MEBCO Engineering

JET - PULSE FILTERS

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

MEB – FIL -TEK

Shymkent
2018
PART 1

SPECIFICATIONS
FILTER: 601 – 602

Description Unit Filter No: 601 - 602

Supplier Type Number 4.2213
Capacity Am3/h 30.000
Quantity unit 2
Filtration Area m² 405
Input Dust Load gr/m³ Max. 150
Mgr/Nm3
Filtration Guarantee 20
dry
Operating Temperature °C 135 (Peak150)
Bag Size mm Ø160x3600
Qty. of Bags pcs 224
Bag Quality %100 Polyester
Number of Timer Output unit 1 pcs – 16 outputs
Size of Solenoid Valve inch 1½
Qty. of Solenoid Valve unit 16
Compressed Air Nm³/min
1.00-1.05
Consumption

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FILTER: 603 – 604 – 605

Description Unit Filter No: 603-604-605

Supplier Type Number 2.2103
Capacity Am3/h 10.000
Quantity unit 3
Filtration Area m² 130
Input Dust Load gr/m³ Max. 150
mgr/Nm3
Filtration Guarantee 20
dry
Operating Temperature °C 135 (Peak150)
Bag Size mm Ø160x3600
Qty. of Bags pcs 72
Bag Quality %100 Polyester
Number of Timer Output unit 1 pcs – 8 outputs
Size of Solenoid Valve inch 1½
Qty. of Solenoid Valve unit 8
Compressed Air Nm³/min
0.30 - 0.35
Consumption

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FILTER: ELV

Description Unit Filter No: ELV

Supplier Type Number 2.1102
Capacity Am3/h 6.000
Quantity unit 1
Filtration Area m² 130
Input Dust Load gr/m³ Max. 150
mgr/Nm3
Filtration Guarantee 20
dry
Operating Temperature °C 135 (Peak150)
Bag Size mm Ø160x2250
Qty. of Bags pcs 64
Bag Quality %100 Polyester
Number of Timer Output unit 1 pcs – 8 outputs
Size of Solenoid Valve inch 1
Qty. of Solenoid Valve unit 8
Compressed Air Nm³/min
0.15 - 0.20
Consumption

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 PART 2

JET PULSE FILTER

INSTALLATION, OPERATION AND MAINTENANCE

INSTRUCTIONS

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1- THE WORKING PRINCIPLES OF JET PULSE FILTERS

The main sections of filter are shown below: (Drw. 1)

 Steel structure (pose 1)

 Filter case and dust hopper

 Dust discharge equipment

 Dirty gas channel

 Filter top box

 Clean gas channel

 Bag, Cage

 Ladder and handrail

 Compressed air line

 Bag cleaning systems

 Pulse control systems

 Electric control systems

1.1 Steel Structure

Steel structure usually should be in Drw.1 -pose 1. Structure height is set at

design stage according to the application.

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1.2 Collecting Dust Hopper

Dust collected around the filter bags, is removed by a pulse of pressurized air.
Hopper walls angle is set according to the type of dust. There is a cover on the hopper
can be opened easily for maintenance.

1.3 Dust Discharge Equipment

Dust discharge equipment includes;

 A screw conveyor + Rotary air lock (for long hoppers)

1.4 Clean Gas and Dirty Gas Channels

The dirty gas section of the filter is the main section, and where the filter bags
are located. The dirty gas which is incoming in this place hits a collision plate first,
where large particles may fill to Cleaned gas is exits the discharge of the filter.

1.5 Bag and Cage

The standard size of filter bags and cages are ø 160 x 1600, ø 160 x 2500,
ø160x3600. Bags are placed inside the tube sheets (Drw.2).

1.6

Is used to reach the top of the filter easily and working safety on the filter.

1.7 Compressed Air Line

Compressed air is provided by compressed air system. (A free compressor unit

can be used for big filters). Filter unit and drying unit in the compressed air center,
should provide clean and dry air to the compressed air input of filter. There is air
conditioner system at entry, which contains filter unit, water separator (which collect
the water vapor), manometer and pressure regulation unit.

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1.8 Bag Cleaning System (Drw. 3)

Bag cleaning system consists of solenoid valves and blow-pipes. Diameter of

the solenoid valve depends on number of bags. 4 solenoid valves is fastened for each
air tank. Solenoid valve is activated by pulse control system and these valves send
compressed air to the blow-pipes in a very short time. Each blow-pipe is fastened to
sequential bags. Compressed air enters the bag from this holes and will be routed to
the bags. Collected dust on the exterior surface of the bag falls to the hopper.

1.9 Pulse Control System

Operation of the solenoid valves is managed by timer. Timer, sends signals with
pre-set pulse range to solenoid valves. Remain open time of each solenoid valve is set
by timer. Pressure difference unit can be used to turn of timer according to customer
request. Pressure difference unit measures and shows pressure differences between
input and output of the filter. Pressure difference unit operates timer when the
difference increases due to increase the dust accumulated around the bag. Timer will
have stopped when the pressure difference falls. This method of controlling the
solenoid may reduce the consumption of compressed air.

