estate,

Co. Wexford.

Ballyconnell, County Cavan, Ireland.

Tel 049 9525200 Fax 049 9525201

[email protected] E-mail www.quinn-group.com

Website

Date:

Company:

Registration No.:

g th December 2014

Quinn Cement

P0378-02

OUINN' rnent

RE: Inclusion of Minor Emission Point A3-54 in Schedule B Emissions to Air for Bag Filter Exhausts throughout the Process of IE licence register number P0378-02

Dear Ann Marie,

A technical amendment (Section 96{1) of the EPA Acts) request was made by the

Agency on 01/12/2014 in relation to the inclusion of a minor emission point to be

labelled A3-54 located at the Kiln Dust Silo.

Quinn Cement had submitted a number of proposed additional minor em1ss1on

points associated with the recent upgrades to the plant for purposes of cofuelling

with solid recovered fuels (SRF) on 27/11/2014. Minor emission points A3-47 (SRF

reception), A3-48 A3-49 A3-50, A3-51 (SRF Storage Bay), A3-52 A3-53 (SRF Feeder)

were all approved. However location A3-54 (kiln dust silo) is not directly involved in

the receiving stations or conveyance system for SRF and so our Inspector advised

that Quinn Cement should seek an appropriate technical amendment to the licence

to regularise this minor emission point.

This application is being made in accordance with Condition 1.4 of the licence

whereby a letter of agreement with the Agency is appropriate to regularise the

matter. Draft guidance published by the Agency for Licensees on requests for

alterations to the installation/facility in 2014 specifica lly lists minor emission points

as an appropriate defining parameter to be regularised by letter of agreement

between the Agency and the Licensee.

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In order to reach agreement, Quinn Cement provide and enclose the following

information:

• The kiln dust silo was a planned structured improvement to the Plant as part

of SRF works and was a flagged piece of the infrastructure in the licence

application for P0378-02. See Section D, Part 3 of the application documents

(Installation of new silo at cement mill for bypass dust).

• Map showing the location of minor emission point A3-54 is enclosed.

• Information on the bag filter abatement, Jet pulse filter CEl-BF, attached to

A3-54 is enclosed.

• Bag filter is best available technology or technique (BAT) and should provide

negligible emiss ions at this point. For enforcement purposes, it should be

considered in the same bracket of existing monitoring points (A3-01 to A3-46,

minor bag filter exhausts throughout the process). It will be included in the

roster of particulate emission monitoring biennially at this location and

appropriate visual checks will be carried out periodically. The limit at this

point should be 50 mg/m3 as consistent with other minor bag filter exhausts

throughout the process. Also application of this limit to A3-54 is consistent

with Agency guidance that the proposed alteration can be accommodated

and controlled under the existing licence conditions and limits.

• Emissions from this monitoring point will not create any significant impact on

the environment. The scale of emissions at this point is anticipated to be low

in both flow and concentration. No further information is deemed necessary

to be provided at this time. Quantification will be provided in the biennial

monitoring proposed across the Plant and the timing for monitoring of A3-54

will be tied in with existing minor bag filter exhausts across the process at the

next planned biennial round of monitoring.

I hope this information will allow the Agency to make an expeditious determination,

if you have any queries or if any further information is required, please do not hesitate to contact me.

Kind Regards,

~ , l ~ l \ \ J ( s~) Michelle Cass

Environmental Advisor

Quinn Cement

Tel (D): 049-9525212

[email protected]

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INSTRUCTION MANUAL H

70005814-1.2 Jet pulse filter CE1-BF

Installation

The text refers to the following instruction manuals etc.

General safety regulations at Installation site ...................... . 32031

RAMSINGSVEJ 30 • 2500 VALBY ·DENMARK + 3231 SCHOENERSVILLE • PA 18017-2188 BETHLEHEM-USA + FLSMIDTH HOUSE-34 EGATOOR -KElAMBAKKAM 603103 -INDIA

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2 70 005814-1.2

Table of contents:

'J!smiDTH

AIRTEC:H

Page: 1 General information .... ... ... .. ...... . ........ .. ..................................... .... ... .. .. .. .... .. 4

1.1 Scope .................. ....... ...... ....... ..... ........ ... .... .. .................... ................. .... ..... . 4 1.2 Design basis ... .... ........ ...... .... ....... .......... .... ..... ...... ....... .. ......... .. ........ .......... . 4 1.3 Normative references ..... ........... ..... ... ... ... ..................................................... 5 1 .4 Documentation ........ .. ... ... ..... ... ... .... ...... .... ... .. .. .............. .... ..... .... .... ..... ..... .... 5 1.5 Definitions and abbreviations .... .. .......... .. ........ ............................ .. .. .......... .. . 6 1.6 Legend ...................................... .................... ..... ..... ..................................... 6

