Separation ‘Operation & Maintenance ManualSeparation ‘SEPARATION TECANOLOGIES Operating and Maintenance Instructions ANDRITZ Membrane Chamber Filter Press Size: 1500 x 1500 (15 barg) Order confirmation —_: 40022979 / C-37-814543-516 Customer : Lipico Technologies Pte Ltd Customer P.O. Number: $12002P-01 Project : Lipoco - Balikpapan Date of Edition : August 2012 2 ‘Operation & Maintenance ManatANNDRITZ. Separation SEFARATION TECHNOLOGIES 4.0 Technical Data: Size of plates and frames: 1500 x 1600 mm Size of carcass: 1800/1500/100 Filter press dimensions: Length: 14650 mm; Width: 2720 mm; Height: 2250 mm Weight of empty press frame: 38000 kg Filtering area: 413/436 m? Contents of press: 7950/7944 | Chamber depth: 40 mm Material of plates: PP Layout pressure of press frame: 415 bar overpressure Max. Squeezing pressure: 16 bar overpressure Max. Admissible closing pressure of press frame: 385 bar overpressure Stability of plate pack as per order (ittration temperature depending on fitration pressure) Min. 58°C = max. bar overpressure Max. 45°C = max. 3 bar overpressure (Filtration temperature depending on squeezing pressure) Min. 5°C = max. bar overpressure Max. 45°C = max. 418 bar overpressure Quantity of oi 4001 Terminal power of closure: 15 kW a ‘Operation & Maintenance Manualie]Ww Separation ‘SEPARATION TECHNOLOGIES 2.0 Preface The enclosed documents shall familiarize you with the machine / plant and to Use its possibilities as designed. Due to their importance we have provided some fundamental safety recommendations at the beginning. They shall serve for a safe, appropriate and economical operation of the machine / plant Observance of the same is to avoid danger, to reduce cost of repairs and down times and fo increase operational reliability and service life of the machine / plant. The operating manual has to be completed with instructions based on existing national safety rules. machine / plant at all times. A ‘The operating manual must be available at the place of operation of the The operating manual has to be read and the procedures and instructions applied by each person that works with / at the machine / plant, as for example . Operation, including set-up, fault elimination in the course of operation, removal of waste products, maintenance, disposal of process materials . Maintenance (inspection and repair) And for © Transport Besides the operating manual and the binding safety rules, valid in the country of application and at the place of operation, also the certified technical rules for safe and professional labor have to be observed, 24 A Fundamental Safety Recommendations 244 Principle; Application as Designed The machine / plant are constructed according to the state of engineering and the certified safety rules. Nevertheless, the application of machine / plant might result in danger to life and limb of the operator or third parties or impairment of machine and other material assets respectively, hence: Use machine / plant only in technically unobjectionable state as well as according to designation, Be aware of safely and possible dangers. Follow the operating manual instructions and procedures. Especially faults which might impair safety must be eliminated immediately; until then stop the machine / plant. 3 ‘Operation & Maintenance ManvalANDRITZ Separation SEPARATION TECHNOLOGIES 242 2.2 224 222 2.2.3 224 225 2.2.6 227 The machine / plant are exclusively designated for filtration of the slurry mentioned in the order confirmation. Use for other slurries or for different applications is inapplicable to designation. The manufacturer / supplier cannot be held responsible for damages resulting from this. The risk is exclusively with the operator. Application as designated also includes following the operating manual as well as inspection and maintenance instructions. Organizational Measures Always keep the operating manual ready to hand at the place of operation of the machine / plant. ‘Supplementary to the operating manual follow and instruct universally valid legal and other binding safety rules. Such obligation may for example also concem handling of hazardous material or placing at disposal / wearing of personal protective equipment / clothes (for example when operating with corrosive liquids). If necessary complete operating manual with instructions for observance of operational peculiarities, for example operations scheduling, sequence of operations, assigned staff. Before starting work the staff instructed with activities at the machine must have read the operating manual and here especially the chapter with respect to safety recommendations. It will be too late to do this during operation. This particularly refers to staffs, who carry out works, at the machine only occasionally, for example set-up and maintenance. It is wise to have proof in writing on that. Follow all safety recommendations and danger signs at / on the machine and keep them in a complete and readable state. Check, at least occasionally, that staff working on the machine / plant are aware of the dangers and that they follow the procedures for their own safety, Do