OPERATION AND MAINTENANCE MANUAL FTP BL XS
Prepared by: Quality Dpto.
Approved by: Engineering & Quality Director MARTA OTEGUI
Ángel Blázquez Blázquez LANGUAGE:
INGLES
REVISION: REVI SION:
01
DATE:
28-02-2019
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
Revision: 01
Date: 28-02-2019
Page
2
INDEX 1
Description .............. ........................... ........................... ............................ ........................... ......................... ......................... ......................... ............................ .................. .. 4
2
Installation............ ......................... ......................... ......................... ............................ ............................ ......................... ......................... ......................... ..................... ......... 5 2.1 Unpacking the equipment ................................................................................................. 5 2.2 Handling and location ....................................................................................................... 6 2.3 Considerations before connecting the equipment............. ......................... ......................... ......................... ....................... ........... 7 2.4 Connections Connections............. ......................... ......................... .......................... ............................ ........................... ......................... .......................... .......................... ............... 8
3
Commissioning .............. ............................ ........................... ............................. ............................ ......................... .......................... ......................... ..................... ......... 9 3.1 Critical points and functioning ........................................................................................... 9 3.1.1 Hammer blow ............................................................................................................. 9 3.1.2 Excess operating pressure ......................................................................................... 9 3.1.3 Excess operating temperature.................................................................................... 9 3.2 Prior cleaning of the filter ................................................................................................ 10 3.2.1 Opening of cover ...................................................................................................... 10 3.2.2 Remove support tubes (only ( only the first time) time) ......................... ............ ......................... ......................... .......................... ............. 10 3.2.3 Remove the cartridges ............................................................................................. 10 3.2.4 Close the cover ........................................................................................................ 11 3.2.5 Cleaning the equipment............ .......................... ........................... ........................... ........................... .......................... ......................... ............ 11 3.3 Clarifying of wound cartridges ........................................................................................ 11 3.3.1 Open the cover ......................................................................................................... 11 3.3.2 Insert cartridges........................................................................................................ cartridges........................................................................................................ 11 3.3.3 Close the cover ........................................................................................................ 11 3.3.4 Clarifying of wound cartridges .................................................................................. 11 3.4 Filling and venting ........................................................................................................... 11
4
Maintenance ...................................................................................................................... 12 4.1 Filter body ....................................................................................................................... 12 4.2 Cartridges (filtering element) .......................................................................................... 12 4.3 Preparation of internal parts ........................................................................................... 13 4.4 Replacement of internal parts ......................................................................................... 13 4.4.1 Open the cover ......................................................................................................... 13 4.4.2 Extract cartridges ..................................................................................................... 14 4.4.3 Insert cartridges........................................................................................................ cartridges........................................................................................................ 15 4.4.4 Close the cover ........................................................................................................ 17
5
Do and don´t table ............................................................................................................. 19
6
Troubleshooting ............ ......................... .......................... ............................ ........................... ......................... ......................... ......................... ...................... ......... 20
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
Revision: 01
Date: 28-02-2019
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3
This manual contains the instructions for the installation, use and maintenance of cartridge filters. To obtain the performance described by the manufacturer in the equipment data sheets, all the instructions in this manual must be complied with and followed to work with safe and long-lasting equipment.
Our commitment to the environment environment Our interest in the total quality and maximum satisfaction of our customers, leads us to take into account certain ecological aspects when designing our products, in a market where the commitment to the environment is increasing. For this reason, our environmental management system is based on the UNE-EN-ISO 14001:2015 standard, avoiding emissions and discharges, minimising wastes and facilitating recycling. The management system for the search of Total Quality through efficiency and continuous improvement is based on the UNE-EN-ISO 9001: 2015 standard, this being the way to achieve it. Our goal is to give the customer the satisfaction of having a service / product that complies with its legal requirements and applicable regulations, within the agreed deadline and at the lowest possible cost. Both used filter cartridges and seals that have already been used and must be disposed of must be placed in an inert waste container. container.
