BALLOKI 1223MW Combined Cycle Power Plant

Debris Filter System

O&M Manual

BUYER：HARBIN ELECTRIC INTERNATIONAL COMPAN Y LIMITED

SELLER：
WUXI HONGXIANG POWER AUXILIARY EQUIPMENT CO.,LTD

Oct., 2016
APPROVED BY：

CHECKED BY：

REVIEWED BY：

DRAFTED BY：
 Safety Precautions

The operation instruction is composed of equipment installation 、 operation and

maintenance、control instruction、drawing and sub supplier manual. Before equipment

installation, debugging, must carefully read this operation manual.

To avoid personal injury or property damage, related personnel must pay attention to

the following：

□ Relevant technical data in the instructions

□ Accident prevention regulations

□ Operating personnel safety regulations

□ Electric protection measures according to local safety regulations

□ Manufacturing technical parameters on the nameplate

□ Warning nameplate on the component

□ Operate by qualified professionals

Operating instructions contain safety precautions, if ignored, may damage equipment

and personal

Warn：

Ignore the corresponding measures, may threaten the safety of life

Warn：

Electric shock operate carefully

 Contents

1 Circulating Water & Debris Filter System main data

2 Main use of debris filter system、working principle & part description

3 Equipment installation

4 Debugging and running of debris filter system

5 Debris filter system maintenance

6 Debris filter system control instruction

7 Debris filter system drawing

8 Sub Supplier manual (offer single)

9 Packing list (offer single)

1 Circulating Water & Debris Filter System main data
1.1 Circulating water main data

NO. ITEM UNIT VALUE

1 Normal flow（One side） t/h 30300

2 Working pressure MPa 0.3

3 Design pressure MPa 0.5

4 Medium River water

5 Working water temperature ℃ 25~33

Circulating water inlet and

6 90"（DN2200）
outlet pipe specifications

7 Circulating water pipe material ASTM A139 CATE B

1.2 Debris filter system main date

1.2.1 Debris filter system
Manufacturer/Model HXDL/WNBD-2200
Nominal diameter 90"（DN2200）
Total length 2600mm
Installation mode Horizontal
Working pressure 0.3 MPa
Design pressure 0.5 MPa
Filter mesh diameter Φ5mm
Running water resistance 0.05Bar
Filter actuator Gear reducer motor
Flange interface specification
Inlet & Outlet flange AWWA C207 NPS 90"（2200）Class B
Blowdown flange ASTM B16.5 NPS 16"Class 150 SO RF
Drain flange ASTM B16.5 NPS 4"Class 150 SO RF
Material:
Body ASTM-A36+Internal corrosion protection
Cover ASTM-A36+Internal corrosion protection
Tube ASTM-A36+Internal corrosion protection
Filter ASTM A240/480
Axle ASTM A240/480
Blowdown pipe ASTM A240/480

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1.2.2 D/P measurement system
Manufacturer/Model EJA/110A series
Output signal 4∼20 mA
Setting value 0∼0.12Bar
Alarm setting value 0.1 Bar
1.2.3 Valve
□ Electric blowdown butterfly valve
Model 16"150LB
□ Drain valve
Model 4" 150LB
□ Vent valve
Model 1/2″150LB
□ Instrument valve
Model 1/2″150LB

1.2.4 Drive mechanism

□ Filter drive mechanism

Manufacturer/Model Rexnord/ XLEDJ74-1505-1.5

Voltage/ Frequency/ Phases/IP

□ Electric actuator of blowdown valve

Manufacturer/Model RICH/ RA series

Voltage/ Frequency/ Phases

1.2.5 Control panel

Manufacturer HXDL
Programmable logic controller AB 1764
Installation method Lead Track Gearing
Voltage/ Frequency/ Phases 400V/50HZ/3
Control voltage/ Frequency/ Phases 230V/50HZ/2
Control voltage 24V DC

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2 Main use of debris filter system、working principle & part description
2.1 Main use of debris filter system
The debris filter system is the latest patent product. It applies to large flow water systems, it is a
clean and effective device that can effectively prevent water and suspended solids and other solid
particles into the downstream water equipment. It is particularly important equipment that
effectively improve safety and economy.
2.2 Debris filter system working principle
Detailed description on the process and principal of working involved in debris
removal/cleaning as follows:
Pressure lowered, backwash(operation flows)
Filter

Water flow

Fibrous impurities

Filter screen

The impurities into mesh net surface by

water pressure

Unfiltered cooling water enters the inner side of the filter screen, Through the filter filtered
effectively, cooling water flow to outer edge of the filter screen.
Drop pressure

Clear fibrous impurities, and make it into a

floating state

Pressure drop area

Discharge bucket

The debris remain on the filter screen surface, then the differential pressure increase. When the
pressure reaches at 0.1 Bar, the butterfly valve will be opened automatically and then drive motor &
discharge bucket will be activated to turn.