not carry out any changes, extensions and modifications at the machine / plant which might impair safety without authorization by the supplier. This also applies to the installation and adjustment of safety equipment and safety valves as well as for welding at supporting structures, ‘Operation & Maintenance MazwalSeparation ‘SEPARATION TECHNOLOGIES 228 229 2.2.10 22.44 23 23.4 23.2 23.3 234 23.5 236 23.7 2.3.8 Spare parts must meet the technical requirements provided by the manufacturer. To ensure this we recommend buying spare parts from the supplier / manufacturer of the plant / machine. Exchange hydraulic hose assemblies in time intervals as indicated even ifno defects can be recognized. Keep to the time intervals stated in the operating manual for periodical tests / inspections. to carry out maintenance or repair work, equipment appropriate to the work is absolutely necessary. Selection and Qualification of Staff; Basic Duties working at / with the machine / plant may only be carried out by reliable staff. Observe the legal minimum age limit Only assign trained or instructed staff. Clearly state competency of staff for operation, set-up, maintenance and repair. Make sure that only staff accordingly instructed works at the machine. Determine machine operator responsibility and give this person Permission to reject third party instructions which are contrary to safety. Let trainees / apprentices only work at the machine / plant if being constantly supervised by an expert. Works at electrical equipment of the machine / plant may only be carried out by an electrician or under the direction and supervision of an electrician according to the electro-technical rules. Works at gas-technical equipment (gas consumption equipment) may only be carried out by staff being trained accordingly. Only staff with special knowledge and experience in hydraulics may arty out work at hydraulic equipment 7 ‘Operation & Maintenance ManualANDRITZ, Separation SEPARATION TECHNOLOGIES 24 244 2444 24.1.2 24.1.3 241.4 241.5 24.1.6 24.2 24.24 24.2.2 24.2.3 24.2.4 Recommendations Regarding Particular Operating Normal operation Refrain from every risky method of operation. ‘Take measures that the machine / plant is operated only if being in a safe and functioning state. Operate machine only if all protective appliances and equipment subject to safety such as detachable protective appliances, emergency- off appliances, sound insulation and suction devices are available and functioning Check the machine / plant with regard o extemal recognizable damages and defects at least once per shift. Immediately report incurred changes (incl, changes in operating performance). If necessary, immediately stop and secure the machine, Immediately stop and secure the machine / plant in case of malfunctions. Have faults immediately rectified. Observe switching on and off procedures and signal indications according to operating manual. Make sure that prior to switching on / starting of the machine / plant nobody is exposed to danger by starting the machine / plant. ‘Special works within the scope of using the machine plant and maintenance activities as well as fault elimination in the sequence of operation; Disposal Observe adjustments, maintenance and inspection activities and dates prescribed in the operating manual incl. information regarding the exchange of parts / subassemblies. Inform operating staff prior to the execution of special works and maintenance works. Nominate chief supervisor. Observe switching on and off procedures and recommendations for maintenance according to operating manual for all works which concern ‘operation, production adaptation, conversion or adjustment of machine / plant and its safety devices as well as inspection, maintenance and repair. if the machine / plant have been completely switched off for maintenance and repair works it must be safeguarded against unexpected restart: 8 ‘Operation & Maintenance ManwalSeparation SEPARATION TECHNOLOGIES 2.4.2.5 24.26 © Lock main control devices and take out key And / or @ Attach a danger sign at main switch. If necessary, carefully secure and affix fiter plates to hoists during ‘exchange to avoid danger. If disassembly of safety devices becomes necessary during set-up, maintenance and repair, reassembly and testing of same has to be carried out immediately upon completion of maintenance and repair works. 