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    FILTRO CC-6-1

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    30 views151 pages

    Filtro CC-6-1

    Uploaded by

    Lenin Misari

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    © All Rights Reserved
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    INSTALLATION CERAMEC® CC-6-01 ’ AND MAINTENANCE MANUAL TEXT PART outokumpu mintec OPERATION: Q VVVVUVUVUVVTUVIVI DIT 2 outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 TABLE OF CONTENTS 1. GENERAL ... 1.1. CERAMEC? filter. 1.2. Liabilities ... 1.3. Using this manual.. 2. PROCESS DESCRIPTION ... 2.1. Principal of operation... 2.2. Cake handling ... 2.2.1. Cake forming 2.2.2. Cake drying . 2.2.3. Cake discharge 2.3.4. Backwash 2.3. Plate cleaning 2.3.1. Ultrasonic washing .. 2.3.2, Acid washing... 2.3.3. Combined washin; 2.4. Types of control... 2.4.1. Automatic control. 2.4.2. Manual control 3. TECHNICAL DESCRIPTION . 3.1. Technical specification of components. 3.1.1, Labels. 3.1.2. Frame and slurry basin 3.1.3. Agitator. 3.1.4. Drum. 3.1.5. Scrapers 3.1.6. Piping 3.1.7. Ultrasonics 3.1.8. Electrical equipment 3.1.9. Instrumentation 3.1.10. Cake washing equipmé 3.2. Auxiliary services . 3.2.1. Electrical powe 3.2.2. Compressed air 3.2.3. Water 3.2.4. Acid .. 2 outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 3.3. Operating conditions..... 3.4. Process diagram. 3.5. Functional sequence diagrams .. 4, INSTRUCTIONS FOR INSTALLATION... 4.1. Space and foundation requirements 4.2. Unpacking .. 4.3. Connections 4.4, Instructions for assembly check. 4.5. Test-run instructions . 5. OPERATION INSTRUCTIONS... 5.1, How to start up. 3.3.1. Slurry .. 3.3.2. Process water 3.3.3. Tap water... 3.3.4, Instrument air 3.3.5. Electrical supply -18 3.3.6. Ambient conditions. -18 3.3.7. Foundations -18 3.3.8, Plate storing -18 3.3.9. Seismic conditions -18 3.5.1. Main sequence 3.5.2. Starting sequence. 3.5.3. Sluy-automatic run. 3.5.4, Plate cleaning sequence. 3.5.5. Normal stopping sequence 3.5.6. Emergency stopping sequence 4.4.1, Frame / Basin. 4.4.2. Agitator 4.4.3. Drum... 4.4.4, Distribution valve . 4.4.5, Pressure pipes. 4.46, Filtrate tank 4.4.7. Membrane expansion vessel 4.4.8. Pumps . 4.49, Scrapers 4.4.10. Ultrasonic vibrators 4.4.11. Electrification and Instrumentatior 4.5.1. Before starting the filter. 4.5.2. During the test-run .... 5.1.1. Checks and adjustments before start-up 5.1.2. Start-up with MANUAL-AUTO switc! 5.1.3. Start-up after a long break.. outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 5.2. How to stop... 5.2.1. Temporary stop with PAUSE ON/OFF switch... 5.2.2. Normal stop with MANUAL-AUTO switch.. 5.2.3. Stopping for a short maintenance. 5.2.4. Stopping for a long period. 5.3. How to make acid and ultrasonic washin; 5.3.1. How to start washing. How to pre-set type and timing of washing How to interrupt washing .... If emergency stop interrupts the acid washin; How to adjust the acid feed. 53.6. How to start up and prime the acid pum 5.4. Checks and adjustments during normal run. . Slurry level . . Plates | Speed of drum and agitator. . Vacuum... . Backwash pressure during the normal run . 5.4.6. Backwash tapwater pressure during start-up and washing... : 5.5. Control panel hand switches and indicator lamps .. 5.5.1. MANUAL-AUTO switch .. 5.5.2. PAUSE ON/OFF switch... 5.5.3. AUTOMATIC WASH START/STOP switch.. 5.5.4. ALARM RESET switch 5.5.5. MAINTENANCE switch 5.5.6. Panel indicator lamps 5.6. Using Operator Interface Unit O1U 5.6.1. Status and alarm displays 5.6.2. Using OIU function keys. 5.6.3. Adjusting display brightness and setting the clock 5.6.4. List of functions without password .... 5.6.5. List of functions with password-check .. 5.6.6. List of alarms with alarm codes... 5.6.7. Safety interlockings .. 5.6.8. OIU status display: 5.6.9. OIU alarm displays 5.7. PLC program back-up arrangements . vee 6. MAINTENANCE INSTRUCTIONS .. 6.1. Instructions for changing a ceramic filter plat 6.1.1. Removing a broken plate .... 6.1.2. Mounting a new plate ... SEES TEELEEELELELEECELECEELEEELEEEEGEUES outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 6.2. Instructions for scrapers 6.2.1. Mounting scraper arms 6.2.2. Adjusting scrapers 6.2.3. Changing scrapers..... 6.3. Distribution valve 6.3.1. Design and operation 6.3.2. Oneration ranges .. 6.3.2.1. Temperature... 6.3.2.2. Pressure 6.3.3. Mounting. 6.3.3.1. Piping, 6.3.4. Maintenance . 6.3.4.1. Lubrication. 6.3.4.2. Changing a lip seal and a wear plate. 6.3.4.3. Disassembly. 6.3.4.4. Assembly... 6.3.5. Adjustment... 6.3.5.1. Surface pressure adjustment 6.3.5.2. Process adjustment 6.4. Timing of backwash.......... vee 6.5. Membrane expansion tank. 6.5.1 Operation .. 6.5.2. Troubleshooting .. 6.5.3. Unproper air pressure adjusting 6.6. Service instructions... 6.7. Lubrication instruction: 6.7.1 Lubrication and grease schedule. 6.7.2 Oil changes... 6.8. Electrical equipment. 6.9. Spare parts. 