SHEET DYyuc DOCUMENT COVER SHEET oF TLE =: {BAG FILTER MANUAL CLIENT : KOREA HEAVY INDUSTRIES & CONSTRUCTION CO..7D PROECT. : P,P SEMAN NUSANTARA CEMENT CO.,LTD SERVICE: BAG FILTER 0 | 96.212 ISSUED for FINAL REV. DATE DESCRIPTION OF REVISION PREPARED | CHECKED | APPROVED | REVIEWED JOB NO ” PREPARED BY _ DOC. NO. [comme v[ | MEMRAM. orsWe are deeply grateful to you for your having purchased our product, BAG FILTER. Please read our handling instructions carefully, which will help you operate and repair the product in accordance with the correct method of use, and to prevent any malfunction in advance and to use for a long-term life span. TABLE OF CONTENTS [1] Summary of equipment 1 UL Specifications 2 [Il] Installation instreetion 3 IL-1. Lay-out 3 T1-2. Installation procedure 4 I1L-3. Adjustment of trial operation, 4 [I] Operation and handling 5 5 6 8 8 8 IV-1. Key points for handling TV-2, Handling of control box ' 1V-3, Key points for operation 1V-4, Durability of bag filter IV-5, Handling method of filter bag IV-6. Compressed air piping lay-out 10 {V] Repair and inspection u [VI] Causes and countermeasures of malfunction 12 VI-1. High filtering resistance(high pressure loss) 12 VI-2. Low filtering resistance(low pressure loss) 1B VI-3. Dust leaking 4 VI-4. Inferior dusting-off 15 VI-S. Others 161. Summary of Equipment The present equipment is a Bag Filter to which effective dusting- off device(Jet-pump) was attached, developed by Dustex company in US.A. and improved by Daeyeol. Gas containing dust passes through the cylinder type bag from the outside into the inside, and the dust are piled up on the outside bag surface and clean gas only is discharged through an exit, ‘The dust attached to the bag are puffed away by the Jet pump per section, which uses the compressed air instantaneously, Therefore, the structure is designed to endure sufficiently even continuous operation without any variation of conducting airflow. Each model such as 3100, 3200 and 3300 Series bag filters are standardized with the filtering areas to the extent of 5.9m*-69.6m! This equipment is used for general dust collection, catching of products and other dust collection. ‘The treatment method of bag for 3100, 3200 and 3300 series bag filters is easy. Namely, by opening its top cover, maintenance, checking, repair, etc. are possible, Accordingly, itis not needed for a worker to enter the inside which dustexists, and the worker is not affected by the secondary pollution. Our company is also producing accessory equipment(double flap dampler, rotary air lock, slide gate valve etc.), prior-treatment devices and exhausting fan in addition to the 3100, 3200, 3300 series bag filters. Please employ them in time as required. In addition, the medium and iarge units of 3400 and 3600 series(filtering areas of 84m? ~ 1430m), customer order of extra- large capacity bag filterfiltering areas up to 7000m*) and intemal resistant cylinder type of housing 3500 series(filtering areas of 5.9m’~102m?), are being produced. If you require them, please contact the staff in our sales or engineering department. We are willing to solve any dust collection problem of your firm with sincerity.Ge h collection efficiency inimum fluctuations in pressure drop aarge treating air volume 4, Suitable for high dust content application 5, Easy maintenance 6. Broad range of application oFC M2. Installation Procedure (for standard procedure) +) ‘The present equipment is supplied as a disassembled state for the convenience sake of delivery in a case, and as completely assembled in another case, At first, please confirm if the main body and accessory machinery have been supplied in accordance with the quantity of the drawings on the previous page (Manometer and control box are packed separately and delivered in consideration of any damage during transportation). Therefore, please assemble and install them according to the following standard procedures: (1) Check if the level and anchor hole position of foundation concrete coincide with to the basic drawings, Correetion is made, if required. Correction of level is made by cutting concrete or adjusting shim plate. (2) Clean up anchor holes. (3) Fix it up atthe right position by using forklift or crane. (4) Insert anchor bolt into anchor hole and pour mortar. The anchor bolt is tightened up after concrete has become hard completely (approx. 