25 A Recommendations regarding particular kinds of danger 264 A Electric energy 25.14 25.1.2 2.5.1.3 2.5.1.4 25.4.5 25.1.6 Use only original fuses with the proper current rating. Stop machine / plant immediately in case of faults in the electric power supply. Works at electrical plants or equipment may only be carried out by an electrician or under the direction and supervision of an electrician according to the electro-technical rules, Machines and plant sections at which inspection, maintenance and repair works are carried out must be Isolated from the supply line. Check that electricity is shut down, then ground and short-circuit as well as insulate adjacent parts still under voltage before commencing work. The electrical equipment of the machine / plant has to be inspected / controlled regularly. Defects such as loose connections or scorched cables respectively must be rectified immediately. If work is necessary at parts which are under voltage a second person has to standby to actuate the emergency-off switch or main switch respectively to release voltage in case of an emergency. Secure operating area by means of a red and white chain and a danger sign. Use only insulated tools. In case of work at high-voltage units, isolate from the supply line, connect the power supply cable to ground and short-circuit the ‘components such as capacitors by means of an earth rod. 7 operon 8 Masiance MaalJANNDRITZ, Separation 25.2 2524 2522 25.23 2.5.2.4 26 261 26.2 2.6.3 2.6.4 26.5 EPARATION TECHNOLOGIES Hydraulic / Pneumatic equipment Work at hydraulic equipment may only be carried out by persons having special knowledge and experience in hydraulics. Regularly check all lines, hoses and screw connections with regard to leakage and extemal recognizable damages. Immediately remove defects. De-pressurize system sections and pressure lines (hydraulic, compressed-air) to be opened according to description of subassemblies before starting repair work. Install and mount hydraulic and compressed-air lines professionally. Do not mix up connections. Fittings, length and quality of hose assemblies must meet the requirements. Portable machines (Machines with possible change of operating place) Only use hoists and load suspension devices with sufficient carrying capacity, Select responsible leader for lifting process. Only professionally lift machines by means of hoists according to the information provided in the operating manual (points for load suspension devices etc.). Carefully reassemble and fix parts which have been disassembled for transport prior to re-commissioning. ‘Only proceed according to operating manual in case of re- ‘commissioning, We recommend having transfers carried out only by experienced staff of the manufacturer. 70 Operation & Maintenance ManvalANDRITL Separation ‘SEPARATION TECHNOLOGIES 3.0 General Works before assembly and commissioning Each filter press is carefully inspected before being despatched. Please observe the following points: 1) Upon arrival please immediately check, if the filter press has been | damaged during transport. 2) Please immediately check, if the consignment is complete, later complaints cannot be considered. 3) For filter presses with electrical units please check, if the electrical > specifications on the name plate correspond to the operating 5 conditions. 4) The electrical connection works must, in any case, be carrier out by an electrician. The sense of rotation of the electric motors must conform to the arrows of sense of rotation. ATTENTION! During maintenance works respectively absolutely necessary manual interference at the filter press on principle always the main power supply must be interrupted! 5) Upon arrangement, the filter press must be horizontally aligned in longitudinal and cross direction. 6) The contact surfaces of the filter press must be examined from time to Y time, especially if being arranged in steel frames, A lowering of the contact surface results in distortion of the filter press and thus malfunctions. CAUTION! We point-out that every structural alteration or variation of processing of the plant, without our knowledge, is not permitted and excludes every warranty. itANDRITZ. Separation ‘SEPARATION TECHNOLOGIES 3.1 Legend to Illustration No, 1.935.585 Membrane chamber filter press with electro-hydraulic closure, plate design OK / GK, with air connection, plate shifting with side cylinders and rope switch in emergency- off switching Head piece Filter plate pack Side bar Side bar cylinder Shifting plate Traverse C Control Panel Hydraulic cylinder Connection for fittate discharge 10 Connection for pulp inlet 11 Connection for membrane inflation via distributing pipe 12. Filtrate discharge pipe 13. Connection for pulp inlet (blind flaned) 14 Filtrate discharge pipe 15 Hydraulic unit 16 Base frame COVE OREN 7 ‘Operation & Maintenance MacaalANDRITZ. Separation SEPARATION TECHNOLOGIES 3.2. Filter Press Frame - Description The press frame is a self-supporting construction with the following main features: Base frame Head piece Shifting plate Traverse Side bars ‘The base frame serves as a substructure for head piece and traverse The flange connections of the filter press are located at the head piece. The tubes in contact with the product are made of plastic material in order to avoid corrosion. The shifting plate is suspended movable on the side bars. The traverse carries the hydraulic cylinder. The side bars are designed to absorb traction forces and to support the filer pack at the same time. The distance piece is connected with the piston rod of the hydraulic cylinder and the shifting plate. 