6.10, Troubleshooting eee eee eee eee nO ON EE KO > outokumpu mintec March 25, 1996 APPENDICES Appendix 1 Drawings ALL. Main assembly A1.2. Guards and nameplates AL3. Agitator A14. Drum and distribution valve 1.5. Scrapers A16. Piping A1.7, Ultrasonics AL8. Electrification A1.9. Instrumentation Appendix 2 Component manuals A2.1, Drum Drive ‘A2.2. Agitator Drive A2.3. Filtrate Pump A2.4, Vacuum Pump A2.S. Acid Pump A26. Inverters A2.7. Level Monitor A2.8, Pneumatic Actuators A2.9. Hose Pinch Valve A2.10. Butterfly Valve A2.11. Ball Valve A2.12. Pressure Regulating Valve A2.13. Pressure Relief Valve A2.14, Ultrasonic Equipment Appendix 3 Test Reports ‘3.1. Assembly Inspection Report A3.2. Test-Run Report Chapter 1 GENERAL OD outokumpu mintec a -_ mann nn hin in inn bh ia hi hihihihhiihih eaeaean5u5un54ag54uauexn g4@a34ua5) sumed xg sorrares * Deus fo, 400 No, 58 AW WASH MATER IN > I iS ome CAIVE, YaLNe Nee Ta i Bt 2) tae ware . ELECTRICAL CONNECTION | Gass wore EQUCTION YRLVE FILTRATE PUMP MUST BE LOCATED MIN 3s BELOW THE FILTER 1 LEVEL CONROL DISTRIBUTION VALVE cto PUMP, es 723 BACKWASH LINE Tec 718 VACUUM LINE VALVE Nes 76 FILTRATE TaN No. 7.28 2 eneTRATE TANK EMPTYING feadcess) FILTRATE TANE EHPTYINS (waste) Ce comearose Figure 2.1 General arrangement 2-1 2 outokumpu mintec CERAMEC® CC-6-01— Mareh25, 1996 sc is submerged in the slurry and vacuum is applied to the plates. The pressure difference a cake to develop, the cake is then dried and finally scraped off. FILTAATE OUT. FILIRAT? OUT vecuu FILTAATE rei g ; PERS ACKWASH SECTOR warer IN MACHINE WASHING Figure 2.2 Process diagram The pressure difference between the atmosphere and the vacuum inside the plates is the driving ‘orce for filtration. In the basin an even cake is formed on the plates, the cake is then dried by the pressure difference. No air penetrates the filter material. After drying the cake is scraped The filter plate is then back washed for a few seconds before the next cycle. 2.2. Cake handling ¢ CERAMEC® filter operation is based on four phases: cake forming, cake drying, cake harging, and backflush washing. ®) outokumpu mintec CERAMEC® CC-6-01 Marsh 25,1996 2.2.1, Cake forming +s the microporous discs rotate through suc. capillary action begins immediately extemal force. A vacuum pump a nearly absolute vacuum, which liquid through the discs into the fil- lines. Solids build up rapidly on the of the discs, with both solids and air hited from penetrating the disc surface o its microporous structure. Figure 2.3 Cake forming 2.2.2. Cake drying discs continue to rotate, capillary ac- ntinues uninterrupted across the of the discs until all free liquid is moved from the solids. The result is an exceptionally dry cake at a fraction of the required by conventional filtration Figure 2.4 Cake drying 2-3 ) outokumpu mintec CERAMEC® CC-6-01 March 25,1996 2.2.3. Cake discharge Scrapers remove the cake from the discs, a thin layer (heel) of solids on the surface. This coating acts as protection ainst mechanical abrasion, reducing main- ance requirements and extending disc life. Figure 2.5 Cake discharge 2.2.4, Backwash During this stage, filtrate is used to flush the discs, removing residual cake and cleaning the discs’ microporous structure. This back- 0 flow washing maintains the discs' exceptional filtration efficiency and ensures a long and trouble-free life. The backflow washing system feeds a small portion of filtrate back into the filter plates immediately after the scrapers, this happens every revolution. The pressure is automatically controlled. Figure 2.6 Backflow washing > outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 2.3. Plate cleaning 23.1. Ultrasonic washing RAMEC® filters design features an matic ultrasonic disc cleaner that rains plates at the highest level of ing efficiency. The ultrasonic cleaning em is used on a periodic basis in ination with chemical cleaning. The mic transducers are interlocked with level in the basin,’ which means that can not be started if water level is not 2 enough to cover the transducers. 2.3.2. Acid washing Is addition to backwash and ultrasonic ning, chemical cleaning with acid is used maintain the highest level of operational ciency of the plates, Selected chemicals may be used, depending on application re- ments, but nitric acid is recommended routine use. Figure 2.7 Ultrasonic washing Figure 2.8 Acid washing 75 ) outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 2.3.3. Combined washing Is combined washing both ultrasonic and acid washes are simultaneously applied to the ce- ramic plates. This is the most effective wash cycle, and it is definitely recommended for normal esc, even if it is possible to select either one of the washing methods alone. After the wash cycle the filter will automatically return to the same state as before the wash was started. 