3-5 days). (5) Construct ducts in front of or rear of the dust collector. (6) Pipes are laid out for compressed air with reference to the page No. 10. (7) Place Control box then wiring is made in accordance with the page No.7. (8) Place manometer. At this time, it is better to put blue or red colored water to read easily and antifreeze solution, and adjust to the basis of zero. (9) Insert the filter bag and bag cage. Refer to the page Nos. 8 and 9 for the inserting method. (10) Close the roof hatch on top and tighten it with clamp. Confirm if itis out of order at seal parts because sealing must be secured on top. Il-3. Adjustment of Trial Operation ) (1) Shut tight the manholes and top cover parts completely. (2) Supply compressed air into header(Approx. 3~Skg/em: ). (3) Confirm if air leaks from diaphragm valve and plug. a. Check if pressure descends with supply valve closed. Ifthe pressure goes down by more than Ikg/em? for 5 minutes, this means abnormal. b. IF air leaks, you may hear the sound of "Shi", (4) Put control box switch ON. Confirm the pilot lamp on the panel if Jet pulse works normally. b. Confirm the progressing state at the close distance of diaphragm valve if Jet pulse sounds equally from each room. c. Confirm if the water level of manometer rises or falls according to notch marks. Normally, it is S0mmH,0 or so. (5) Operate blower a. Open and adjust damper until the rated airflow is available. ’. Confirm the initial filtering resistance (Normally, itis below than 5OmmlH,0) c. The filtering resistance of dust collection varies according to the operation condition, but operate between 100 - 200mmE,O normally.DYM-IV-10 Series Bag Dimension Bag Dimension 186* x 2475" 156" x 2085" su SE DYM-IV-8 Series veda | en] a [rao Passe | Power "SOM etna Hopper (nt) | Bags | Sections) A Ke ad ov! oa | a | 4 | 1950 3200 | 40 |pyramia lovm-iv-8-10-10| 117 | 100 | 5 | 2000 3700 | 50. [Pyramia DYM-IV-8-10-12, iai_| 120) 6 2850 4300 | 56 Pyramid JOYM-IV-8-19-14) 164 140 7 3300 4800 62 Trough pym-iv-8-10-16| 188 | 160 | 8 | 3750 | seo | 66 | Trough Dym-iv-8-10-18 2 | 180 | 9 | 4200 00 | 74 ‘| Trough DYM-IV-8-10-20| 235 200 10 4650 6300 80 ‘Trough lbvm-iv-s-10-22| ase | zo | 11 | 5100 6800 | 86 | Trough IDYM-IV-8-10-24 "282 240 12 5550 7500 | 9 Trough DYM-IV-10 Series (it) | Bags sections | A B | timin | Keac | kw | Ke nt | Tye IDYM-IV-10-12-8 | 141 96 4 1950 3500 282 5 5.5 4300 56 [Pyramid DyM-lv-10-12-10, 176 | 120 | 5 | 2400 | 3500 32 | 5 75 | 500 | 64 |Pyramia [Dym-v-10-12-12 211 | 1s | 6 | 2850 | 3500 | az | 5 75 | 5800 74 Pyramia IDYM-IV-10-12-14] 247 168 7 3300 3500 494 5 18 6400 81 Trough IDYM-IV-10-12-16) 282 192 8 3780 3500 564 5 11.0 7000 31 Trough IDYM-IV-10-12-18 317 216 9 4200 3500 634 5 11.0 7600 100 Trough lov -WV-10-12-20) 352 240 10 4650 +3500 704 5 1.0 8300 109 Trough [ovat-iv-10-12-22] 388 | ase | 1 | sio0 | 3600 | 776 | 5 | 110 | e900 | 112 | Trough bva-v-to-r2-24] 423 | 288 | 12 | 5580 | 350 | o | 5 | 110 | 9800 | 18 | trougnWV. OPERATION AND HANDLING V-1. Key Points for Handling ) (1) Dust-off Dusting-off bag is operated by supplying compressed air. On the right side picture, when the snap switch of control box is put ON, the input pulse signal is operated automatically, and solenoid valve is charged with power at uniform interval. This opens diaphragm vaive and dusting- off start - (2) Establishment of filtering resistance During the bag filter operation, set up a proper dusting-off interval to obtain the filtering resistance(AP) of 100-150mmH,0 (check manometer). The dusting-off interval means the bag minute(B.M) taken from dusting-off one bag until re-dusting off it. 3) Standard value of dusting-off conditions ‘The standard value of B.M is 4 minutes (240 seconds). The B.M value increases or decreases in accordance with the dust load. Adjust the dusting-off pressure to the extent of 2-Skg/cm* pulse or so. (4 Setting value and adjustment of timer a Setting value ON TIME: 0.1-99 sc (standard value 0. -02sec) OFF TIME: 249 sec (standard value) ("N" means the number of solenoid valve being used) b. Adjustment 1) The number of "N" being used varies depending upon model of bag filter. The timer’s scale marks in the small-sized control box for the use of 6 section are as shown on the right figure. Adjust the timer for the filtering resistance of bag filter to each 100~ 150mmH,0. 