3.3. Filter Press Frame - Assembly The filter press frame is delivered ina semi-assembled state due to transportation constraint. The fitter plates, fitter cloths and other accessories as per the GA drawing will need to be assembled at site with supervision. iB ‘Operation & Maintenance ManalANDRITZ. Separation SEPARATION TECHNOLOGIES 3.4 Construction of Press Frame Sturdy, plain and exactly horizontal foundations which are made according to the filter press dimension sheet are the basic requirements for a sate assembly and a faultless function of the filter press. ‘The head piece is screwed with the base frame. The traverse is roller-borne (illustration 1.914.308) on guide plates which are screwed with the base frame. ‘Abbatdung t92aete Preture 928s lustration akan For the transport the traverse is equipped with a safety device (illustration 1.924.418) which must be removed before commissioning of the press. The side bars are suspended in the head piece and traverse and secured by covering plates. The shifting plate is sliding on the side bars. % ‘Operation & Maintenance ManualSeparation ‘SEPARATION TECHNOLOGIES 4.0 Hydraulic Power Pack Hydraulic Power Pack with Compact Control Plate 4.1 Legend to Illustration No. 3466-1-4-00 Perea ee ee 15 ‘Operation & Maintenance ManualANDRIZ. Separation SEPARATION TECHNOLOGIES Hydraulic Power Pack with Compact Control Plate 4.1 Legend to Illustration No. 3466-1-4-00 101 Filter (return line) 373 Non-retum valve 102 Pressure gauge Oto 250barg 401 4/2-way valve 103 Pressure gauge Oto 600barg 402.1 Pressure relief valve 104 Pressure gauge Oto 40barg 402.2 Pressure relief valve 105 Electrical level and 403 Pressure reducing valve temperature supervision 404 Non-retum valve 200 Pump element including 408 4/3-way valve triple pump and coupling -«408.—=2/2-way valve 301 Lowpressure piloted valve 601 -—2/2-way valve 302 Non-return valve 602 Throttle 303 Non-return valve 603 Non-return valve + sleeve 304 = 4/S-way valve 604 Non-return valve 305 4/2-way valve 605 Throttle 308 —_—Pressure relief valve 606 Non-return valve + sleeve 308 Check valve, piloted 607 —_—Pressure relief valve 308 Non-return valve 608 = Throttle 351 Pressure relief valve 609 ©—_2/2-way valve 352 © 4/2-way valve 610 Pressure relief valve 371 Non-return valve 61 Plug 372 Non-return valve 612 Throttle 4.2. Functional Description of Hydraulic Control for Model 3466 4.2.4 Closing of Press Switch on the drive motor, item 200. The valves Y1A1, Y3A1, Y4A1, YA1, YBA1, ‘Y11A2, Y12A2, and Y20A1 are activated. All three-stage pumps P1, P2 and P3 convey oil to side “A1” of the main cylinder. In addition, ofl from side “81” will flow to side “A1". When reaching approx. 30 barg, Y4A1 is deactivated. The three-pump stages now continue to convey without differential system. When reaching approx. 50 barg, low-pressure stage P1 is switched to depressurized circulation via the pressure relief valve, Y1A1. When reaching approx. 150 barg, the medium pressure stage P2 is switched to depressurized circulation by switching off valve Y3A1 and Y8A1. The high-pressure stage P3 continues until max. Closing pressure of approx. 380 barg is achieved. Then, the motor and vatve Y6 are switched off. When the pressure falls below the minimum closing pressure the motor is started and then valve Y6A1 is activated until the required pressure is reached again. At 100 barg the signal which will allow the feeding pump or membrane inflation process to commence, i.e., "Ready for Filtration” is activated. 6 ‘Operation & Maintenance ManualANDRITZ, Separation SEPARATION TECHNOLOGIES ‘The valve Y20A\1 is activated all the time. In combination with the pressure relief valve, iter 610, it avoids excessive pressure in case of an electric power failure. 4.2.2 Opening of Press Prior to opening, the pressure in the press is reduced below 20 barg via valve Y5A1 Then, the motor is switched on and valve Y1A1, Y2A1 and Y8A1 are activated. All three-pump stages now convey oil to side "B1” of the main cylinder. The side cylinders are hold in closed position by activating valve Y11A3 and Y12A3 with a time delay of approx. 2 second after main cylinder is retracting. This will avoid early ‘opening of the subsequence plate pack section. 4.2.3 Opening of the subsequence plate pack section After the shifting plate has reached its home position and thus the first plate pack section is opened, the subsequence plate pack section will be pulled apart by activating valve Y7A1, Y11A1, Y12A1, and Y13A1. Immediately after all plate pack sections have been opened, the filter press will be closed under normal operation. In order to protect the drive motor and coupling from unnecessary loads, the motor will continuously run from start of opening process until desired closing pressure is reached. 4.3. Electro-hydraulic, automatic closure - type 319.83 4.3.1 Assembly of hydraulic unit ‘The hydraulic unit is mounted onto a supporting construction at the feet of traverse, piped with hydraulic cylinder and the contact pressure gauge so that it is ready for Use; itis delivered in this state. 