2.4. Types of control 2.4.1. Automatic control The filter is normally run in automatic control, which means that all operations are PLC controlled. The following description refers to the fig. 2.1. - Start up sequence: The agitator (item no. 4.00) and the drum (5.00) starts. The vacuum (7.02) and the filtrate (7.01) pumps start. The slurry discharge valve closes (7.13). Tap water is fed to the back wash line (7.10). Slurry is fed to the filter basin (1). After a pre- set time backwash turns to use filtrate. ~ Operating: When the filter is operating normally, filtrate and vacuum pumps are running. Slurry level is controlled by the ultrasonic level control (10.01) and the feed valve. The filtrate level is controlled by the float switches in the filtrate tank (7.20) and the filtrate discharge valve (7.12). Note: The agitator and drum speed can be adjusted during automatic run with potentiometers on the operating panel. The agitator will be locked at a preset low speed, when basin level is below a certain locking level - Normal stop: When the filter is stopped the vacuum is released, the slurry is dumped from the filter basin that is also flushed with water (7.14), and the plates are back washed for a pre-set time before the complete stop. - Pause stop: When the filter must be stopped for only a short moment it is possible by the pause mode that leaves the slurry in the basin and the agitator running. - Washing: The filtering is stopped and the slurry is dumped from the filter basin, The filter is flushed (7.14) with water. Nitric acid (7.03) is fed to the backwash line (7.10) to make an approx. 1% solution and the bath is filled with water. The ultrasonics (8.01) are operated for a pre-set time, and when ready, the washing water is discharged through the drain valve. When the wash is completed, the filter restarts automatically. The whole -edure is completely automated. 2 outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 fety features: The filter can be stopped by external alarms from the customers’ system, as conveyor failure. When emergency stop button is pressed, the filter is stopped completely, and the power feed to the contactors is disconnected. The slurry is discharged from the slurry basin. Saf 2.4.2, Manual control Manual control (star/stop motors, open/close valves) can be done using functions from the erating panel. O outokumpu mintec Chapter 3 TECHNICAL DESCRIPTION . . > ° . , . , . > » . . . , , : , , , 7 , , 7 , , , , , J , , , , , : j ) J } O outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 3. TECHNICAL DESCRIPTION 3.1, Technical specification of components Table 3-1 Technical data of CERAMEC® CC-6-filter FILTER AREA 6m NUMBER OF PLATES 24 pes LENGTH 2700 mm HEIGHT 3050 mm EMPTY WEIGHT 4000 kg VOLUMES: SLURRY BASIN 17m FILTRATE TANK 0.16 m* | MATERIALS: | FRAME MILD STEEL SLURRY BASIN AISI316 AGITATOR AISI 316 and MILD STEEL DRUM cylinder AISI 316 flanges AISI316 piping AISI316 SCRAPERS scraper blade CERAMIC arm. AISI 304 PIPING AIST 316 filtrate tank AISI 316 ULTRASONIC transducer AISI 316 2 outokumpu mintec CERAMEC? CC-6-01 — Maren2s, 1996 3.1.1. Labels The machine label contains the following information: - manufacturer a Bee ad ee Qoutckumpu mintec | - year of manufacture eT ee en emtona = gross weight - no. of main assembly drawing CC-6-81 | 8-4081-81 1995 4388 kg Figure 3.1 Machine label 3.1.2. Frame and slurry basin Pe pot oO. r bY aol Goa WASHING PIPE qi _overrLow PIPE WASHING PIPE ure 3.2 Frame and slurry basin The slurry basin is made of AISI 316 stainless steel and is equipped with: - mild steel frame, epoxy coated - overflow pipe - basin washing pipes - drain pipe 32 2 outokumpu mintec CERAMEC® CC-6-01 March 25,1996 7 - service hatch - extra drain pipe - seismic reinforcement 3.1.3. Agitator BEARING INTERMEDIATE SHAFT © 3.3 Agitator tator is of a cradle type design, supported in both ends from the filter frame. It consists - cradle submerged part, AISI 316 stainless steel - cradle upper parts, mild steel, epoxy coated - cranks, mild steel, epoxy coated - drive type, gear with motor - ball bearings, prelubricated Option: central lubrication system 1D outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 3.1.4, Drum 4 LERAMIC PLATE ! ou | COurLiNS sean BEARING DISTRIBUTION Bi TRANSPORTATION SUPPORT Figure 3.4 Drum The drum consists of: - shaft, AISI 316 stainless steel - plate mounting flanges, AISI 316 stainless steel - support cones, AIS] 316 stainless steel - internal filtrate channels ‘tribution valve, consists of: - housing AISI 316 stainless steel - wear plate, carbon filled PTFE - wear face, ceramic coating - planetary worm gear with motor cing: - roller bearing, pre-lubricated ter plates, fastened with AISI 316 stainless steel bolts, are made of alumina based porous ceramic material, edges sealed with polyurethane. tions: - Coupling between motor and drive 3-4 FFFEEELEEEEEGEEEEEEEVELELUEUULEEEEEEESERETEEEEESTS QO outokumpu mintec CERAMEC? CC-6.01 — March25,1996 3.1.5, Scrapers cenwvic sone | 7 SCRAPER ARM CERAMIC PLATE re 3.5 Scrapers The scraper assembly is a rigid construction mounted on the frame. The scraper angle is table. The assembly consists of: - mounting beam, mild steel, epoxy coated - scraper arm, AISI 304 stainless steel - scraper blade, aluminium oxide, fixed in a AISI 316 stainless steel holder The scrapers are adjustable to leave a thin heel cake on the plates There is no mechanical contact between the scraper and the plates 3-5 >Qoutokumpu mintee —cuxanecece. JECT TTTTEUTELT TCP PP bbe cere burr ereubb nbn pep panne’ 01 March 25, 1996 3.1.6. Piping All piping is situated inside the frame except the filtrate pump assembly which in a min. 3 