2) [eis possible to adjust the filtering resistance by increasing and decreasing pulse pressure (2-Skg/em’), but adjusting B.M as far as possible. (5) Establishment of output number Display light flickers by operationg gradually from 1 until Pin No. which has been established and inserted, the established number is reached by solenoid valve operating simultaneously and then motionis repeated after retumed to | . READ THE WATER LEVEL, DIFFERENCE TRANS FORMER FUSE ON/OFF. SWITCH INPUT TERMINAL INO. OF SOLENOID VALVE (1) (2i_(31_(4:_(5:_161_(7; WATER LEVEL «ADJUSTMENT AND WATER DISCHARGE MANOMETER, oP switch OFF TIME CHAMBER DISPLAY. CONTROL BOX PANEL. t i PULSE SIGN ONTINE] OFF TIME 4 BM PULSE SIGNAL DIAGRAMWV-2. Handling of control box ») (1) Summary ‘Time control equipment that the life span is semi-permanent as LC. Circuit using semiconductor, and ON TIME and OFF TIME of output time are set up at discretion for use. (2) Specifications 1) Power source AC 110V/220V+10% SO/60H2 2) Consumable power Under SW (NO-LOAD) 3) Output 1-14CH (optional setting) 4) Output voltage AC 110V/220V 5) Output current MAX 2A 6) Used temperature -15 ~ +45 T 7) Insulating resistance Over 20M (within DC S00V) 8)ONTIME 0.1 ~ 99sec (variable) 9) OFF TIME a sec N-=setting chamber No. (3) Wiring method ‘The wiring method is based on the drawings, but the drawings are described by the standard 6 chambers. 1) The input power source is varied by the solenoid valve's voltage ; in case of 110V solenoid valve, input power source will be 110V, and in case of 220V solenoid valve, input power source will be 220V. ingle phase connection is wired by 2 types of power sources of 110V 20), and valve lines are connected in the same way. 3) In case the bag filter power control line is interlocked automatically, single phase. wiring is made to power line, 4) The power input source is displayed by a red light, and chamber will turn ON instantaneously by signal of luminous iode, and return to the first order again with the last one turned ON. 5) The pulse signal is set at discretion by utilizing Dip vw of OFF TIME, and ON TIME is set voluntarily (0.1 sec) by Dip s/w-afier (242) pulse is connected with ON TIME. 6) Shipment is cared out by exact inspection, but the exact connection shall be done by using the pressed terminal in case of any malfunction caused by uncertain extemal connection. 7) The correct wiring is required to prevent any intemal damage as a result of failure of valve line connection as the picture shows (DYBF 3300-20) (Confirm if COM terminal of valve line has been correctly wired, in particular), ure (DYBF 3300- (4) Operation 1) In case of auto inter locking with the outside, confirm if the extemal power source is the same input voltage as the solenoid valve's. If any difference arises, damage to the unit or malfunction will happen. 2) Turn on snap switch after the connection drawing is confirmed. 3) First, switch-on of pilot lamp is confirmed, and then any malfunction of unit shall be confirmed. 4) If there is no abnormality, ON TIME is fixed to 0.1 sec, and OFF TIME shall be selected by 240/N. 5) When the above mentioned is confirmed and no other defect is found, normal operation shall commence.(CONTROL BOX WIRING SKETCH ‘SELECT a oO oO oO co [eae | [Fass | [eee | OFF TIME ONTIME CHAMBER DISPLAY O-99sec | 0.1-9see 14H 3(m|§ O | 0000000000000 0 CO CO0000 9 10 11 12:13 14 83) 8] &3 | €5|/63| 1. Maigpuation ante —4 of SE ona ees . Fiaweeeg | | = ee 20000 | 2 on sw sessuie “iaemgay | | « Place SELECT S/W to the position to adjust, binary scale setting valve Pepeecnanel coat sige han || « SN EE enon | Si inne eS 2) Ae singe he, sce sacra Bene jam) peenenteneten inita. V-6. Compressed Air Piping Lay-out Connect the air pulse compressed air pipes to the socket(PT 3/8 or 1/2) of the main body header using the rubber hose for the high pressure air or gas pipe as shown on the following drawing. (1) For using a small-sized compressor a. Place a compressor close to bag filter. b. Connect the compressed air line to the in and out-lets of compressed air(place pressure reducing valve and drain separator set close to header if possible). . ¢. Drain the condensed water of compressed air through the drain bellow tank in time. (2) For using air in factory a. Confirm if air pressure contains Skg/cm? or not. b. Lay pipes of factory air down to the bag filters treatment. c. Connect the drain separator setof pressure reducing valve as the following drawing (place Close to header if possible), d. In case of long pipe laying, use the pipes'at bigger step (pressure drop is greater). HEADER, COMPRESSED AIR EG —— (PT 3/8, 1/2) aa COMPRESSED AIR SUPPLY LINE 3eSkg/em* ? (COMMENCE AFTER ORAIN PLUG _// INSTALLATION IS COMPLETED) INSIDE FACTORY AIR, (Bkg/em* or higher) ORAIN SEPARATOR AIR OUT-LET 10Vy. Repair and inspection Please check the following to operate the equipment normally. © = Date of check 2 = Date of repair and maintenance CHECK UP POINT —_ ed REMARKS a TIMELY | DALY wx oT ois oss ee : Manometer indicating value 0 Standard value : 150-450 mm, [Pipe lying of Manometer | o[4 | Checking water evel and ceng socket of pesae tes | | Air pressure O° y_ Set point 3-Skg/em® Drain oO a Drain discharge Diaphragm valve operation | O | Confirmation by pulse sound [Any damage filer bag | | lo TA | Topeaveropencheck — i | Nirleak tom piping aeafose gars] | “| ° || Piping system check 1 o | Conti display igh on panes | Dust leak from exaust opening) © | | Visual confirmation Air leak from B/F seal | ‘Checking the main bodys’ seal | Frsrcompressor operation Oo Oo]. Drain discharge and supaly ol V-belt tercion condition | Dasvextausiscevcomv DV. ec) O | 4 Confirm function or mal-funtion | | BlowerFAN) operation ° | 2. | Confimingstnonna sound, vibration. curent ad vokaue Painting, rusting _ O° [A | Quality of painting Loosing from boling parts oO ] Forther joining Hopper area TS | al f ‘Anachment and the remains clean-up\I. Cause and countermeasures for malfunction C1, High filtering resistance (High pressure loss) ) SITUATION CAUSES MEASURES Indication of ‘Manometer( filtering resistance)is high (Over 200mmiH,0) 1. Airflow is excessive 2. Dust content is exremely high(Over 100g/Nm*) 3. Life span of fier bag 4, Deteriorating the filter bag by erosive gas orheat. + Drogping down tothe stipulated air flow rate by tightening damper of blower. + Atfirst, collecting dust by preduster, etc., and reducing the load of bag filter, + Replacing it with new filter bag” + Confirming specifications and conforming the conditions. 5. Forgetting to snap-switch on 6. Control box function is poor. + power source employment is bad. + Circuits inferior + Snap-switeh on. + Confirming to light pilot lamp. * Confirming the power source parts and constant voltage circuit. + Removing earth line completely in panel + Insert TIETRANCE into power source. + Replacing the print board 7, Manometer, tube are clogged, or air is leaking + Cleaning up the dust on socket connection part of inside of tube. 8. Filter bag is blocked by humidity + Required to compare and check the + Insulation is needed on the exterior wall of the equipment. + Heating air conditions of specifications + Upon completion of dust collection, dry is required to the upon delivery. filter bag by blowing dry air into. | 9, Re-scattering the collected dust + Exhausting dust ‘Dust exhaust or exhaust treatment + Frequentexhausting in rotary system, and continuous is poor. exhausting in the continuous exhausting structure.C2. Low filtering resistance (Low pressure loss) ) indication(fitering resistance) is insufficient. {below 50mmH,O) + Filter bag s excluded, connection is bad. + Filter bag is.damaged, we SITUATION CAUSES | MEASURES 1, Pulse pressure is high. + Lowering pressure (5 4—9 3kgiem’) 2. Frequency of dusting-off is much, + Extend B.M. (tefer to Page 5 for timer adjustment) Manometer 3. Leaking in the course of filtering. + Opening top cover and check. + Correctly attaching the filter ba, + Replacing with a new filter bag: | 4. Manometer ube is clogged. * Cleaning up the tube inside, connection parts to socket and ripple. 5.Dust centent is extremely low. + Operating continuous\y 6. Shortening operation time with new filter bag. Checking for several hours and days and observing until resistance increases up to normal state Remarks : If each part has no abnormal state and dust collection is satisfactory, you can operate the equipment without any anxiety regardless of low pressure loss)(1-3 Dust Leaking SITUATION CAUSES COUNTERMEASURES 1. Lecking in course of filtering. + Filter bag is excluded, or attachment is poor 1. Able to observe dust + Filter bag is troken off. * Refer to item 3 in page 13. continuously fromexit 2 Filter bag is deterioratedi(life span) | + Replacing with new product duct. 3. Working airflow rate is excessive. + Reducing tothe specified air flow rate. 4, Selection of filter bag isnot appropriate. + Reconfirming dust property, and re-selection of filter bag. 1, Dust out by excessive pressure of pulse. 