7Separation ‘SEPARATION TECHNOLOGIES 4.3.2 Operation data of hydraulic unit Press size mm 7500 x 1500 ‘Closure fig. no.: 319 Nominal power of cylinder KW 15 Voltage cylinder Vv 400 Piston 6 ram 360 jon rod & ram 270 Piston stroke total mm. 1900 Piston stroke (useful stroke) mom. 1200 Piston stroke (reserve stroke) mim. 700 Tank volume i 400 Pump conveying stream 400 bar Umin 36 Pump conveying stream > 480 bar Lmin. 22 Pump conveying stream 80 bar 1 rmin 87, Motor speed Ui min. 1450 Protection lass 1P 54 Max. filter plate surface pressure | Kg/om2 75 4.3.3 Choice of oi Use only accepted branded hydraulic oil. The high lubricate of these products guarantees faultless function (see summary table 1.931.406). For this project, grade of ol ELFOLNA DS - 32, is used. 4.3.4 Oil filling: [see summary] The oil level is checked at the oil level indicators at the front side of the hydraulic oil tank, when the piston is with drawn, and if necessary, itis comected. O 4.3.5 Oil temperature: Optimum operating temperature +20 - +50°C. The operating temperature of the oil must not exceed 70°C. 4.3.6 Lubrication: ‘The lubrication of the two-stage pump is carried out by means of hydraulic oil. 8 ‘Operation & Maintenance Manual=, ANDRIIZ. Separation SEPARATION TECHNOLOGIES 4.3.7 Recommended Hydraulic Oil Only use hydraulic oil types approved by us. See the table below. The correct Properties (lubrication properties, viscosity, aging etc.) are essential for faultless function. EP [Castrol Hydraulic Fluid |Bartran |Fyspin (High Vitype) |HV32. |AWH 32 BP [Castrol Hydraulic Fluid | Energot | Hyspin (Anti-wear type) | HLP32 | AWS 32 BP [Castrol EW [Esso Mobil [Shell Hydraulic Fluid |Bartran |Hyspin /Hydrelf |Univis |DTE —_‘| Tellus (High Vitype) |Hv4s |AWH4s |Ds46 | NaS, 15M = |T46 BP |Casirol [EI [Esso Mobil [Shell Hydraulic Fluid /Energol|Hyspin | Elfolna |Nuto OTE — | Tellus (Anti-wear type) |HLP46 |AWS 46__|Ds46_|H4s. 25 46 *Power pack is prefilled with ELFONA DS32 in ASG factory. Note: 1) Different type of oil can not be mixed (row can not mix). Example: High VI type can not mix with Anti-Wear type or Esso Univis N46 can not mix with Esso Nuto H46 2) Same type of oil or equivalent type of oil but different brand can be mixed (column can mix). Example: Shell Tellus 46 can mix with Esso Nuto H46 3) Check the label on the power pack before re-filling of hydraulic oil to avoid oil contamination. 4) If not sure, drain out all the old oil completely from the hydraulic system (power Pack, cylinder, hydraulic motor, hose and fittings) before adding the new oil 4.3.8 Closing pressure: Max, 385 bar overpressure ro ‘Operation & Maintenance ManuSeparation SEPARATION TECHNOL 4.3.9 Sense of rotation: The sense of rotation of the pump motor can be recognised from outside via the pump effect or at the arrow of sense of rotation. When the motor is properly connected, the hydraulic piston moves rather quickly. if it moves very slowly from its resting position, the gear pump of the low-pressure stage does not convey because of wrong sense of direction. In this case the polarity of the motor must be reversed. 4.3.10 Oil change: Change the oil filter and air filter after the first 100 operating hours and then again after 500 hours. Change the oil after the first 500 hours and then follow the table below: Daily: check oil level, check function, and check for external leaks Weekly: as above, clean heat exchanger Monthly: check oil level, check function, and check for external leaks Yearly: check oil level, check function, and check for external leaks 1000 hours: change oil fiter and air fiter (in case of low usage change at least once a year) 2000 hours: change hydraulic oil (in case of low usage change at least once a year) 15000 hours: change hydraulic hoses 16000 hours: change piston seals > Keep the hydraulic components clean at all times as that will enable you to detect leaks. Check the oil tank level with the filter press completely open. Top-up also only in this position as otherwise the tank might be over-filed, Filter top-up oil through a fine filter and use straight from manufacturers’ container. Do not transfer Into buckets or similar to refill the oll tank. N.B. The hours mentioned here refers to the hydraulic motor running hours. 2 RBSeparation SEPARATION TECHNOLOGIES Changing the hydraulic oil 1. Open the Filter Press Fully retract the main oylinder and the side cylinders, 2. Draining of Hydraulic Oil from Tank ‘il Fier a. Method 4 Remove the cover from the air-bleeder (point A, Fig. 1) of the hydraulic tank. Use ‘a manual pump to drain the hydraulic oil 10 a clean tank/drum. b. Method 2 Remove the ‘Helen’ key cap, M22 (depending on the hydraulic pack) to drain the hydraulic oi! to a clean tank/drum (point B, Fig. 1). Fat 3. _ Clean the Hydraulic Tank Remove the Hydraulic Tank side cover (point C, Fig 1). Use non-fiber cloths to clean the interior of the hydraulic of Take note: a. If the tank is very ditty, debris may choke the inlets of the pumps. Please ensure that the inlets for the pump are clear of material. b. Moisture in the tank can cause black sludge settling in the bottom of the tank. Ensure the tank is free of moisture. Put back the side cover. 