2 Design and operating principle .. .. .. ............ .... ...... .................................... ..... 7 2.1 Construction ............. .......................................................... ... ............. ....... ... 7

2.1.1 Filter housing (Appendix 1 ) .. ...... ........ ................................ ............. . 7 2.1.2 Filter chamber (Appendix 1) ............ .......... .. ............................ ........ 7 2.1.3 Clean-air chamber (Appendix 1 ) .... ............. ......... ........ .. ............. .. .. . 7 2.1.4 Compressed-air system (Appendix 2) .. ...... ........ .............. ............. .. 7 2.1 .5 Connection for differential pressure measurement (Appendix 2) .. .. 7 2.1.6 Valves on the cleaning system (Appendix 3, 4 &5) ... ............ .......... 8 2.1. 7 Controller (Appendix 6) .................................................................... 8 2.1.8 Insulation .... ......... .... ... ......... ...... .................... ........................ ... .... ... 9

3 Safety instructions ........................... .. ................ .... .. .................................... 9 3.1 General notes .... .. ....... ... ... ........... ...... ... ... ... ... ....... .. ............. .. ........... ... ... ..... 9 3.2 General notes on safety for the jet pulse filter ................................ ....... ...... 9

3.2.1 Design requirements ....................... .......... ............ ............... .. ... .. .... 9 3.2.2 Marking of equipment.. ........ ... ....... .. ......................... ........ ............... 9 3.2.3 General notes relating to the posting of signs ................................. 9 3.2.4 Scrap and waste .. .... .. ... .................... ....... ...... ... .... .... .. .. .. .. .. ... .... ... .. . 9

3.3 Specific safety precautions concerning Installation ................................... .. . 10 3.3.1 Permission to work .... .. .. .. ................................................................ 10 3.3.2 Lifting of heavy parts ..... .. ................................................................ 10

3.4 Specific safety precautions concerning O&M ............................................... 10 4 Installation .... .... ........ ..... ... ... .... .... ... ...... ...... .... .. ...... ................ .. ... .... ...... .... .. 10

4.1 General notes ....... .. .... .. ........ .... ...... .. ......... .. .. ... ... ... ... ..... .. ....... .... .... ..... ... .. .. 1 0 4.2 Modifications .... .... .. ... .. ............ .. ... ... ..... .... ... ... ... ................. .... ................ ... ... . 11 4.3 Planning and installation procedures .. .. ........... .. ..... ...... ....... ......... .. .. .. ......... 11

4.3.1 Resources and documentation ... .. ..... .. ... .. ............................... ........ 11 4.3.2 Planning and schedule .............................................................. ...... 11 4.3.3 Checking the dimension of buildings and foundations .................... 12 4.3.4 Auxiliary tools. ~ .............. ... ... ... ...... .. .. .. ... ... ............ ......... ... ......... ...... 12 4.3.5 Scaffolding ............................ ...... .. ... ..................... .... ...... .. ............. .. 12

4.4 The task on a step-by-step basis .............. .. ....... .............. .. .. ........ ................ 12 4.4.1 Introduction ....... .... .... ..... ....... ... ... ... ... .. ........... ... ........... ..... ........ ....... 12 4.4.2 Bottom frame ... ........ ...... ..... .... .... ... .. .. ........ .... ....... ..... .... ..... ..... ... ... 13 4.4.3 Filter chamber .............. ..... ... ............... ... .. ... ..... ............ ....... ... ... .... . 13 4.4.4 Stiffening stays and supporting irons ............. .... .......................... 13 4.4.5 Tube sheet .... .... .. ..... .. ... ... ............. ...... .................. .. ....... .... .. .......... 13 4.4.6 Clean air chamber ........ ..... ........ .... .... ........... ..... ...... ............... ....... 13 4.4. 7 Frame plate .. .. ... ... ... ...... .. ..... .. .. ... ... ..... .. .... .. .... ...... ... ...................... 14 4.4.8 Ladder and railing .... ....... .... ..... ..... ... ...... ..... .. ....... ...... ... ........... ...... 14 4.4.9 Compressed-a ir system .. ............ .............. ............................ ... .. ... 14 4.4.1 0 Filter bags; blow pipes and access doors ...... ..... .. .. .. .. ...... .. ............. 15

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[jl!smiDTH AIRTEC:H 70 005 814-1.2

4.4.11 Controller ............. ... ........... ..... ... .. .... ... ... ........ ... ... ... ..... ... .... ......... ... 16 4.4.12 Connection to differential pressure measurement ............ ...... .. .. 16

5 Operation ................. ..... ..... .... ..... ..... .. ........ ... ... .. ... ... ..... .. ..... .. ......... .... .... ..... 16 6 Maintenance .. ..... ...... ........ ... ... .... .... .. ........... .... .... ... ...... .... ........ ..... ... .. .... .. ... 16 7 Description of components .... .. ........ ...... .... .... .. ...... ......... ..... ..... ...... ..... ..... .... 16