m, below. - all piping, AISI 316 stainless stee! - hose pinch valve for slurry feeding EMPTYING OF EXPANSION suynay seo vessel Valve BASIN WASHING Wave BASIN WASHING VALVE fi O I ese i WaSHING WATER : ~s | Trews WASHING _OF oma 9516 DRAIN VALYE FILTRATE IN Figure 3.6 Piping equipment 3-6 : QO outokumpu mintec CERAMEC? CC-6-01 March 25, 1996 PSST ELCECEECECCEPELEVDEVEULUUUUEUUUEUUUEUEteee eee eee - filtrate tank, AISI 316 stainless steel - flexible hoses between the distribution valve and the filtrate tank Figure 3.7 Filtrate tank - membrane expansion vessel Figure 3.8 Membrane expansion vessel 7 JEL EEE EEL ULEL UU UE EL ELE REESE SENN "10 outokumpu mintec CERAMEC® CC-6-01 March 25,1996 - cartridge type backwash filter - pressure reduction valve = relief valve, for backwash pressure PRESSURE RELIEF VALVE TO OISTRIBUTION VALVE PRESSURE REDUCTION VALVE FROM ACID PUMP TO/FROM EXPANSION VESSEL WATER FILTER To BASIN DIS: CHARGE VALVE 4 To vACUUM PUMP MACHINE WASHING. Figure 3.9 Pressure piping Pumps: Filtrate pump with motor, centrifugal type, AIST 304 stainless steel - coupling between motor and pump Figure 3.10 Filtrate pump coon ene IEE EEE IO outokumpu mintec CERAMEC? CC-6-01 March 25, 1996 ‘Vacuum pump with motor, liquid ring type, EP resin (glass fiber reinforced) FILTRATE TANK j {Se out WASTE LIQUID QUT WATER FROM PRESSURE PIPES Figure 3.11 Vacuum pump Acid pump, diaphragm type, PVC/PTFE, adjustable speed and stroke FOUR FUNCTION VALVE RETURN LINE BACKWASH LINE. ACID PUMP. SUCTION LINE Figure 3.12 Acid pump POPPE EEC TUL UL ULE EEL UUUUUUUUUUU ebb baba baad Q outokumpu mintec CERAMEC? CC-6-01 March 25, 1996 Options: - barometric leg for filtrate discharge - high pressure plate cleaning system - header tank for backwashing 3.1.7. Ultrasonics CONNECTION BOX VIBRATOR CASING PROTECTION GUARD Figure 3.13 Ultrasonic vibrators The ultrasonic transducers are situated between the discs. The transducers are double sided and mounted in AISI 316 stainless steel housings. 3-10 PEP PPE E EEUU UL UCL UU UUUUUUUUUUU bd 1) outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 3.1.8. Electrical equipment Main power is 440 V, 60 Hz, instrumentation feed is 24 V DC. The electrical control cabinets and other electrical equipment are installed in the basic framework. CONTROL PANEL | SERVICE PANEL INSTRUMENTATION CABLES 4 rm PNEUMATIC HOSES CABLE TUBING MAN CABI Figure 3.14 Electrification The main cabinets, protection class IP 65, include: - contactors - ultrasonic generators - frequency converter for the drum drive - frequency converter for the agitator drive The control panel, protection class IP 65, includes: - programmable PLC, GE FANUC Options: - PC with graphical control program - additional /O for client interface - air conditioning for main cabinets 3411 PRCT EP EEE PERE CRUE UUUULULUUUUUU bbb Q outokumpu mintec CERAMEC? CC-6-01 March 25, 1996 3.1.9. Instrumentation The instrumentation contains the following equipment: SOLENOID VALVE CABINET BASIN LEVEL CONTROL g209 E ML GAUGE PANEL WACUUM BUMP PROTECTION Ce RATE LEVEL CONTROL FILTRATE PUMP PROTECTION Figure 3.15 Instrumentation Solenoid valve cabinet, protection class IP65, includes: - solenoid valves - air pressure regulators - water separator WATER SEPARATOR AIR PRESSURE REGULATOR | SOLENOID VALVES VA_VE FOR NOENSATION WATER Figure 3.16 Solenoid valve cabinet 3-12 ID outokumpu mintec CERAMEC® CC-6-01 — March25,1996 Vacuum control - pressure switch Basin level control - ultrasonic, programmable Filtrate level control - float switches Filtrate pump protection = float switch Vacuum pump protection - float switch Slurry feed valve control Gauge panel, gauges for: ~ vacuum - filtrate pump / external feed pressure - pressure afer backwash filter - backwash pressure [Te RESIST Fla 9) | YRCULM CONTROL, lo __ REAR OF PANEL o| 40, BACK FLUSH LET TO 8A TO PLATES LUSH LINE a 5 4 f 37.BACK FLUSH d TER FILTER Figure 3.17 Gauge panel 3-13 PEP TTP E PERE DUPE PURER UEUUUUUUU ade eee eaeee -O outokumpu mintec (CERAMEC? CC-6-01 March 25, 1996 3.1.10. Cake washing equipment Options: ‘The equipment includes: - hood, glassfibre - piping, AISI 316 stainless steel - automatic valve - water filter - wash nozzles PPP PAT ETRE LD DLLUUUUL ULL URN UU ERO b Dada DED DOD seen eee eee eee tw! outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 3.2. Auxiliary services 3.2.1. Electrical power The filter requires power according to the following table. Table 3-2 The power requirements of the filter CERAMEC® CC-6 INSTALLED POWER kw ‘la AVERAGE OPERATING POWER kW 4 AGITATOR DRIVE | BAUER AG33-137 DK84-200L, 16.95 440V/60HZ/17451/1.1kW DRUM DRIVE, BONFIGLIOLI PL303+ MVF63+IEC80BS5, i= 1338 440V/60Hz/ 1800r/0.9kW_ FILTRATE PUMP KSB ETACHROM | N 25-160 (150) | 440V/60H2S | 35005/2.5kW VACUUM PUMP ‘SIHI LEMA 25 AZGALICO | 3400r/1. 