1.10 Electric Control System

Electrical supply and control of motors are provided by others.

2- INSTALLATION OF JET PULSE FILTERS

2.1 Filter Main Structure

Carefully and thoroughly check the delivery to confirm all goods are received
and undamaged

Pre-assembly of the filter should be performed in accordance with the erection

drawings.

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 The following steps during filter assembly has been given below. Filter, can be
sent as a whole or pieces and these pieces are adjusted according to size or customer
requests.

 Before beginning the installation of the filter, installation and adjustment work of
steel structure must be made
 Dust collection hopper is fixed to the steel structure with bolts (or by welding).
Silicon is used to seal all joint. Select a silicon has to suit the operating
temperature of filter.
 The assembly of dirty gas section is made by coated flange connections with
silicon. If filter is small, this part can be pre-assembly in workshop, completely.
For big filters, this part is best pre-assembled piece by piece on site.
 The assembly of clean gas compartment is made on dirty gas section.
 Installation of reinforced pipes is completed (Drw. 1). Silicon is used in
combination pipe location.
 There is a manhole on the hopper, which can be opened quickly.
 Ladder and handrail will be placed according to technical drawings.
Note: dust discharge unit should be installed in the latest stage.

2.2 The Main Form of Filter

Installation of the filter bag is shown in Drw.4 installation is should by following

the steps in accordance with Drw.4

2.3 Bag Cleaning System (Drw. 3)

Solenoid valves and blow pipes can be installed in this way:

 Connection socket and nut can be installed by compression.
 The connection of rubber gasket at the top and bottom section should be
made. Rubber gaskets at this stage should not be too compressed.
 Blow pipe should be placed inside the connection socket
 Solenoid valve connects to the air tank.
Note: use Teflon strip when making connections.
 Connect blow-pipe to the output of solenoid valve
 Blow-pipe should be installed in according to the Drw 3.

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2.4 Compressed Air Line (Drw 5)

Installation of compressed air line should be made according to the Drw 5.

Piping by others should continue from air tank to the plant compressed air supply.
Teflon tape should be used for all threaded connection point.
Pressure switch must be installed on compressed air system (Drw.5).
Air conditions set (filter, regulator and manometer) should be installed to the
entrance of the pressurized air system of filter. Factory air source is connected to the
entrance of filter unit.

3- CONTROL PHILOSOPHY

 Compressed air source must be selected in sufficient capacity to provide air

pressure. Sufficient pressure at the level of the system is measured by
pressure switch. If pressurized air is not sufficient; pressure drops is
occurred and the pressure switch stops the system.

 Dust discharge equipment starts to work.

 Pulse control system comes into operation. Pressure difference on the filter is
measured with the pressure difference device. Timer enters into an activity
and sends a signal to each solenoid valves.

 Fan starts to run as dedusting process starts.

 If a problem of dust discharge equipment is felt by the speed switch, the
system sends an alarm to controller.

 When decommission process of filter; fan, pulse control system and dust
discharging equipment stop in sequence.

3.1 Filter

 After installation, should not be any residue which may cause damage to
dust discharge equipment in the filter.
 Manhole of hopper is closed.

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  Clean air duct is cleared and top cover of the filter are closed.
 Check all the bolts in the flange connections are suitablt tight.

3.2 Compressed Air Line

 Before connecting solenoid valves, air is supplied to airline. The last

connection is done after this process.
 The valves are opened on the line. So that air can reach to solenoid valves.
 Adjustment of pressure is done by regulator unit switch. Pressure range is
used 5-6 bar usually.
 Concentrated water should be taken from the filter, periodically.

3.3 Dust Discharge Equipment

The dust discharge equipment include

 Screw feeder,
 Rotary valve,
 Speed switches for both.
Screw conveyors and rotary valve controlled by speed switches. This switches
send I/O signal to controller consistently. If any problem has occurred motors
of these equipment, speed switches halt this signal to controller.

3.4 Pulse Control System

See the relevant sections.

3.5 Fan

See fan supplier manual.

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4- START-UP

Before the commissioning, all items should be controlled step by step which
described below.

 Base plates should be checked visually as horizontal and vertical,

 All torque values should be checked for anchor bolts,
 Casing bolts torque should be checked,
 All sealing material should be checked to avoid any leakage,
 All leakage should be checked from inlet side by going into the filter from
manhole,
 Pressure pipes should be checked to avoid any leakage under the 6 bar
pressure,
 All cables should be checked,
 All burr should be cleaned inside of the filter,
 All burr should be cleaned inside of the filter duct,
 All bags should be checked from hopper side and adjusted, if there is any bag
which touch others,
 Direction of baffle plates should be checked from bottom side,
 Direction of rotation should be checked for screw conveyors,
 Position switched should be checked for fresh air damper and maintenance
damper,
 Timer should be set and all valves should be checked with air,

Cold test should be done according to steps, described below,

 Fresh air damper and maintenance damper should be closed,

 Screw conveyor should be started first during 30 seconds,
 After screw conveyor, timer unit should be started during 30 seconds,
 After timer unit, fan should be started during 30 seconds,
 After fan, Maintenance should be opened.