7.1 Key to appendices ...... ... .. ... ......... ... ........... .. ..... ......... .......... .... .. ................ ... 16 8 Appendices .... .. .... .. ........ .. ....... ............. ....... .. ....... ........ ... .... ... .. ...... ........... ... 19

List of Appendices

3

Appendix 1 ........... .. .. ....... ..... .. ... ...... ... ..... .... .......... .... .... ..... .......... ....... ............. .. ....... ....... . 20 Appendix 2 ..... .. ... ... ..... ... ... .... .............. .... ... .... ..... ............. ................ ......... .......... ... ... ....... . 22 Appendix 3 .... .............................................. .. ...... .......... ......................... ... ......... ............... 24 Appendix 4 ...... ....... ... ...... .. ......... ....... ... ......... .... .. ..................... ....... ... ... .... .. .... ... ... .... ........ 26 Appendix 5 .. .... .................. ... ... .... ...... ............. ..... .... ............. ... ...... ... ..... .... ..... ... ...... ......... . 28 Appendix 6 .. ....... ....... .......... ... ... .... ... ... ... .......... .. ... .. ... .... ... ... .... ... ....... ................... .......... .. 30

List of figures

Figure 1 .... ........ ....... .... ...... .... .... .. .... .. .... ........................... ... .. .. ............. ........ .. ..... .... ...... .... 14

List of tables

Table 1 .... ...... .... .... .. .... ........ ...... ... ... .... ... ... ... ....... ... ... .... .. .. .. .. ..... .......... ............. ...... ... ... ...... 5

Created by: ECR Sort code: E25 Translated by: JRO

Approved by: HVP Approved date: 2008-10-06 Pages: 31

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4 70 005814-1.2

NOTE!

IJ!smiDTH

AIRTECH

The present instruction manual is concerned with the situations which, according to the experience of FLSmidth, are the most likely to occur. An exhaustive enumeration of all conceivable situations, which may occur during manufacture, installation, operation and maintenance of the equipment, cannot be provided. Consequently, if a situation should arise, the occurrence of which is not foreseen in the instruction manual, and which the operator is/or feels unable to handle, it is recommended that FLSmidth is contacted without undue delay for advice on appropriate action.

1 General information

1.1 Scope

The jet pulse filter CE1-BF is an automatically operated bag filter which is known as a bunker filter and it is specifically designed for cleaning of dust-laden air from silos and bins.

The choice of materials and the installation dimensions of the filter are specifically adapted to the purpose for which the filter is intended. Any changes with respect to the range of application or the operating environment of the filter are to be implemented only subject to prior approval from FLS.

Attention! Use the filter only for the aforementioned purpose.

1.2 Design basis

The jet pulse filter type CE1-BF is a modular structure, containing 1, 2, 4 or 6 modules, with filtration areas ranging from 25 m2 to 252 m2 .

Each module is equipped with a variable number of bags which means that a series of 11 filters with variable capacity ratings is available.

The filter is supplied without bottom hopper and supporting structure . At the bottom the filter housing is provided with a base frame, which is specifically designed for direct mounting on silo roof and similar locations.

The filter is designed for a max. Operation negative pressure of 4.5 kPa

The type designation of filter is structured as indicated below:

CE1 - 1 - 05 SF

+-- bunker filter type

+-- number of bag rows and valves

+-- number of modules

+--centra l filter type 1

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Ejl!smtDTH

AIRTEC:H 70 005 814-1.2

The accompanying table shows the filters with type designation CE1 -BF:

Table 1

Designation Number of Number of Number of Total Filtration modules bag rows bags per number of area

row bags ( m2)

CE1-1-03 BF 1 3 7 21 25

CE1-1-04 BF 1 4 7 28 34

CE1 -1-05 BF 1 5 7 35 42

CE1-2-06 BF 2 6 7 42 50

CE1-2-08 BF 2 8 7 56 67

CE1-2-10 BF 2 10 7 70 84

CE1-4-06 BF 4 6 14 84 101

CE1-4-08 BF 4 8 14 112 134

CE1 -4-10 BF 4 10 14 140 168

CE1-6-12 BF 6 12 14 168 202

CE1-6-15 BF 6 15 14 210 252

1.3 Normative references

5

The jet pulse filter is prepared for inclusion into a dedusting plant, which should be approved according to the standards applied by the regulatory authorities and FLSmidth.

All references to design standards are given in the EC declaration of conformity.

Local regulations take precedence over instruction manuals.

For dated references to any publication, subsequent amendments to or revisions of any of these publications apply to this instruction only when incorporated in it by amendment or revision .