4. Draining of Hydraulic Oil from the Main Cylinder ‘A. Draining from the Front of the Main Cylinder Remove the hydraulic hose that connect from the front of the main cylinder at the hydraulic pack (point D, Fig. 3). Drain the hydraulic oil to a clean tank/drum. Re- connect the hose after it is fully drained. B. Draining from the Back of the Main Cylinder a, Method 1 (with cylinder block on the main cylinder) aANDRITZ, Separation ‘SEPARATION TECHNOLOGIES Remove the cylinder block with “Helen” keys, Drain the remnant hydraulic oil and remove any residue accumulated in the cylinder. Fo.2 b. Method 2 (without cylinder block) Remove the hose that is connected at the bottom of the main oylinder; drain the hydraulic oil into a clean drumftank. ‘Ar Fiter Fos 5. Changing of Filters Air Filter (Fig. 3) and Oil Filter (Fig. 1) must be changed during hydraulic oil change. (Frequency: about every 6 months) 6. ing of Hydraulic Tank Fill the Hydraulic Tank with specified oil as advised to the top of the level glass attached to the tank. Please take note that the main cylinder is not filled with oil, hence when the press is closed, the oil level will drop and the hydraulic tank may 2 Operation & Maintenance ManaalANDRITZ Separation SEPARATION TECHNOLOGIES need to be topped up (Fig. 1). If the hydraulic oll level fall below the red line of the level glass when main cylinder is extended, top up the hydraulic oil about tom above the redline. 7. Alr-bleeding of Main cylinder! Side cylinder Main cylinder is air-bled by releasing the sorew of the hydraulic transmitter (point E, Fig. 4). While the filter press is closing, hydraulic oil will leak out of the opening. Stop (pulled the rope switch) the press, tighten the screw. Continue to close the press to pressure then open the filter press. Do this a few times to ensure smooth operation. Side cylinder is air-bled by releasing the screws (points F & G, Fig. 5) from inlet and outlet of the side cylinder. Point 6 Fi. Fo. NB: Do not use hydraulic oil that is not equivalent to the hydraulic oil that is supplied with the machine. If there is any doubt, please check with Andritz Singapore Pte. Ltd. A use only lint-free cloth for this! Make sure no cloth is left behind in the tank! Close man-holes and fill tank directly from manufacturers’ containers using a purnp and a fine strainer. If available use a motor driven micro-fitration unit to fil the tank. B ‘Operation & Maintenance ManualANDRTZ Separation SEPARATION TECHNOLOGIES 4.4 Malfunctions and their elimination — 4.4.1 The hydraulic cylinder cannot keep the pressure constant: (The pump switches on too often) a) Leaky screwing b) Defective sealing in hydraulic- Cylinder ©) Leaky magnetic valve tighten screwing replace sealing or replace hydraulic- cylinder. Do-i-your-self only if you are Experienced enough, otherwise call for service. In case of contamination: Screw off From base plate and blow through. Replace defective sealing. Do-it- your-Self only, if you are experienced Enough, otherwise call for service. h ATTENTION! After replacing the sealing set in the hydraulic cylinder, absolute care must be taken, that all screws are replaced and greased before screwing in! The tightness torque for the screws must be taken from the table below! Press sze | Operating | Screwsize | Propertyclass ] Tightness, pressure — torque _ a 1500x1500 mm| 15 bar 436x200 | 42.97 DING12 | 2240 Nm Prior to re-commissioning, the hydraulic cylinder must be vented carefully! Note for tightening the screws! The tightness torque mentioned above is for example to be generated by means of a wrench with extension and a tightness torque of 35,8 kg in a distance of 1 m from the screw. This then relates to 358 Nm. 44.2 Pressure Adjustment ‘The pressure transmitter, the pressure relief valves and the pressure control are adjusted to the filtration pressure by the manufactures. All indicated pressures refer to a filtration pressure of 15 bar over-pressure. The closing pressure is calculated and adjusted according to the chamber pressure. For the relation between the two see the diagram. ‘Operation & Maintenance ManualSeparation ‘SEPARATION TECHNOLOGIES 4.4.4 Stroke control of hydraulic piston The hydraulic piston may not be completely extended under pressure in closing direction, as otherwise the filter pack is not sufficiently closed. This would have the consequence that the filter press will splash during fitration. Afier removing or exchanging the filter plates or filter cloths, the stroke of the hydraulic piston necessary for the closing must be carefully examined. It may not exceed the valve given in the table, because of safety reasons after carrying out works at the set of filter plates. If upon controlling it tums out that a bigger stroke becomes necessary for closing, a spacer must be inserted between piston and shifting plate. 