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5- MAINTENANCE AND REPAIR

To avoid any problems in the use of filter to the filter following sections should
be checked periodically.
 Filter Bags
 Pressure Air Line
 Bag Cleaning System
 Pulse Control System
 Dust Discharge Equipment
 Fan (see supplier manual)

Note: The system must be de-energized and isolated prior to performing

any maintenance activity.

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5.1 Filter Bags

 Lid should be opened on the clean gas compartment, and these actions must
be done.
 Checking should be done when there is no space between filter bags and tube
sheets.
 If the bag is damaged, damaged bags should be removed and new bags will
have replaced (Drw.4).

 Bags will be cleaned with dry cleaning. Do not wash filter bags with water.

5.1 Compressed Air Line

Filter regulator should be controlled periodically. If there is any dust or water in

bottom cap of regulator, this cap should be cleaned manually.

Compressed air pipes should be cleaned avoid any burr before erection to
solenoid valves.

5.3 Bag Cleaning System

Air tanks should be cleaned before start-up avoid any burr.

Solenoid valves should be controlled every 6 months.
Solenoid valves membrane should be controlled every 6 months and cleaned
before start-up.

5.4 Pulse Control System

Timer unit, the differential pressure unit and relevant piping should be
controlled by pulse control system. If there is a broken device, it should be
changed with new one.
Air connections of the difference pressure unit should be checked. Input and
output pipes of the filter should be cleaned and should not be bent. If dust has
run into the pipe, the pressure difference unit will not show the correct rate.

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14
15
16
DRW.4

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18
 Installation of Filter Bags and Cages
 Fılter bag is placed to the tube sheets according to Drw 4- Drawing 4.1.

 Erection version of bag is like in Drw.4.

 Filter cage hangs down into the bag like in Drw4- Drw. 4.

 Erection version of the bag and cage is like in Drw4

PHASES OF CLEANING FOR BAGS

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INSTALLATION FOR CAGES WHICH INCLUDE 2 PARTS

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Drawing 7 – CLEAN SEQUENCE (RECOMMEND)

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 PART 3
THE METHODS FOR PULSE SYSTEMS

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PULSE SEQUENCE

The pulsing sequence can play an important part in minimizing the re-
entrainment of material. Pulsing one row adjacent to another row (sequential order)
can cause the fine, submicron material to migrate to the cleaned row. Staggering the
order of rows to be pulsed puts distance between the recently cleaned rows and those
rows get to be cleaned, and can improve the dust cake for optimum filtration.

Recommended sequencing is given Table A.

THE PERIOD OF PULSE

Effective tuning of distance must be about 0,1 - ,15 sec. for each pulse duration.
The pulse duration is set up by the timer. Some factors, which are below, to effect to
pulse duration.

 Pressure air consumption

 Quantity and size of solenoid valve

The calculation is presented below for your filter.

EXAMPLE:

Fabric Filter design and operating conditions.

Filter area (m²) = 506
Quantity of solenoid valve = 20
Size of solenoid valve = 1½“
Pressure air consumption is about 1,10 – 1,26 Nm³/h.m² ( as our experience )
Pressure air consumption was choosen 0,15 Nm³/h.m²
Pressure air consumption = 0,15 x 506 = 75,9
Air volume to solenoid valve (according to ASCO catalogue )

1½" valve, 7 bar, 0.1 pulse duration, 30 pulse/h = 4.27 Nm 3/h. valve

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Air volume for 20 valves = 4.27 Nm3/h. valve x 20 valve = 85.4 Nm3/h.
Hereby air is passed overmuch for 30 pulse/h. correct pulse quantity could be
founded by that equation below. (1½" valve, 7 bar, 0.1 for pulse duration).

75,9 Nm3/h 30 pulse/h

Quantity of pulse for each hour : x = 26,6
3
20 valve 4.27 Nm /h

Therefore each solenoid are doing 26,6 pulses .

pulse
Total quantity of pulse : 26,6 x 20 solenoid = 532 pulse/hour.
h.solenoid
* Sequence of pulse ( recommend ) 3600 = 6,8 sec.
460

* Duration of pulse (recommend): 0,1 – 0.15 sec.

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 TIMER – SELENOID JOINT FOR YOUR FILTER (601 - 602)

AIR COLLECTOR 1 2 3 4

SOLENOID VALVE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TIMER INPUT 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16

TIMER – SELENOID JOINT FOR YOUR FILTER (603 – 604 – 605)

AIR COLLECTOR 1 2

SOLENOID VALVE 1 2 3 4 5 6 7 8

TIMER INPUT 1 3 5 7 2 4 6 8

TIMER – SELENOID JOINT FOR YOUR FILTER (ELV)

AIR COLLECTOR 1 2

SOLENOID VALVE 1 2 3 4 5 6 7 8

TIMER INPUT 1 3 5 7 2 4 6 8