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 The filter backwash

The D/P will drop after opening the

butterfly valve and then remove the
impurities on the mesh surface by
generates reverse flow

Debris filter reducer motor rotate and drive discharge bucket, the impurities on the mesh
surface will be removed by generates reverse flow.
2.3 Debris filter assembly
2.3.1 Debris filter assembly

Fig.1 Debris filter general drawing

Debris filter is horizontal structure，inlet and outlet are in the same horizontal line. It is
composed of filter body, filter screen, transmission system（contain reducer, motor, axle, gear box etc）,
Discharge system(contain backwashing rotor channels, sewage pipe and blowdown valve and
actuator), support, lifting lugs.

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Note:
1) HXDL has no special tools & tackles required for the installation and maintenance, common
tools can be used for installing and repairing the equipment.
2）Lifting the debris filter system equipment must be through the both sides of the lugs, the
installation unit may lift the equipment in accordance with his the rules of normal safe operation.
① Screen Section
Inside the filter body, there are 24 same fixed filter screen. The surface of the filter screen has a
plurality of 5 mm holes. The filter screen is made of ASTM A240/480 stainless steel material.
Maintenance requirement: The Debris Filter System is only allowed to run in the design pressure,
design temperature range.
Precautions: You must remove the large residue inside the pipes and prevent large residue to
damage the filter screen after all the equipment and pipes have been installed.

Fig.2 Filter screen

② Filter Rotor
The Filter rotor is located on the outlet side (clean side) of the filter screen. During backwash, the
rotor drive motor automatically turns the debris rotor within the filter, the filter rotor is made of
ASTM A240/480 stainless steel material.
③ Discharge system
Discharge system is composed of backwashing rotor channels and backwashing pipe, they are
made of ASTM A240/480 stainless steel material.
2.3.2 Blowdown Valve and Actuator
Blowdown valve is butterfly valve (Type: 16" 150LB). The Debris Filter System automatically
opens and closes the backwashing pipe route by motorized valve.
2.3.3 D/P measuring system
Differential pressure transmitter continuously monitors the pressure differential across the debris
filter screen. The blowdown valve will be opened automatically, then the filter will be backwashing
and remove the accumulated debris when D/P value reaches the setting value (0.1 Bar), .
2.3.4 Control system
Control system is main composed of AB 1764 series PLC、touch screen and relay, it is used for
operation, control and monitoring of debris filter system.
All more operation function is controlled by buttons on control panel, details see Section 6 debris
filter system control instruction.

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 3 Storage & installation of debris filter system
3.1 Parts store

、 Warn:
1. Product packaging’s life is six months
2. You can not store the packaging of parts in the open air.
3.If you will not install the parts, they should be placed in dry, sealed chamber.

Delivery Check Inspect frequency Remark

You should cover with a thin foil You should seal the parts with
when the parts will be in the box waterproof packing, not splash –
Packing Once every 3 months
or on the tray(Store not more 6 proof packing
months)
You should seal the parts with
waterproof packing, not splash –
The parts in box should be sealed Packing Once every 6 months proof packing. If the package has
tightly with plastic (Store not more been opened, you should seal it
6 months) again.
Dryer Once every 6 months Update the dryer

Note:
1. The parts have not be sealed with plastic should be removed from the box, stored in a dry
room.
2. If the parts can not be stored in accordance with the above provisions way, please contact
HXDL service Department.