For undated references the latest edition of the publication referred to shall apply.

1.4 Documentation

This manual contains important information about the procedures recommended to ensure that the filter is erected in the safest and most efficient manner.

The manual constitutes a supplement to the rules and regulations of the respective countries in regard to safety measures and environmental protection.

This manual must always be available at the point of filter usage.

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6 70 005814-1.2 IJ!smiDTH

AIRTECH

The manual must be studied by anyone involved in activities on or near the filter, i.e. activities such as:

• Installation

• Modification (repair work).

• Transport

Further to instructions given in the present manual, the mandatory rules and procedures, the regulations for safety and environmental protection applicable in the respective countries and the general directions given by FLS, due attention must also be given to the generally recognized technical rules for the safe and correct installation of the filter.

1.5 Definitions and abbreviations

Responsible manager Operator's representative during operation of the cement manufacturing plant.

Qualified person A qualified person is a skilled person, who is able to judge the tasks he is entrusted with on the basis of his training, his knowledge and experience, his acquaintance with the respective regulations, accident prevention rules and operation condition, and to recognize and avoid possible dangers.

Authorized person An authorized person is a skilled person, who is qual ified and who by either the responsible manager or a qualified person is entrusted with certain tasks.

External expert A specialist who is educated and trained in an equipment supplier company and may be trained as a skilled person or as an engineer.

Internal expert A specialist who is educated and trained in the cement manufacturing plant and may be educated as either a skilled person or an engineer.

Certified person A person, who is ski lled and authorized from any legal authority to perform tasks, which must be certified by a third party or which requires a legal authorization to perform.

Skilled person A person, with a craftsman's background who is capable of performing skilled work.

NA Not applicable.

O&M Operation and maintenance.

1.6 Legend

A Mandatory! This symbol appears in the instruction manual to indicate dangers which, in case of non-observance, may cause fatal or serious injuries!

Attention! This sign is shown in the instruction manual where specific attention and caution is needed to avoid damage to or destruction of the equipment and/or parts of the installation.

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DmiDTH

AIRTEC:H 70 005 814-1.2 7

2 Design and operating principle

2.1 Construction

Basically, each filter consists of filter housing, filter bags and cages, pneumatic equipment for cleaning the bags, controller for control and supervision of the cleaning process and a set of ladders and railing.

(See Appendices 1-6)

2.1 .1 Filter housing (Appendix 1)

The filter housing consists of the assembled filter modules forming the filter chamber (21 ), the clean-air chamber (20) and a bottom frame which is used to support the filter. The bottom frame is equipped with grating (05) in order to prevent bags from dropping out of the filter. An inspection cover (31) is fitted on the filter housing to allow inspection of the filter chamber.

2.1.2 Filter chamber (Appendix 1)

The filter chamber (21) is separated from the clean-air chamber (20) by means of the tube sheet (19). The cages (30) with the filter bags (28) and the Venturi (29) are fitted to the tube sheet and introduced into the filter chamber. The collars of the filter bags which are directly fitted to the tube sheet act as sealing.

2.1 .3 Clean-air chamber (Appendix 1)

The clean-air chamber (20) is provided with the air outlet connection ( 14) through which the cleaned air is discharged from the filter. In the clean-air chamber there is, for each row of bags, a blow pipe (11) which, in conjunction with the Venturi (29) in the cages (30), constitutes the injectors for the clean-air. The top of the clean-air chamber is also provided with access doors (15) for replacement of bags.

Note! No special tools are required for the replacement of the filter bags which is effected by relaxing the nuts for opening of the access doors and dismantling the blow pipes.

2.1.4 Compressed-air system (Appendix 2)

The compressed-air inlet on the filter is equipped with a ball valve (4 7) and a pressure regulator ( 45) with automatic water separator, air filter and pressure gauge. The compressed-air inlet is located on the compressed-air receiver (12) from which the compressed-air is conducted to the electronically controlled solenoid/diaphragm valves (1 0) and onward to the blow pipes (11 ).

2.1.5 Connection for differential pressure measurement (Appendix 2)

The filter is provided with connections for differential pressure measurement which is connected to the clean-air chamber (20) and filter

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8 70 005814-1 .2 [ilsmiDTH

AIRTECH

chamber (21) for constant indication of the cu rrent pressure drop (differential pressure) across the bags.

2.1.6 Valves on the cleaning system (Appendix 3, 4 &5)

The solenoid/diaphragm valves (1 0) consist of a pilot valve and main valve.