4.4.5 Ventilation of hydraulic cylinder Is carried out by slightly loosening one of the connections at the pressure transmitters and retightening after bleeding the entrapped air. (Do not open under pressure) 4.4.6 Stroke Control of Lateral Cylinders The lateral cylinder is adjusted in such a way that it does not reach the stop at any position. The side cylinder must be checked over carefully after removal or exchange of filter plates or filter cloths. Supposing that it would eventually reach the stop, when doing the check -over the cylinder must be adjusted again 4.4.7 Ventilation of Side Cylinders |s effected by slightly loosening the hose connection at the rod side of the hydraulic cylinder. Procedures 1. Close the filter press to closing pressure. Mark the original positions of the side cylinders’ proximity sensors, and remove the sensors. Protect the proximity sensors from excessive hydraulic cil by covering the sensors with cloths or plastic coverings. See Fig. 1. s ‘Operation & Maintenance ManualSeparation SEPARATION TECHNOLOGIES Fig. 3, To bleed the front of the side cylinders, loosen the joint as shown (Fig. 2) on both sides of the filter press. Put a clean bucket below the joint to collect the hydraulic oil. Retract the side cylinders and let the hydraulic oil leak through the joints unti itis fully retracted. Stop retracting the side cylinders after 2 seconds delay (fully retracted) to purge out excessive air. Re- install the side cylinders’ proximity sensors to the original marked position. Tighten the joints. Repeat procedures for all the following side cylinders, Re 4. To bleed the back of side cylinders, loosen the joint as shown (Fig. 3) on both sides of the filter press. 26 ‘Operation & Maintenance ManualSeparation ‘SEPARATION TECHNOLOGIES Put clean buckets below the all joints for all side cylinders to collect the hydraulic oil. Close the filter press and let the hydraulic oil leak through all the joints until it is closed to pressure. While closing the filter press, tightened the joints when hydraulic oil is leaking at the joints. Noted: Repeat procedures for at _least twice to ensure maximum purging of air. 5. Refill the hydraulic oil from the clean bucket back into the hydraulic oil tank if the collected hydraulic oil is clean. If not, refil the lost oil with new hydraulic oil of the ‘same grade used in the hydraulic oil tank. m7 ‘Operation & Maintenance ManualSeparation SEPARATION TECENOLOGIES 5.0 Shifting Device — Description 5.1 Chain Up of Filter Plates One with Another: The filter plate pack is chained together by self-locking drag hooks’ (see illustration 1.924.573) being fixed at the plate handles on the left and on the right. ‘The partial packs are not chained one with another. 5.2 Lateral Traction Cylinders for Two-Stage Operation: The first plate of the second partial pack is pulled against the shifting plate by two laterally mounted hydraulic cylinders each. 5.3 Functional Description: 1. Opening of the First Stage: By returning the shifting plate the first partial pack will be pulled open. The lateral cylinders retain the remaining partial pack. 2. — Opening of the Second Stage: After stop of the shifting plate the two lateral cylinders are activated. In acting this way, the second partial pack is pulled open and the first one closed again. The lateral cylinders are moving to a stop and by limit switches the two lateral oylinders are switched no-pressure. B Operation & Maintenance ManualVS ANDRITZ, Separation SEPARATION TECHNOLOGIES 5.4 5.5 3. Opening of Further Stages: After stop of the lateral cylinders the ones following next are activated, The partial pack is pulled up and the preceding pack is closed again. The lateral cylinders are moving to a stop and by limit switches the respective lateral cylinders are switched no-pressure 4, Closing of Press: The shifting plate pushes the whole filter pack against the head piece, whereat the lateral cylinders are following-on in an empty state. Opening of Plate Chain-Up For Removal of One Filter Plate 1. Pulling apart the filter pack by means of opening hydraulics up to that plate which shall be taken out. 2 ‘Swing out drag hooks of the following plate. 3, Open further the press by means of the opening hydraulics until a comfortable gap is created. The last plate of this pack is the filter plate to be picked. Push the last plate to be taken off against the last but one. ‘Swing out the drag hooks of the plate to be taken out, Take out plate(s). Execute always the exchange by pairs. Noe Closing of the Plate Chai -Up after Completion of the Filter Pack 4. Alllthe drag hooks of the open partial pack completed again are suspended. 2. Puts together smoothly the pack by means of closing hydraulics, Suspend manually the drag hooks of the first plate of the closed partial pack. ‘When superposing the pawis, please see to it that its shingle-type arrangement in layers is preserved (see illustration no. 1.924.573). = Operation & Maintenance ManualSeparation SEPARATION TECHNOLOGIES 6.0 Accident Prevention - Description The accident prevention unit is consisting of: Rope switch as Emergency-Off function. The pull cord Emergency-Off function serves for preventing ‘occupational accidents which, based on their functioning or operating principle could be dangerous for the operator. The rope switch is operating as follows: When the pull-cord is pulled, the respective movement is interrupted immediately and intervention into the filter press can be affected without danger. For restart there must be: Press on the reset button mounted on the rope switch. The interrupted movement will commence immediately. Note: The Product Warranty shall be null & void If there is any unauthorized change on the machine control program after Handling Over. 3% Operation & Maintenance ManualSeparation SEPARATION TECHNOLOGIES 7.0 Electrical Installation - Description Operating box with control elements. HX, Kind of protection IP 55 ‘> Arrangement directly at the filter press Kind of protection of all other electrical plant parts of the filter press: IP 55 Please refer the electrical diagram and panel layout drawing at Attachment of the operating manual. 