3.2 General installation steps

● Remove the parts from warehouse.
● Check the parts whether have been damaged during storage (See 3.8)
● Send the parts to installation site
● Check the parts whether have been damaged during transit
● Installation (See 3.6 and 3.7)
● Check the parts whether have been damaged during installation (See 3.8)
● Protection of the debris filter system after it has been installed (See 3.8)
3.3 Supply and installation scope: Supply scope of debris filter system see packing list.
3.4 Installation requirement

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、 Note:
You should sewage and insulate cooling water circulation system before debris filter system
will be installed, and take effective measure to prevent flooding and isolation failure.The
installation parts should be responsible for issuing by team leader.
● Check their integrity when you will remove from the storage room.
● Keep installation location dry and clean.
3.5 Installation tool
Do not need any special installation tool.
3.6 Installation
3.6.1 Prepare before installation
● Please make relevant preparations before installation(See 3.4)

Warn:
Please observe the following provisions when unloading components at the installation site.
● Carefully open the package
● Especially careful, about differential pressure measurement system and electrical components
● Moving the equipment with special suspension when the equipment is installing.

● Check their integrity when you will remove from package (According to 3.8). If you find that
paint has been worn, usually must be repaired timely.
● You should prepare flange, gasket, bolt, nut and washer.
3.6.2 General precautions
Under normal situation, must comply with the following rules during installation.
● Prohibit ferrite materials or tools contact with stainless steel.
● The lubricating oil on “O” ring must be silicon valves lubricating oil, does not contain
hydrocarbons.
● Nuts and bolts must be properly lubricated before assembling the equipment.
3.6.3 Debris filter
It has completed the assembly before equipment consignment, see general drawing. D/P
measuring system installation see 3.7.
Installation location Condenser pit, horizontal installation
Equipment weight 9500kg
Before installation:
● Visual inspection. Especially the primer is damaged during transport.
Installation:
● Only use lugs when you lift the equipment.
● You should prepare gaskets, bolts, nuts and washers（In accordance with the order）.

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 ● Ensure has no any stresses when the equipment will be installed.
● Tighten the bolts evenly, do not use a wrench; According to the selected washer and bolt,
correctly select fastening torque ( see site management manual).
● After installation, check the blowdown bucket whether can be rotated freely.
● Check debris filter system whether has any external loss.
● You should pay attention to the open interface gear part, to prevent debris filter system is
damaged.
3.6.4 Control panel
The control panel has assembled and debugged in the factory, can see the electrical principle
diagram.
Installation location 0m
Weight 200kg
The preparations for installation
● Check installation position according to the drawing, ensure that the panel door can be fully
opened.
● Check whether it has been damaged in delivery, especially electrical equipment and primer
● Random processing packages
Installation:
● Mark the center line according to the base on existing foundation bolt hole.
● For anchor bolt drill. The borehole perpendicular to the control panel mounting surface. If a
drill failure, gravity hole location and spacing of primary holes must be two times of the original
hole depth.
● Insert the anchor bolt unit into the ground. Anchor bolt unit should be stress free into the
borehole.
● Uplift the fixed control panel on the base, make the installation holes on the base vertical
above the anchor bolt unit. Fix the control panel with nuts and gaskets.
● Bolt must be used torque wrench calibration (torque: 80 Nm). If bolt loose after has been
installed, must be re tightened to the bolt holes as specified torque.
● Check the control panel whether has been external damaged, especially the primer and
electrical equipment, to prevent mechanical damage and pollution.
3.7 Part installation and wiring
Before commissioning, all the components shall be timely together. According to the electric
drawing of control panel, Correctly connect the electrical equipment and the control panel with wire.
Please also note that the terminal box or on the motor wiring diagram, and manuals of suppliers etc.
3.7.1 D/P measuring system
● The needle valve is installed on the right connection pipe.
● Fix the differential pressure measurement system on the bracket of filter shell.
● Complete the connection between the differential pressure transmitter and control panel.

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3.7.2 Electric actuator of butterfly valve
● According to the electrical files and manufacturer's product specification (power supply
voltage and control), connect the actuator and control panel with wire.
● Adjust and check limit switch of actuator when you are debugging.
3.7.3 Electric reducer motor
● According to the electrical files and manufacturer's product specification, connect the
electric reducer motor of debris filter system and control panel with wire.
3.7.4 Control panel
● Connect all field cable terminal with the control panel according to the electrical files
● The thermal relay of reducer motor should be adjusted to the rated current (see the
nameplate).
3.8 Preserving method before debugging
If debris filter system has been installed, will not debug immediately, should take the following
save measures and check:

Warn：
If debris filter system need to be stored for more than half a year or not in accordance with our
proposal to save / maintenance, please contact HXDL services.