2, Dust leaks out whenever + Refer to item 1 in page 13. 2. Selection of filter bag isnot suitable + Refer to item 4 in page 12. pulse is in operation 3. Deteriorating filter bag + Refer to item 3 in page 12. 3. Dust leaks periodically | 1. Dust load or particle distribution is variable (Seasonal, working state etc.) periodically. + Lowering pulse pressure and operating with high pressure loss. + Checkifg the dust causing state and improving. 4, Dust attached to the 1. Refer to item 1 on the above I inside of top cover Replacing or revising filter bag. 1. Caused by dust drift. 5.Damaging only the specified filter bag \ 3.Filter bag is inferior(quality, sewing) 2. Caused by variation and projection of bag cage. 4, Entering of primary spark or commosive substanog. + Attaching and adjusting the duct dispersing plate to suetion opening. + Revising or replacing the bag cage. Replacing with a superior quality one. + Taking proper measures for protectionC4. Inferior dusting-off (pulse) SITUATION CAUSES COUNTERMEASURES 1.No pulse-working atall 1 Forgetting the snap switch -on, 2. Disconnecting fuse in control box. 3, The connection terminal is loose. + Switch on, + Replacing fuse(cause isto be detected) + Thightening sufficiently ‘Gontrol box, solenoid valve) 2. Pulse signal works butno pulse working at all 1. The Sompressed air is not supplied + Opening the supply valves. 2. Pilot tube(6 $ dis clogged. + Confirming the function of diaphragm valve by pressing the tube at solenoid valve side with a hand and by repeating the opening and shutting 2~3 times. 3.qhe specified pulse only does not work or is incomplete. 1. Buming solenoid for the pulse, or not working. + Replacing with new one, Utilizing spare coil, ifavailable, insufficient wiring connection to te facing solenoid valve. Tightening sufficiently 3. Damage to diaphragm valve, or alien substance attached to the valve seat. + Disassembling for maintenance, or replacing with new one, 4, Dust or nist stuck to pilot tube. ‘5. Slackening rubber hose of injection nozzle, + Disassembling for maintenance of tube, diaphragm valve te + Tigening sul he op and butom hose band. 4, Pulse function inegularly of incompletely. no pressure increases at al! 1. Refer to item 6 in page 12. (improper function of control box) exists within several meters electric line as far as possible. 3, Voltage is low. 4, Pulse width(ON TIME) for the use of pulse signal is very short 1. Packing of diaphragm valve is damaged. 5. Compressed airleake or |” 2. Grooving valve seat of diaphragm valve, or alien substance attached. + Confirming ifitis within: 10% + In case pulse widl(ON TIME) is set less than 0,1 sec increase of 02-033 sec. will be viewed, and restoring to 0.1 sec + Replacing with new Product. + Disassembling for maintenance 3. Air leaks from pilot tube or connection pans + Blocking up the leakingCis Others SITUATION CAUSES COUNTERMEASURES 1. Rainwater’ intrusion + Connection parts of inlet duct, + Completely sealing or repairing the leaking parts. 3. Deteriorating hood sucking force + Inferior packing of top cover. 1. Humidity to fiter + Hoising connection pats bag and dust 2. Forming dew by-exterior wet air + Refer to item 8 of cause in page 12. + Forming dew on the bag filter internal wall, + Exhausting from drain hol, + Stagnating water on Jet panel 1. Pressure loss increases + Reducing airflow rate, 2. Intake of ar from 2. Alien substance atached to outlet damper + Disassembling for maintenance, or replacing dust outlet with new product. 1. Slackened blower’ belt + Tightening belt. 2. Clogged filter bag 3, Leaking air from dust collection line. + Taking action according to general inspection. + Repairing the leaking parts. 4, Leaking valve of dust exhausting + Repairing the leaking part. 5. Deteriorating function of pulse device + Refer ot the item concemed.INSTALLATION REFERENCEWood Chip & Dust Collection Sys. 600 Am'/min x 30 units 165 Ton/hr, Cement Mill Explosion Proof Type 8,800 Am’/min x 2 units Ru UsletHt ENS Certificates of Qualified Company ae GB Filters (USA) - DYM-EGB A) ~ Pneumatic Sys. 2. HOTAKA ENG. (JAPAN) - E.A.F De-Dusting Sys. G(UK) - Venturi Wet Collector 3. BWF Filter(GERMANY) - Filter Bag. 6. P. M, Filter (SWISS) ~ Cartridge Filter