The filters type CE 1-01 and CE1-02 incorporate solenoid/diaphragm valves , size 1 in single stage (66), whereas the filters CE1-04 and CEI-06 incorporate solenoid/diaphragm valves size 1.1/2 in double-stage (67). The function of the valves is as follows:

Solenoid/diaphragm valve 1 in (66) - (Appendix4)

The annular chamber (70) is connected to the compressed -air receiver (69) directly. The chamber above the diaphragm (71) is connected to the annular chamber through a channel, so that the same pressure is sustained across the diaphragm (71 ). The surface area of the diaphragm is greater above the diaphragm than in the chamber (70), causing the valve to remain closed.

The diaphragm is opened by an electrical signal being fed by the filter controller to the solenoid (75), causing it to lift the pin (73). Air from chamber above the diaphragm thus escapes to the atmosphere. Since the pressure in annular chamber (70) cannot escape at the same velocity, the diaphragm (71) is lifted, allowing the compressed air to pass through . When the electrical signal to the solenoid is no longer applied , the pin (73) is lowered, thereby closing the connection . As a result , the pressure in annular chamber (70) and above the diaphragm (71) is re-balanced, thereby causing the diaphragm valve to be closed.

Solenoid/diaphragm valve 1 Y2 in (67) - (Appendix 5)

This valve operates as a two-stage valve. One stage ensures that the air above diaphragm (79) escapes more quickly. This stage consists of a complete diaphragm valve (80 - 82) of a smaller size mounted on top of the big valve. The small diaphragm (81) shuts off an extra large opening on the intermediate cover (80) from chamber above diaphragm (79) to the atmosphere. When the solenoid (85) lifts the small diaphragm (81 ), the chamber above diaphragm (79) is vented. This causes diaphragm (79) to be lifted, thereby allowing the compressed air to pass through.

2.1. 7 Controller (Appendix 6)

The bag cleaning operation is controlled by a controller that is connected to the connections for differential pressure measurement on the clean-air chamber (20) and filter chamber (21 ). The controller inco rporates a pressure transmitter that will constantly inform the electronics about the current pressure drop (differential pressure) across the bags .

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70 005 814-1.2 9

2.1.8 Insulation

In case the operating environment of the filter involves attendant risk of condensation in the filter, it must be insulated .

3 Safety instructions

3.1 General notes

The jet pulse filter must only be used under the intended technical circumstances as defined in current instruction manuals.

It is a prerequisite for the safety that all relevant rules and regulations for the prevention of accidents are held available at all times .

FLSmidth will not assume responsibility for any damage resulting from abuse or improper operation or inadequate maintenance of the jet pulse filter or resulting from its operation or maintenance by unqualified personnel, including personnel who have not acquired the skills required to operate or maintain the equipment on the basis of the directions provided in the technical documentation.

3.2 General notes on safety for the jet pulse filter

3.2.1 Design requirements

The machine must be stopped and started from the Central Control System (CCS) which also controls the interlocking between the machines. The machine cannot be started unless full compliance with all safety and protective interlocks has been ensured .

See separate instructions O&M manual concerning start-up and shutdown procedures

3.2.2 Marking of equipment

The jet pulse filter is delivered with marking plate to be placed as shown on the assembly drawing for the specific filter.

3.2.3 General notes relating to the posting of signs

See separate instructions on 0 & M manual

3.2.4 Scrap and waste

After Installation work, inspect the interior of the filter through the inspection cover. Remove any scrap and waste which may have dropped into the filter housing. Remove all scrap and waste from the clean air chamber and vacuum-clean it in order to prevent undesirable dust emissions. Clean-up on and around the machine and pack scrap properly for removal.

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10 70 005814-1.2

3.3 Specific safety precautions concerning Installation

Attention!

rilsmiDTH

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Any Installation activity must be carried out by skilled persons and is subject to the supervision of a qualified person or an expert. See sub-section 1.5.

A Mandatory! The directions outlined in instruction manual 32031 "General safety regulations on Installation site" must be strictly observed at the site of Installation.

3.3.1 Permission to work

It is the responsibility of the Installation supervisor to ensure that all personal involved in the Installation work have studied and fully understand the following:

• The permission given to perform work in the specific area.

• All relevant instructions concerning health and safety and the contents of this instruction manual.

3.3.2 Lifting of heavy parts

Depending on the specific filter type, it may become necessary to handle heavy parts in connection with installation procedures. This may involve hazards but it is foreseen to be a normal procedure for personnel carrying out Installation work at a cement plant. This aspect is outside the scope of the present instruction manual.

Attention! The suspension and load capacity of support system must be checked prior to application of loads from the filter.

3.4 Specific safety precautions concerning O&M

See separate instruction manual.

4 Installation

4.1 General notes

Attention! Quality control! The words "Installation inspection" on any drawing or text mean that the Installation supervisor must carry out an inspection and approve Installation status before proceeding with Installation work.

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4.2 Modifications

.&. Mandatory!

70 005 814-1.2 11

It is a prerequisite for the performance of any repair work and assembly operations that the filter has been taken out of operation .