3.8.1 Debris filter system

Part Name Measurement / Inspection Period Remark

● Coating
● External damage
● Sign of decay
Debris filter system Once every 6 months
● Flange connection
● Whether the observe manhole has
been closed
● Coating
● External damage
● Tightness
Electric reducer motor Once every 2 months
● Cleanliness
● Operability and flexibility rotation
(use the hand wheel )

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3.8.2 D/P measuring system

Part Name Measurement / Inspection Period Remark

External damage and
D/P Transmitter Once every 2 months
measurement range

Measuring tube Fixed Once every 2 months

3.8.3 Valve

Part Name Measurement / Inspection Period Remark

● Coating
● External damage

Valve ● Sign of decay Once every 2 months

● Flexibility of valve when open
and close

3.8.4 Control panel

Part Name Measurement / Inspection Period Remark
● External damage
Actuator ● Coating Once every 2 months
● Cleanliness

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4 Debugging and running of debris filter system

4.1 General

Debris filter system using automatic operation mode. Differential pressure measuring system is

used for monitoring the debris on screen. If the pressure difference reaches setting value, the control

system will start to backwash and sewage.

4.1.1 Basic position

If you want debris filter system to enter fully automatic operation, you should be in "basic

position", defined as follows:

Parts / Components Status

Electric butterfly valve Close position

Cleaning system will leave the basic position in either of the following conditions

● D/P reaches to the setting value.

● The program "filter backwashing" will be started by the timer.

4.2 Running mode

4.2.1 Local automatic operation mode

In local automatic operation mode, all the motors and actuators are controlled by control

program, signal light on control panel will display the actual running state of the equipment.

4.2.2 Remote automatic operation mode

Remote automatic operation mode is the same as the local automatic mode. But it will be started

or stopped only in the DCS control room.

4.2.3 Local manual operation mode

All motor drive mechanism are respectively driven by the corresponding button, the operation

panel shows the actual running state of the equipment.

You should select manual operation mode in the following case

● Debugging

● When Local automatic/Remote automatic mode has fault

● Reset alarm value

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Note:

Under normal case, you should not operate the system into manual operation mode

In the automatic mode and the system is stop, when the pressure difference duration reaches a

preset value, the system will send out the alarm signal and automatically open the butterfly valve and

backwash.

4.3 Pre debugging setting and check

Conditions:

● All the parts have been installed.

● All the electrical connections have been completed, and check the running voltage and frequency,

see chapter 8 (electrical document)

4.3.1 Test and set of control panel

● Check actual running voltage

● Check thermal relay’s rated current of filter reducer motor according to chapter 8 electrical

document.

● Check the terminal connection

● Switch on all miniature circuit breaker , then the power supply will be switched on.

● Toggle on the CPU switch to the RUN position (green light - emitting diode display RUN mode:

STOP - display closed).

When control panel will be switched on, the power light is on, if it has no fault, you can operate it.

4.3.2 Function test in the anhydrous state

You should check the following part’s function before the cleaning system has water.

Condition:

Debris filter Press “bucket rotate” button, observe rotation situation of filter’s screen.

Valves Check whether the valves operation is smooth.

4.3.3 Actuator debugging

Keep “Manual/Automatic”, “Local/Remote” select switch on “Local”, “Manual” position, then

you can operate the equipment.

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4.3.3.1 Electric actuator of debris filter system

Setting the limit and torque of actuator (See actuator’s manual) .

4.4 System debugging

4.4.1 Water to the debris filter system

Check the following things before watering.

● Remove the larger impurities in cooling water system.

● Close drain valve and vent valve.

Water:

Water to the cooling water pipe，ensure that the debris filter system filled with water.

4.4.2 Debugging D/P measurement system

Condition:

● Cooling water flow meet the main data (see Chapter 1.1)

● Debris filter system is on basic position (see Chapter 4.1.1)

● D/P measurement system complete exhaust

D/P alarm value setting on the control panel

Manufacturer has set and check the D/P transmitter measurement range. D/P alarm value is

setting by PLC program.