3 pra & Maisons MaalANDRITZ. Separation SEPARATION TECHNOLOGIES 8.0 Commissioning 8.1 Closing of Filter Press Before closing the filter press it absolutely has to be taken care that the sealing rims of the filter pack as well as of the groove A knob area are completely free from contamination and that the filter cloths lie close without folds. In case of non-observance of the above a trouble free operation of the filter press may not be guaranteed, 1) Main switch "ON" 2) Control voltage "ON" 3) Rotary switch in position "Close Press” 4) The closing process will be started. Pulling the rope of the rope switch means an immediate interruption of the movement of the filter press. By resetting the rope-switch the closing process will be continued. Pressure is maintained automatically according to the calculations programmed. (See diagram). > The closing pressure is calculated and adjusted automatically and the settings can not be changed. The hydraulic unit pumps until the set pressure is obtained. If the pressure drops to 20 barg below the set pressure the hydraulic unit will start again. Should the pressure rise to 20 barg above the set pressure, the pressure will be released down to the set pressure. Only after the min. closing pressure has been obtained, filtration may begin. 2 Operation &NANDRITZ Separation SEPARATION TECHNOLOGIES 9.0 Spare Part List The item numbers marked with * are parts subject to wear and tear having an average service life of two years. (In case the plant is running eight hours a day) The item numbers marked with ** are parts subject to wear and tear which are extremely dependent on the number of cycles per day as well as on the operating condition (thermal, chemical and mechanical). a Operation & Maintenance MasualSeparation ‘SEPARATION TECHNOLOGIES 9.1 Electrohydraulic closure oO Item Designation z 3 4 5 $ Te A oF 1 ue Pressure sensor iraulic cyinde? Hydreulic unit Three-phese mater Pressure hose Pressure hose ‘Side cylinder Pressure hose Pressure hose Pressure hose When placing an order, please indicate no. of order confirmation, press size as well as quantity of the parts required. 4 ‘Operation & Maintenance Manual‘SEPARATION TECHNOLOGIES 9.2 Hydraulic unit Fy ‘Operation & Maintenance ManualSeparation ‘SEPARATION TECHNOLOGIES tem | Piece _| Designation 401" 4 Filter (return line) “105 | 1 Electrical evel and temperature supervision 200. [Pump element including triple pump end coupling 301 7 [Low pressure unloading vaive, electrical piloted ‘302 [1 [Non-retum valve ‘303 | 1 [Non-return valve 304 [1 —Yareaway vaive 306 4 [472-way valve 306 4 Pressure relief valve _ 308 4 ‘Non-return valve, piloted | 309 | —1__| Non-return valve 354 4 Pressure relief valve_ 352_| 1] 4?2-way valve 371 |_1.__| Non-return vale 3721 [Nonretum valve '373_[ 1 Nonwetum valve 4011 | 4-way valve 402.7 | —1___| Pressure relief valve 402.2_| 1] Pressure relief valve 4031 | Pressure reducing valve 4042 | Non-etum valve 406 3 4-way valve 408 3 | 2/2-way vaive 601 |_| 2r-way vaive 602 | _1__| Throttle 603 2 'Non-retum valve + (steave x1) ‘604_| 2 | Non-retum valve 605 4 Throttle 606 | 2 | Non-returi valve + sleeve 607 | 1__| Pressure relief valve 608_| 1 | Throtle 609] __1__| 2-way valve 610 | _1___| Pressure relief vale 611_| 1 | Pug 612 |__| Throtle eis | 1 | Filter ‘When placing an order, please indicate no. of order confirmation, press size as well as quantity of the parts required. 36 ‘Operation & Maintenance ManualSeparation SEPARATION TECHNOLOGIES 9.3 Hydraulic cylinder i | | 5 i y Item _| Piece | Designation ‘When placing an order, please indicate no. of order confirmation, press size as well ‘as quantity of the parts required. 7 Operation & Maintenance ManualSeparation SEPARATION TECHNOLOGIES 9.4 Side cylinder Ttem__| Piece _| Designation id Piston guide fa Piston seal * ‘O-ring seal = ‘O-ring seal = ‘Oring seal eo Piston rod seal 7 Scraper = ‘Seal set complete When placing an order, please indicate no. of order confirmation, press size as well as quantiy of the parts required. 8 ‘Operation & Maintenance Mnualnz. Separation SEPARATION TECHNOLOGIES 9.5. Interlacing of plates y 7) ltem__| Piece _| Designation 216 | Transpor hook 216 [Short Pin '§__[Long Pin (divider plates) 234 | End disk 216 | Circ rt When placing an order, please indicate no. of order confirmation, press size as well as quanti of the parts required, 3 ‘Operation & Maintenance ManualSeparation ‘SEPARATION TECHNOLOGIES 10.0 Attachments o ‘Operation & Maintenance Manual