When carrying out such activities, it is essential to ensure that it will be impossible to restart the filter, e.g. by means of a remote control unit.

The guidelines for the shutdown procedures are outlined in the operation and maintenance manual and must be strictly followed . The repair work must only be carried out by skilled persons and is subject to the supervision of a qualified person or an expert. See sub-section 1.5

Attention! Due to the fire hazard involved , welding must never be performed on joints sealed with joint filler.

Attention! Due to the fire hazard involved , welding and flame cutting operations must not be performed on the filter house after the filter bags have been fitted in the filter.

4.3 Planning and installation procedures

4.3.1 Resources and documentation

.&, Mandatory! The Installation activities described in the following sections must only be carried out by skilled persons and subject to the supervision of a qualified person or an expert. See sub-section 1.5

Prior to assembly, see the general arrangement drawings, assembly drawings and Appendices.

4.3 .2 Planning and schedule

The Installation of filter must be co-ordinated with the construction of adjacent mechanical equipment, buildings and steel structures. The following measures should be considered in the planning of Installation activities:

• Check the availability of all materials and equipment prior to commencement of work.

• Define critical tasks and ensure that a critical task to be performed can be completed before end of shift.

• Ensure current detailed specifications and drawings are available for carrying out the works.

• Ensure space for preassembly of filter parts, if required .

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12 70 005814-1.2 msmiDTH

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• Ensure space for storing of cladding and thermal insulation mats, if any.

• Check that work area is protected in accordance with current site regulations.

• Containers for collection of waste materials in particular insulation and sheet waste must be prepared.

4.3.3 Checking the dimension of buildings and foundations

4.3.4 Auxiliary tools

4.3.5 Scaffolding

4.4 The task on a step-by-step basis

4.4.1 Introduction

The CE1-BF filters can be mounted with the outlet flange and the location of ladder, if incorporated, fitted in several positions. For relevant position see general arrangement drawings.

The filter is supplied in sections to be welded or bolted at site.

Prior to assembly check the extent of joints to be welded or bolted on the assembly drawing.

Attention! Welded joints in filter house must be absolutely air-tight.

Attention! Seal all the joints that will not be subject to welding carefully using the supplied silicone joint filler.

The joint filler and the jointing gun are supplied with the filter.

Prior to assembly of bolted joints apply a string of filler with a thickness of approximately 3-4 mm on the joint faces using the jointing gun supplied.

Attention! Due to the fire hazard involved, welding must never be performed on joints sealed with joint filler.

Attention! Due to the fire hazard involved, welding and flame cutting operations must not be performed on the filter house after the filter bags have been fitted in the filter.

Prior to assembly, see general arrangement drawings, assembly drawings and Appendices.

Check that parts have not sustained damage while in transit.

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4.4.2 Bottom frame

70 005 814-1.2 13

Assemble the bottom frame from side section (03) and gable section (22), and fix the grating (05) to the bottom frame .

Align the bottom frame very carefully and fix it to the foundation.

Installation inspection

4.4.3 Filter chamber

Mount side plates (06) and gable plates (04) that form part of the filter chamber (21) on bottom frame. Start by mounting a corner consisting of one side plate and one gable plate in order to ensure stability during Installation .

Note! Welded joints must be absolutely air-tight and bolted joints must be sealed carefully using the supplied silicone joint filler .

Make sure that the orientation of the side and gable plate is correct, see assembly drawing of filter.


4.4.4 Stiffening stays arid supporting irons

Stiffening stays and supporting irons (08) welded during Installation. Place the supporting irons so that they are level with the upper edge of the side plates, see Installation drawing of stays. (Stiffening stays and supporting irons are not used on filters CE1-1-03, CE1-1-04 and CE1 -1-05).

4.4.5 Tube sheet

Place the tube sheet (19) on the top of the filter chamber (21) and supporting iron. For mounting position of the compressed-air receiver see general arrangement drawing. The clamp (33) is to be mounted opposite to compressed air receiver (12)

Note! Welded joints must be absolutely air-tight and bolted joints must be sealed carefully using the supplied silicone joint filler .


4.4.6 Clean air chamber

Mount side plates (09), gable plates (07) and air outlet connection (14 ). These parts form the clean air chamber (20). It is essential to ensure that the plates with holes for blow pipes and outlet connection are correctly positioned. See the general arrangement drawing.

On filter types CE1-2, CE1 -4 and CE1-6, the tube sheets (19) must be welded together with supporting irons to ensure effective sealing.

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14 70 005814-1 .2

Note!

[i!smiDTH AIRTECH

Welded joints must be absolutely air-tight and bolted joints must be sealed carefully using the supplied silicone joint filler.


4.4. 7 Frame plate

Mount frame plate (18).

Note! Welded joints must be absolutely air-tight and bolted joints must be sealed carefully using the supplied silicone joint filler.