4.4.3 D/P measuring system function test

Condition 1:

● Cooling water flow meet the main data (see Chapter 1.1)

● Debris filter system is on “Local”、“Automatic” position

Function test

● When the differential pressure alarm value is 0.1Bar, blowdown valve will be opened，then the

filter will be backwashing.

4.5 Operation of debris filter system

Debris filter system operation see control logic diagram

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5 Debris filter system maintenance
5.1 Maintenance inspection schedule: Check
5.1.1 Debris filter system

Parts Name Check Frequency Qualification Remark

● Cleanliness
Shell ● External damage Every year Skilled workers
● Sign of decay

Seal ● Tightness of flange Every year Skilled workers

● Activity:
screen backwashing
Actuator ● Coating Every week Skilled workers
● External damage
● Sign of decay
● Tightness between two
Bearing Every month Skilled workers
bearings
Switching and
● Operational Every year Skilled workers
signal device

5.1.2 D/P measuring system

Parts Name Check Frequency Qualification Remark

● Normal function
Whole D/P
● Cleanliness Every week Skilled workers
measuring system
● Tightness
● External damage
Instrument valve ● Sign of decay Every year Skilled workers
● Tightness of flange

5.1.3 Valves

Parts Name Check Frequency Qualification Remark

● Coating
● External damage
Valves ● Sign of decay Every year Skilled workers
● Flexibility rotation of actuator
●Tightness of flange connection

5.1.4 Control panel

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 Parts Name Check Frequency Qualification Remark
● External damage
● Cleanliness
Control panel Every month Skilled workers
● Terminal connection
● Control panel function test

5.2 Maintenance schedule: Lubrication

Lubrication
Parts Name Lubricant Quantity Frequency Qualification Remark
Points
Gear, rack Between gear #2Lithium Change every Skilled
500g
Of strainer and gear Grease 3 years workers
Change every Skilled
Reducer Reducer See manual See manual
6 months workers

5.3 Maintenance
Follow the following matters when you maintenance the equipment:
● Avoid ferrite materials or tools contact with stainless steel。
● Lightly grease on bolts and nuts before installation.
● Strictly according to the prescribed tightening torque, avoid damaging contact surface.
After maintenance, according to the manual and restart debris filter system.
5.3.1 Debris filter system

、 Warn:
1.You should cut off the power and ensure safety before you repair it,
2. You must close and lock the main cooling water flow before you repair the valves. The
cooling water inlet pipe and debris filter system must be flowed, in order to avoid the staff by
the impact of water flow, ensure personal safety.
3.After maintenance, according to the manual and restart debris filter system.

Change the seal ring and packing

Remove:
● Open the reducer coupling, remove the speed reducer and motor.
● Loosen the bolts on packing gland, remove the gland.
● Push shaft bushing of shaft from the inner cylinder, pushing leading flow, remove seal ring
and packing.
● Loosen the bolts on gland of guide shaft, remove the gland.
● Remove the gland sealing gasket
Installation:
The strainer is installed in reverse order to removal.

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5.3.2 Valve

Warn:
1.You should cut off the power and ensure safety before repair it,.
2.You must close and lock the main cooling water flow before you repair the valves.
3.After maintenance, according to the manual and restart debris filter system.

Please follow the steps below when you will replace or repair wear parts:
● Remove butterfly valve from pipeline and repair.
5.3.3 Actuator

Warn:
1.You should cut off the power and ensure safety before repair it,.
2.After maintenance, according to the manual and restart debris filter system.

Electric actuator’s maintenance see the attached instructions.

5.3.4 Control panel

Warn:
1.You should cut off the power and ensure safety before repair it,.
2.After maintenance, according to the manual and restart debris filter system.

The control panel has no any wearing parts. Please see the electrical files, if you want to repair
the electrical components.

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6 Debris filter system control instruction

Special attention: You must cut off the power when debris filter system is repairing.