1k ACID PUMP LMI C 731-26-L 120V/60Hz ULTRASONICS 6pes/0.9kW transducer 32x20-6/30 (Gener.1.2kW) OTHER EQUIPMENT 0.75kW PROGLOG.CONTR | GE FANUC 90-30 24, VDC control panel HORNER OIU 327 24 VDC PNEUMATICS. JOUCOMATIC (R1/4) 24 VDC LEVEL CONTROLS: basin MILLTRONICS PROBE yac.tank ELECTROMATIC FREQUENCY CONV. _| MITSUBISHI FR-AOM4 AUTOMATIC VALVES | AXEL LARSSON+WM-ACTUATOR FLANGES DIN 2501, THREAD DIN 2999 (SO 7) PINCH VALVES DURHOLDT FLANGES DIN 2501 DISTRIBUTION, AISI 316/CERAMIC/PTFE VALVE 3-15 PSF TELE CE LELELUELELUUULVUUULUULULEEE EEE EPP PPP PPP PD IO outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 3.2.2, Compressed air Instrument air is required for valve actuators 3.2.3, Water The vacuum pump requires water for operation. The filter uses extemal water only during washing. Process water can be used for cleaning the slurry basin. 3.2.4, Acid Nitric acid, HNO3 60% is used for the acid wash. =O outokumpu mintec 3-17 CERAMEC® CC-6-01 March 25, 1996 _ _ _ ll = 3.3. Operating conditions —_ —_ m 3.3.1 Slurry = Foreign particles screened for > 0.5 mm —_ Temperature 5...50 °C yy pH 1...12 -_ a The following compounds are not allowed: —_ - hydrofluoric acid - phosphoric acid a - hot alkalis - organic solvents 2 Sulphuric acid is not recommended. Chloride resistance on request. - 3.3.2. Process water Pressure 5...7 bar, for washing, required flow see following table o a 5 ‘Table 3-3 Connections 2 MAX FLOW PRESSURES Q(am's bar -) CONNECTIONS Gms) MAX. (MIN.) T_| SCURRY FEED FLANGE DNGORDS DINISOL — PNIO_ (TUBE 62") S 2_[ SCURRY OVERFLOW | TUBE ok8 912.603) DINE [3 [ SUURRY BASIN FLANGE DNIOO/1143 DIN2501 = EMPTYING PNIO_(TUBE of”) 3 | POTABLE WATERINLET | HOSE20 O72 backwash wih pouble wae) | 733) a | (HOSE CONNECTOR Ri"20) | 0.02 (o vacuum pur sed PROCESS WATERINUET | FLANGE DN25133.7 DIN2S01 TaD PNIO (TUBE 61") 2 7 | PROCESS WATER INEET | FLANGE DN2S/937 DINDSOL 73s PNIO_CTUBE gi") =o 97) ALTRATETaNE FLANGE DNGORED DINDEOT |__| ewervincrrocess | pio CruBE 6s") — ("9 [ wast water HOSE wo 10 FILTRATE INCE HOSED | (HOSE CONNECTOR RH"-20), 2 a RCRA oor TUBE 633,781,691") DINDA63 12 | RELIEF VALVE HOSE 20 — (HOSE CONNECTOR RH”-20) 13 | NSTROMENTATR ‘CONNECTION 6 bar TOIT (tantaeous consumpdon) 7) = L FEMALE Ri" 13 | ELECTRICAL “HOV, OF —_ CONNECTION 2 iz [Aci IN 16 | VACUUM PUMP LIQUID’ HOSE 20 —_ DRAIN (HOSE CONNECTOR R'4"-20) 17 | FILTRATE TANK FLANGE DNSOSS 9 DIN2S01 mL evervincwastuna | prio crusess") —_ —_ — = outokumpu mintec CERAMEC? CC-6-01 — Mareh 25, 1996 33.3. Tap water Pressure 3.5...7 bar, for the vacuum pump and acid wash see table 3-3 Max. solids 5 ppm Solids particles less than SO jum (microns) 3.3.4. Instrument air Pressure 5...7 bar, required flow see table 3-3 Max. particle size 40 jum (microns) Dew point - 35°C * Lubricated if necessary 3.3.5, Electrical supply 3 phase 440 V + 10% 60 Hz, single phase 120 V + 10% 60 Hz, 3.3.6. Ambient conditions ‘Temperature 5...50 °C Protect from freezing Protect electric cabinets from direct sunlight 3.3.7. Foundations Vibration free foundations. 3.3.8. Plate storing conditions Temperature 5...50 °C, protect from freezing Relative humidity < 80% 3.3.9. Seismic conditions Consult with the supplier. eee — — ™ . =O outokumpu mintec ceiaupct Ceci March 25, 1996 3.4. PROCESS DIAGRAM Process diagram of the CERAMEC” filter is seen in figure 3.17. Numbers in the diagram refer Table 3-4 , which lists the names of components Figure 3.18 Process diagram PELE E CEL ULULUU eee u cu Ue ba dbadaaaaa 3-19 outokumpu mintec CERAMEC? CC-6-01 March 25, 1996 Table 3-4 Names of the filter components No Component name Description 1 Control panel 2 Electric cabinets 3 Ultrasonic transducers 4 Agitator drive 5 Drum drive 6 Solenoid valves (3 bar, for slurry feed valve) 7 Solenoid valves (5 bar, for other valves) 8 Expansion tank 9 Air pressure regulator with water separator 10 Slurry feed valve Pinch valve DNSO 12 Air pressure regulator with water separator 15 Distribution valve 16 Lower vacuum line valve Ball valve R1” with pneumatic actuator 17 Upper vacuum line valve Ball valve R3/4” with pneumatic actuator 18 Vacuum control switch Pressostate 19 Pressure gauge, vacuum to plates. PSSA ELE T EL ELT URLULUUUU UU aaa 20 Basin drain valve Butterfly valve DN100 23 Low level control sensor, filtrate tank Float switch 24 ~~ High level control sensor, filtrate tank Float switch 3-20 POUR TA LUE CTU LULU UU UU UUM DDR DDD oe IO ouftokumpu mintec CERAMEC® CC-6-01 March 25, 1996 No 27 30 31 32 33 34 35 37 38 39 40 41 43 45 46 47 48 Component name Filtrate drain valve Filtrate Pump Vacuum pump inlet manual valve Vacuum pump sealing water, automatic valve Vacuum pump sealing water, manual valve Vacuum pump Backwash filtrate valve Pressure gauge, backwash after filter Backwash water filter Backwash pressure regulator Pressure gauge, backwash to plates Pressure gauge, expansion tank Basin drain valve flushing valve Maintenance control panel Filtrate tank Pressure gauge, backwash before filter Backwash pressure relief valve Connection hose for plate Filtrate drain throttling, manual valve Backwash tap water, check valve Basin wash water valve 3-21 Description Ball valve RI” with pneumatic actuator Centrifugal pump Ball valve R1” Solenoid valve R1/4” Needle valve R 1/4* Ball valve R1/2” with pneumatic actuator Ball valve R1/2” with pneumatic actuator Ball valve DN25 with V- opening Check valve R 1/2” Ball valve DN25 with pneumatic actuator j =O outokumpu mintec PPP EEE ETUC U UU UU RU UUUUUUUUUUU bab bbe aaa CERAMEC® CC-6-01 March 25, 1996 No. 61 74 76 77 78 79 80 81 82. 