4.4.8 Ladder and railing

Mount the side and gable sections of the railing (13) on frame plate (18) and weld the joints between hand and knee rails. Then fix the floor rails by welding at a distance of 20mm from the filter so as to allow rainwater to drain off. If insulation of the upper side of the filter is required, the floor rails must be mounted on top of the insulation. See drawings of side and gable sections and assembly drawing of railing.

Drill holes in the foundation for fixing bolts for the lower ladder (23) and mount same as indicated on the assembly drawing of railing.


4.4.9 Compressed-air system

Weld Brackets (35) with clean air chamber (20). See figure 1

Figure 1

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AIRTEC:H 70 005 814-1.2 15

Mount the compressed-air receiver assembly (12) to the mounting bracket (35) . Attach the elbow (34) to the compressed air receiver valve (68) for -1" (76) for - 1% and pull rubber hose (36) over the clearance between the valve and elbow and tighten the hose clamps (37).

Fix the tube (38) to compressor air receiver ( 12) inlet and elbow (40) than fix the tube (39) with elbow (40) with tube (41) and than tube (41) with elbow (42) and union (43) with elbow (42).

After completing the compressed air receiver assembly fix the regulator bracket to the railing .

Fix the ball valve (47) with pressure regulator (45) by using nipple (46). Another end of pressure regulator (45) to be fixed with Tube (44) and than tube (44) to be fixed with union (43)

Close threaded connections without pipe connections with plugs.


4.4.1 0 Filter bags; blow pipes and access doors.

Attention! In case additional welding operations are required on the filter, e.g . in connection with holder for controller, insulation binders, etc, such operations must be carried out prior to the installation of the filter bags.

Verify that the holes in the tube sheet (19) are clean and smooth; otherwise clean the holes in the tube sheet with a steel brush. Lower the filter bags (28) down through the holes in the tube sheet. Fold the snap ring on the top of the bag with thumbs and push the bended side in shape. Verify that the bags are correctly fitted to the tube sheet. Lower the cage (30) with the Venturi (29) down into the bags and push it into the correct position . Check that the collar on the Venturi is fully aligned with the tube sheet.

Check from the inspection cover on the filter housing that all filter bags are freely suspended without any contact between the bags , with the sides of the filter chamber or with stiffening irons. If necessary, adjust the position of any bags that are not freely suspended .


Fix the blow pipes (11) to the clan air chamber by using the clamp (33) and tighten the nut. And the other end to be fixed with elbow (34)


Mount the access door (15), check that the packing cords (16) are correctly positioned and tighten the bolts on the clamps (17) .


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16 70 005814-1.2

4.4.11 Controller

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Mount the controller (57) on the side of filter or very close to the filter but in a position where exposure to solar radiation is minimized .

Fix the supplied tube (2 in) for the cable to the filter by welding, and run the cables through the tube to the cable tray and through the supplied distribution box to the solenoid valves. Mount the d istribution box on the filter housing close to the cable tray.

Connect the cables as indicated on the forwarded "wiring diagram".

The controller has 10 outputs. For filters with more than 10 solenoid valves it will be necessary to connect more than one solenoid valve to each output.

For type CE1-6-12 BF (12 solenoid valves) only 6 outputs are used . Two solenoid valves placed end-to-end are connected to each output.

For type CE1-6-15 BF (15 solenoid valves) 8 outputs are used. Two solenoid valves placed end-to-end are connected to each of the seven outputs, whereas the last solenoid valve is connected to the output No. 8.

4.4.12Connection to differential pressure measurement

Connect the differential pressure measurement of the controller (62) to filter chamber and clean-air chamber through the hose (52).


5 Operation


6 Maintenance


7 Description of components

7.1 Key to appendices

03 Bottom frame - side section

04 Gable plate

05 Grating

06 Side plate

07 Gable plate

08 Stiffening stay

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Ei!smiDTH 17 AIRTEC:H 70 005 814-1 .2