6.1 Touch screen operation instruction

6.1.1 Boot interface：Select language to enter system operation interface

6.1.2 Equipment selection interface: Select equipment

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6.1.3 Equipment operation mode interface: Select operation mode

6.1.4 Manual operation interface: Local and manual operate

6.1.5 Automatic operation interface: Local and automatic operation

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6.1.6 Time setting interface: Set running time

6.1.7 D/P value setting interface: Set the D/P value

6.2 Touch screen monitor screen instruction

6.2.1 Fault view interface

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6.2.2 Equipment monitoring interface

6.2.3 Time monitoring interface

6.2.4 To DCS signal interface

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6.3 Buttons & lights instruction

6.3.1 The red light will be turned on when blowdown valve is on fully open position;

6.3.2 The green light will be turned on when blowdown valve is on fully close position;

The light will flash when the blowdown valve is opening or closing

6.3.3 The red light will be turned on when blowdown bucket is rotating

6.3.4 The red light will be turned on when select switch is on “DCS”、 “Auto”、“Work”position;

6.3.5 The red light will be turned on when the system is in the state of automatic operation;

6.3.6 The yellow light will flash when debris filter system has any fault.

6.3.7 If difference pressure achieves setting value（electric current achieves 12mA）, PLC will send

out signal and differential pressure alarm light will flash.

6.3.8 Auto/ Manual switch button:

The debirs filter system can be manually operated when the switch button is on “Manual”

position; The debirs filter system can be automatically operated when the switch button is on “Auto”

position.

6.3.9 Time / Work switch button:

You can set relevant system running time When the switch button is on “time” position; It would

be operated when the switch button is on “work” position.

6.3.10 Remote(DCS) /Local switch button:

You can operate the equipment in DCS when the switch button is on “DCS” position; You can

operate the equipment in local when the switch button is on “Local” position

6.4 Debris filter system operation instruction

6.4.1 Equipment manual operation

Conditions: If you want to manual operate, you should keep the select switch on “Local”、

“Manual”、“DCS”status.

6.4.2 Automatic operation of debris filter system

1）Local、Automatic operation

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 Condition: If blowdown valve is on fully closed position, ensure the select switch on “Local”、
“Auto” status, and press “start-up” button, then it will perform the steps according to the control
logic diagram.

Order Name of parts Performance request

1 PLC The system performs the automatic control program

1.The blowdown valve begins to open, when the valve is fully
opened position, system timing 10 minutes.
2 Blowdown valve 2.The blowdown valve begins to close after 10 minutes, when
the valve is fully closed position, system timing 30 minutes.
3.System will repeat above control program 30 minutes later.
1.When the blowdown valve is fully opened position, system
timing 1 minute, then the blowdown bucket (backwashing
rotor channels) begins to rotate.
3 Blowdown bucket 2.The blowdown bucket will stop rotating when it touches
proximity switch.
3.Then system will repeat above control program, and it will
stop 10 minutes later.
Note: Specific details see the debris filter control logic diagram.
2) DCS automatic operation
Condition: If blowdown valve is on fully closed position, ensure the select switch on “DCS”、
“Auto” 、“Work” status, and press “start-up” button in DCS, then it will perform the automatic
control program.
6.5 Equipment operation instruction
6.5.1 Time control：The debris filter’s automatic operation according to the setting time，details see
control diagram.
6.5.2 D/P control: The filter will backwash and sewage when D/P reaches to the setting value, and it
will perform automatic control program by setting time until D/P is less than the setting value.
Details see control diagram.

6.6 Feedback signal to DCS

Condition: Keep select switch on “DCS”、“Auto”、“Work” status，and start-up it in DCS.
1）PLC will send out remote control signal to DCS.
2）PLC will send out running signal to DCS.
3）When it reaches to the setting value, PLC will send out D/P alarm signal to DCS.
4）When the debris filter has any fault, PLC will send out fault alarm signal to DCS.

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7 DEBRIS FILTER SYSTEM CORRELATIVE DRAWING

7.1 WNBD-2200-00-BHIKKI DEBRIS FILTER GENERAL DRAWING

7.2 WNBD -2200-DK01-BHIKKI FIRST ELECTRIC PRINCIPLE WIRING DRAWING

7.3 WNBD -2200-DK02-BHIKKI PLC WIRING DRAWING

7.4 WNBD -2200-DK03-BHIKKI TERMINAL BLOCKS WIRING DRAWING

7.5 WNBD -2200-DK04-BHIKKI CONTROL PANEL OUTSIDE DRAWING

7.6 WNBD -2200-DK05-BHIKKI CONTROL LOGIC DRAWING

7.7 WNBD -2200-DK06-BHIKKI PLC I/O LIST

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8 Sub Supplier manual (offer single)

9 Packing list (offer single)

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