83 84 87 90 91 Component name Basin level sensor Backwash tap water valve Acid pump Level indicator Low level alarm sensor, filtrate tank High level alarm sensor, filtrate tank Upper vacuum line, manual valve Pressure gauge, upper vacuum line Expansion tank, manual drain valve Tap water inlet manual valve Filtrate pump inlet, manual valve Washing hose, manual valve Quick exhaust valve R 1/4” for slurry feed valve Filtrate tank drain valve Description Ultrasonic level sensor Ball valve R1/2” with pneumatic actuator Diaphragm pump Sight glass Float switch Float switch Adjusting valve R3/4” Ball valve R1/2” Ball valve R1/2” Butterfly valve DN80 Ball Valve R1/2” Butterfly valve DN80_ Por! PEEEC EERE CEE UUUUUUUUUU UU a bee aaa Q outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 3.5. FUNCTIONAL SEQUENCE DIAGRAMS 3.5.1. Main sequence Detailed function of the sequences are shown in the sequence diagrams. Please notify that the Pause Stopping and the Emergency Stopping sequences do not exist as real sequences. When needed the filter is "set" in the required state. je Fihure 3.19 Main Sequence, SEQ-1 3-23 PREECE EERE UU U ANU UNAAANN Ae Joutokumpu mintec —cenasecrce-sot March 25, 1996 3.5.2. Starting sequence, SEQ - 2 su onac0 er wo om won nexaer aeons Be BRB Se Se Shades whe Dower so-10 sio-t1 sea-t2 scouce sme fas sae exer F sane Sane ‘aac oP GED ST a 3 Canes amie oom a0 rn #008 Figure 3.20 Starting and Stopping Sequences The starting sequence for automatic run is started by tuning MAN AUTO switch to AUTO. The sequence consists of seven steps: 3-24 Fee eee eee NN ON NN a I outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 on DE TSI OFAN VANE ONTO. Hea | BSE TATE ORAN VE con as ane exces TLTAT ie Tee [a BoM: HP WATER VANE y [pee [ose ase sa ICUUM INE ASE (OER wcuun PaWP t eT [E wa Tae acu IRENE (PP FLAT PMP AFOO2 3. 21 Starting and stopping sequences pneumatically actuated valves will be tumed to starting position as follows: Table 3-5 Starting position of the pneumatic valves ‘0. Description On manual mode Atstarting sequence Basin drain valve Closed Closed - Filtrate drain valve Closed Closed Basin wash water valve Closed Closed lan a, outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 Basin drain valve flushing valve Closed Closed 7 Vacuum line valves Closed Closed Backwash filtrate valve Closed Closed ms Backwash tap water valve Closed Open Slurry feed valve Closed ‘Open Filtrate tank drain valve Closed Closed >= vacuum pump (34) and filtrate pump (30) will be started. Starting Sequence Step 2 and 3, SEQ-2 itator (4) will be started. If the agitator is not running within 3 seconds, the process interrupted and alarmed. See “Interruption sequence". 3-26 veeeereereer eee eS SSPE Seeeee eee eee ee SHEL HEHSSHBHEABAHE ») outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 Ss drum (5) will be started. If the drum motor is not running within 3 seconds, the process errupted and alarmed. See "Interruption sequence”. © arcs SS Figure 3.23 Starting Sequence Step 4, SEQ-2 minimum vacuum level set value (normally -0.7 bar) has not been reached within 120 the process will be interrupted and alarmed, See "Interruption sequence". ) / tokumpu mintec CERAMEC® CC-6-01 March 25, 1996 4 Oe [EUW ear aoe gro ae =e] saa ae ceed ise oe eo 24 Starting Sequence Step 5 and 6, SEQ-2 suum line valves (16, 17) will be opened. If vacuum after 10 seconds is less than the _ 2, the process will be interrupted and alarmed. See "Interruption sequence". feeding will be started and the automatic slurry level control will be engaged. ‘If the ‘el has not reached the upper set level within the set time, the process will be stopped ed. See "Pause stopping sequence”. AVAL utokumpu mintec CERAMEC® CC-6-01 March 25, 1996 “07 aD 3.25. Starting Sequence Step 7, SEQ-2 he filtrate level in the filtrate tank has reached the upper level switch, the backwash tap valve (74) will be closed and the backwash filtrate valve (35) will be opened. The sys- "5 now been set in automatic run and the starting sequence will end. $3. Slurry - automatic run asonic level controller controls slurry feeding. When the slurry level reaches the upper feeding valve (10) will be closed. The lower limit again opens the valve. If the filling basin from the lower limit to the upper limit takes more than the set time (10 - 30 2s), the process will be stopped and alarmed, See "Pause stopping sequence. ° uto! kumpu mi ntec CERAMEC® CC-6-01 March 25, 1 Float switches in the filtrate tank control the filtrate level. Upper and lower limits will op nd close the filtrate drain valve (27) accordingly. If the level reaches either the upper ower safety limit, the process will be stopped and alarmed. See "Pause stopping sequence”. If the vacuum becomes insufficient (i.e. less than the set value), the process will be stopy nd alarmed. See "Pause stopping sequence. = If a thermal relay trips, then filter operation will be stopped and alarmed (see "Pause stopp sequence"). In the cases that the agitator stops or if an emergency stop button is pushed, | process will be totally stopped and the slurry basin will be emptied. See "Emergency stopp quence". 