09 Side plate

10 Solenoid/d iaphragm valve (1 " or 1 %")

11 Blow pipe

12 Compressed-air receiver

13 Rai ling

14 Air outlet connection

15 Access door

16 Packing cord

17 Clamps and bolt

18 Frame plate

19 Tube sheet

20 Clean-a ir chamber

21 Filter chamber

22 Bottom fra me-gable section

23 Ladder

28 Filter bag

29 Venturi

30 Cage

31 Inspection cover

32 Bracket for controller

33 Clamp

34 Elbow

35 Bracket for (1 0)

36 Rubber hose

37 Hose clamp

38 Tube

39 Tube

40 Elbow

41 Tube

42 Elbow

43 Union

44 Tube

45 Pressure regulator

46 Nipple

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18

4 7 Ball valve

48 Long sweep bend

49 Tube

50 Socket

51 Push in fitting

70 005814-1.2

52 Hose (Connection to filter controller)

53 Compressed-air system (Appendices 2 & 3)

55 Filter housing (Appendix 1)

56 Terminal box (Not indicated in Appendices)

57 Controller (Appendix 6)

58 Switch button "Cntr"

59 Indication (display)

60 Button "j "

61 Button "mode"

62 Connection for differential pressure measurement

63 Screwed cable entry, PG 9

64 Screwed cable entry, PG 13.5

65 Screwed cable entry, PG 21

66 Solenoid/diaphragm valve, 1 in

67 Solenoid/ diaphragm valve, 1.1/2 in

68 Valve below pipe

69 Tank

70 Valve body (Angular chamber)

71 Diaphragm

72 Top cover

73 Pilot group compete with base and ferrule

7 4 Din connector

75 Solenoid

76 Valve below pipe

77 Tank


79 Diaphragm (Secondary)

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80 Intermed iate cover with opening to the atmosphere (Double diaphragm)

81 Diaphragm

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82 Top cover

70 005 814-1.2

83 Pilot group complete with base and ferrule

84 Din connector

85 Solenoid

8 Appendices

See next pages.

19

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20

Appendix 1

03 Bottom frame-side section

04 Gable plate

05 Grating

06 Side plate

07 Gable plate

08 Stiffening stay

09 Side plate

10 Solenoid/diaphragm valve

11 Blow pipe


13 Rail ing

14 Air outlet connection

15 Access door

16 Packing cord

17 Clamps and bo lt

18 Frame plate

19 Tube sheet

20 Clean-air chamber

21 Fi lter chamber

22 Bottom frame-gable section

23 Ladder

28 Filter bag

29 Venturi

30 Cage

31 Inspection cover

70 005814-1.2 [ilsmiDTH

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Appendix 1

70 005 814-1.2 21

- -- ...

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22

Appendix 2


38 Tube

39 Tube

40 Elbow

41 Tube

42 Elbow

43 Union

44 Tube

45 Pressure regu lator

46 Nipple

47 Ball valve

48 Long sweep bend

49 Tube

50 Socket

51 push in fitting

70 005814-1 .2

52 Hose (connection to filter contro ller)

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Appendix 2

70 005 814-1.2

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" "

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U:: U : : : II : : II u U I~ __ :_i_,,~ ---- - It II

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iii '" ,, '" ,,

23

39

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24 70 005814-1 .2

Appendix 3

10 Solenoid/diaphragm valve (1" or 1 y;")

11 Blow pipe


19 Tube sheet

28 Fi lter bag

29 Venturi

30 Cage

33 Clamp

34 Elbow

35 Bracket for (1 0)

36 Rubber hose

37 Hose c lamp

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I I

I I

l._l_ -~--------,..,

Appendix 3

70 005 814-1.2

-----------

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I

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25

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26 70 005814-1 .2

Appendix 4

66 Solenoid/diaphragm valve, 1 in

68 Valve blow pipe

69 Tank


71 Diaphragm

72 Top cover


7 4 Din connector

75 Solenoid

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Appendix 4:

70 005 814-1.2 27

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28 70 005814-1 .2

Appendix 5

67 Solenoid/ diaphragm valve, 1.1/2 in

76 Valve blow pipe

77 Tank


79 Diaphragm (Secondary)

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80 Intermediate cover with opening to the atmosphere. (Double diaphragm)

81 Diaphragm

82 Top cover


84 Din connector

85 Solenoid

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Appendix 5

70 005 814-1.2 29

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30 70 005814-1 .2

Appendix 6

57 Controller (Position number not indicated in the appendix)

58 Switch button "Cntr"

59 Indication (display)

60 Button "i"

61 Button "mode"

62 Connection for differential pressure measurement

63 Screwed cable entry, PG 9Sh ( *)

64 Screwed cable entry, PG 13.5 ( ** )

65 Screwed cable entry, PG 21 ( *** )

( * ) PG 9Sh: Not used

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( ** ) PG 13.5: Main input, Control input, Alarm output, Analog output

( *** ) PG 21: TRIAC output to terminal box

PG = steel conduit thread

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Appendix 6

'() \ j_ w

.L

70 005 814-1.2

---oOo---

m ~ ~~.,....C:•r•e-•_,

0 .,,_ I

... ,_ -·-· ·-. --·-·- · .. -.. ----·-·-.... _, ___ ,.

. - ··-· -·-4 .. .. _ .. _, --------- -----·-···"'·--- -------- ... . h .. - ----- .... .. .... ___ .. .. - --- .... . ---.. ·--·---· .. -·-·--·

Transformer T 1 side view

31

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ouinn' rnent - epaauthorities and flsmidth. all references to design standards are given in the ec...

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