3.26 Washing Sequences Basin emptying, SEQ-3 cn automatic wash has been started during automatic run, the slurry basin will be em srding to the basin emptying sequence in four steps: .utokumpu mintec CERAMEC? CC-6-01 March 28, 1996 ¥ 1 3 = | = 7 | AFQOS ® m2 he 2 3.27 Basin Emptying Sequence Step 1, SEQ-3 arty feeding valve (10) will be closed and the slurry level control system will be inter~ 5. Filtration will continue until the slurry level has reached the set low limit. If the sequence is tured off, slury feeding will be restarted and automatic run will con- the drum motor stops, the process will be stopped and alarmed; see "Main ce/Interlockings” and "Pause stopping sequence”. sutokumpu mintec CERAMEC? CC-6-01 March 25, 1996 .28 Basin Emptying Sequence Step 2, SEQ-3 : ultrasonic washing the basin must be filled with water so that the ultrasonic transducers totally submerged. The basin drain valve (20) will be closed and the basin wash water 60) will be opened until the upper water level has been reached. If the upper level has been reached with the set time (20 minutes), the process will be stopped and alarmed, ‘See "Pause stopping sequence”. eeevrvevrvrvrvrvreaisvseyverevwereses 8s sf rerlUmTlUm® outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 a aE 7 = eax 7 wae Fa oom (sae maar <8 o- ef wears 23.32. Ultrasonic Washing Sequence Step 2, SEQ-4 ultrasonic generator will be started for the set time (maximum 120 minutes). If the water ©) goes down below the probe limit, the basin wash water valve will be opened until the oper water level has been reached. e@geeecteceedceesesesegesFesseyr"r"ry"r”" ,* *~ outokumpu mintec CERAMEC? CC-6-01 March 25, 1996 5 STEP 2 STEP 2 Sh Sh Sh oO ® © r LS l T=20 OPEN BASIN DRAIN VALVE. Y Wy=60 CLOSE BASIN WASH WATER VALVE T V S04 ‘STOP ULTRASONIC WASHING SEQUENCE Y Fat Set ULTRASONIC WASHING READY AFO14 TD 33. Ultrasonic Washing Sequence Step 3, SEQ4 asin drain valve (20) will be opened and the ultrasonic washing sequence will end. 3-37 - a a * ” o a a 4 “ 2 - o “ . 2 o » ] . . ¢ . _ 2 . . > * . utokumpu mintec CERAMEC® CC-6-01 March 25, 1996 id washing sequence, SEQ-5 ORs NOV spa 34. Acid Washing Sequence Step 1, SEQ-5 ~ the slurry level in the basin has gone down under the low limit, the acid pump (76) will d for the set time (maximum 120 minutes). If running multi-wash, and the ultrasonic sequence (SEQ-4) is stopped because of low water level, the acid washing sequence so be stopped. (This is because transducers must be below water level during the ultra- wash.) 2.22 a@@ee#seer,,.,.,.,.,,.,r.,* * >utokumpu mintec CERAMEC? CC-6-01 March 25, 1996 wos? 3.35 Acid Washing Sequence Step 2, SEQ-5 { pamp (76) will be stopped. The backwash tap water valve (74) will stay open and zg and the plates will be flushed for the set time (15 minutes). 3-39 (2 outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 Step 2 Sh2 SHEP 3 Weve CLOSE. BACKWASH TAP WATER VALVE $£0-5 ‘STOP ACID WASHING SEQUENCE FLAG SET [ACID WASHING READY AFOIS Ei) 36 Acid Washing Sequence Step 3, SEQ-5 acid washing sequence ends. 3-40 $4#48406800080068680688932895 "56" " oskumpu mintec CERAMEC® CC-6-01 March 25, 1996 > Nushing sequence, SEQ-6 wots RY waar washing sequences are completed, the basin flushing sequence will begin. sare 3.37 Basin Flushing Sequence Step 1, SEQ-6 the water level in the basin has fallen below the set low limit, the basin wash water - "2 (60) will be opened and the agitator (4) will be started. 4 the basin not empty in the set time, the process will be stopped and alarmed. See suse stopping sequence” 3-41 C >utokumpu mintec CERAMEC® CC-6-01 March 25, 1996 a cP ag [ee ora ap 4015 3.38 Basin Flushing Sequence Step 2, SEQ-6 ‘hing of the basin will continue until the set time (5 minutes). that time, all the washing sequences are complete and the program will return to the ame mode as when the washing sequences began. 3-42, ARABRVTW_—~*+VAUOeeeeheht)aehkl ahaa a teataattha aa aaaage ) outokumpu mintec ee March 25, 1996 After the lower limit has been reached, the vacuum (34) and the filtrate (30) pump will be stopped, the filtrate level control will be interlocked, the vacuum line valves (16, 17) will be closed and the basin wash water valve (60) will be opened. Step2 mm Peed A023 a Figure 3.40 Automatic Stopping Sequence Step 2, SEQ-10 Flushing of the basin will continue for the set time (5 minutes). After that, the basin wash Water valve (60) and the backwash tap water valve (74) will be closed and the agitator (4) and the drum (5) will be stopped. The filter will stay in the stand-by mode. 3-44 PEPECUEE TEC TEE EERE U UEC U ECU Q outokumpu mintee —curanncece-so1 March 25, 1996 After the lower limit has been reached, the vacuum (34) and the filtrate (30) pump will be stopped, the filtrate level control will be interlocked, the vacuum line valves (16, 17) will be closed and the basin wash water valve (60) will be opened. Step 2 023 L Figure 3.40 Automatic Stopping Sequence Step 2, SEQ-10 Flushing of the basin will continue for the set time (5 minutes). After that, the basin wash water valve (60) and the backwash tap water valve (74) will be closed and the agitator (4) and the drum (5) will be stopped. The filter will stay in the stand-by mode. 3-44 ) outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 Pause stopping, SEQ-11 pause stopping sequence will stop all operations, except the agitator, which keeps run- 1 [sco — a Senora ——| Seem suet 3.41 Pause Stopping Sequence, SEQ-11 en the filter has to be shut down for a short time (for example, in order to change the =e: filter cartridge or a ceramic sector plate), the pause stopping sequence can be used. > alarm situation, the program will go into the pause stopping sequence, retum to the automatic run, the PAUSE ON/OFF switch must be turned. SSSELSELELELELAEECAEEEEEEEEHSESESEHSESSOeeeeeeeeee” 3.45 eeeseepeeeneeeeeegeegeeeeee eb aeeece eevee ee ECT CRC EEE ES \ , outokumpu mintec = ~~” CERAMEC® CC-6-01 March 25, 1996 ecruption, SEQ-20 “ruption sequence stops and closes the operations already begun during the starting ROM AUTOMATIC START SEQUENCE. 50-2 vase [Bro VAG Pune ——_—__ ro STP TRURCE Pu (vas a ASTATER REMC | eacenasi 1 LTR We Y Sara SrSTeW WAAL Wane, Y Ene \WIERRUPTON SELENE 4°027 0) 2 Interruption Sequence, SEQ-20 ram will move into the interruption sequence if the agitator motor (4) or the drum *) will not start within three seconds after the starting impulse during the automatic = S=quence (SEQ-2). The program will move into the interruption sequence if the pre- “sum vacuum level has not been reached within 120 seconds after starting the vacuum ). or if the vacuum level stays under the pre-set value for more than 10 seconds “somatic run outokumpu mintec CERAMEC? CC-6-01 March 25, 1996 3.5.6, Emergency stopping sequence SEQ - 12 ency stopping causes all the operations to stop and close, and the slurry basin to be d, * Aw» cum SP a T= BERT StF = rr must > BEADACY SP . wens woGine => NEN Sor aa he eo H 3 i i gi § : 4 T poo hae epee Ta ® 50 Gam) Figure 3.43 Emergency Stopping Sequence Step 1, SEQ-12 nn NV » _— utokumpu mintec CERAMEC® CC-6-01 March 25, 1996 SEP. Sh ® Y FAG RESET PAUSE ON FLAG. RESET WASHING RUN FAG RESET SYSTEM AUTOMATIC MODE END 5.44 Emergency Stopping Sequence Step 1 (continue), SEQ-12 =r has two emergency stop buttons; one is on the control panel and the other is on the ance panel tator stop during the automatic run, the process goes into emergency stopping i ee ee ee 3-48 2 outokumpu mintec Chapter 4 INSTRUCTIONS FOR INSTALLATION © outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 4. INSTRUCTIONS FOR INSTALLATION 4.1, Space and foundation requirements ‘The filter foundation are to be done according to figures 4, 1--4.3 150 280, WITH NORMAL SLURRY LEVEL LOAD INCLUDING SLURRY 172d 1, DENSITY 3.5 kg/l FILTER MASS 4202 kg TOTAL LOAD 121 480 N Fi= 35182N — F2 = 15608 N Figure 4.1 Foundation loads and tolerance 4-1 PELEEELELELLLVLLELULLUELELULDELUELLSE REDE DaDDED AIS SAADTDDS 1D outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 Figure 4.2 Free space reguirements © outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 cor OF os-cHUTED TaeiR CORE oF os-OUTE Fox gone oF Figure 4.3 Cake discharge sector a ee eee eee Se Se Se See Se utokumpu mintec CERAMEC® CC-6-01 March 25, 1996 Unpacking THE FILTER WEIGHT AND LIFTING ANGLES ARE SHOWN IN FIG. 4.4, MAKE SURE THAT THESE DEMANDS HAVE BEEN TAKEN INTO CONSID- ERATION WHEN THE FILTER IS LIFTED. 205 2678 345 Py FOR LIFTING LUGS we 250 | 41825) {5621 {ents L 3308 DIMENSIONS ARE INSIDE MEASURES OF THE CONTAINER, THE FILTER IS PACKED TO THE CONTAINER WITH THE LIFTING CIRCLE. Figure 4.4 Container Remove the filtrate pump from container Remove spare parts container (if supplied) Remove container Lift the filter to it's foundation / outokumpu mintec CERAMEC® CC-6-01 March 25, 1996 Fasten the filter to it's foundation according to fig. 4.5 390 ty 2705. ——_41____, bs j \ TITS oe 5 & a] | ee a ele} 2 [hea “a é cnn e00e oF TS-SHirT Tee FLLTAATE PUMP WS BC LOCATED MIN. 3 m GELOW THE FILTER ava 1828 i | 1972 Hb eh 5 fa Ia oA 7. | atti 1a Figure 4.5 Assembly dd dd ee ee oe 6. Install the filtrate pump according to fig. 4.5 ampu mintec CERAMEC® CC-6-01 March 25, 1996 nove the lifting frame LIFTING LUG 1420 2672 Vigure 4.6 Lifting frame Remove transportation support of the drum TRANSPORTATION SUPPORT 2 4.7 Transportation support of the drum 46 1iokumpu mintec CERAMEC® CC-6-01 Mareh 25, 1996 Connections vnnection numbers refer to the fig. 4.5, Assembly. Fasten the following connections able 4-1 Connections NRX FLOW PRESSES INNE Q (amis) bar col ‘CTIONS (3 mis) MAX. (MIN.) URRY FEES FLANGE NSO DINE PN10_(TUBE #2") TUBE 0852267) DINGS SICRRY BASIN FLANGE DNIDOIG3 DINESOT Serine NID (TUBE) “OTABLE WATERINEET | Hose 20 OF facioh wn paabiewand | FE5y OSE CONNECTOR Rs.20) | Ont vacuum sess PROCESS WATERINDET | FLANGE DNDSE37 DINGSTT Tas NO (TUBE a") ®ROCEIS WATER INLET" FLANGE DRED DINIDI TES PRO CURE ARATE TANE FLANGE DNBIHE DINGSOI svirrnareocess | PIO BE) "AS WATER HOSE SUTRATE INLET HOSED (HOSE ConvEcTOR RY 20 —SCIERTEOOTLT rose tt rhs or) Dini TEPVALVE HOSE) _ (HOSE CONNECTOR Ri.20, SSIRIMENTATE CONNECTION ar 107 Gaston goo) | TES EEMALE RI TIECTRICAL “OV, ke _coxwecrion Sc

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