Equipment naming description Example: 70 FTP – 4 / 40” BL 40” BL XS PN10 Where:
70. 70. - Number of cartridges or filtering elements in the filter. FTP. – Polyester filter. filter. 4. - Length of cartridges in multiples of 250 mm. / 40”. t he cartridges are in inches, blank if in millimetres. 40”. - Extension if the BL XS XS.. - Tipo de filtro. PN10. - Filter design pressure. 10 bar bar is is common common to all models.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
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Date: 28-02-2019
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1 De Descri tion
This a filter degree. in the FTP family, designed and made to filter fluids with solid particles greater thanproduct a givenisfiltration
The liquid enters the equipmen equipmentt through the inlet flange to the unfiltered water chamber and then passes through the filter cartridges where the solid particles are retained. The filtered product passes through the cartridge core to the filtered liquid chamber and exits through the outlet flange. Physically, the filters consist of three elements, as shown in the following diagra diagram. m.
Upper lid
Filter
Body
Cartridges
Lower lid
Note: to identify the materials and other technical details, see the client’s drawing.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
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Date: 28-02-2019
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2 Installation COMMISSIONING
LOCATION
MAINTENANCE
• Unpa Unpack ck and and prepare the filter.
• Critic Critical al points points and functioning.
• Stop Stop th the e equipment.
• Install Install the the filter filter in it´s final location.
• Cleani Cleaning ng of the filters. filters.
• Isol Isolate ate the the equipment.
• Con Connec nectio tions. ns. • Filters Filters with double flange.
• Install the intern internal al elements and cadtriges in the filter. • Carry out a previous previous flusing when using wounded cartridges.
• Extrac Extrac the the internal internal parts. • Repl Replac ace e the internal parts. • St Star artt-up up..
Note: the filters are delivered suitably packed and in suitable packaging to facilitate their
unloading and movement. 2.1
Unpacking the equipment
The transport, handling, removal from packaging, erection and later assembly of the equipment must be carried out with GREAT CARE to avoid any type of damage. Fluytec accepts no liability for the incorrect handling of the equipment
Once the equipment is loaded for transport until its final location, its stability in the chosen position must be checked to prevent any unexpected movement movement or change of position. The packages containing the goods must be OPENED with EXTREME CARE. All the packages must be kept away from any exposure to harmful environmental condition conditionss and must not be exposed without protection to any external situation that is potentially dangerous to the goods. The goods must be stored in a dry place away from any bad weather such as rain, wind, snow, etc., protected from sunlight and insulated from the damp on the floor. The equipment must also be kept away from any source of heat, flame, etc. Welding work to the equipment itself or near to it is forbidden. Take care when removing the plastic from the cartridges to avoid leaving the cartridges on the floor (leave them on a clean surface until their installation) since they could absorb dirt from the location.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
2.2
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Handling and location
ALL LOADS MUST BE HANDLED WITH EXTREME CARE, due to the volume and weight of the equipment. They must be handled with a gantry crane or other equivalent mechanical device, always taking the recommended safety measures for persons and equipment. Careless handling of the goods involves a serious risk for persons and installations. Do not handle the goods without being certain that: The loads will be handled with a safe lifting system that can withstand the forces generated with a suitable safety margin.
The materials to be moved are anchored in a balanced way to prevent swinging or risks of hitting persons or things.
After the equipmen equipmentt is in its final location and before commissioning, it is good technical practice to make a final general inspection of it to check its proper condition before operation.
IMPORTANT: The lugs must not be used to move the equipment full of liquid since they are
not designed for this weight (the lid lugs are only for lifting the lid).
See manipulation images:
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
2.3
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Considerations before connecting the equipment
The equipment is supplied with the upper closing gasket removed and collected inside with a plastic protection to prevent deterioration before putting it into use. See images and place in their support.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
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Date: 28-02-2019
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2.4 Connections -
Inlet: may be on the lower or upper body of the equipment – see drawings. Its function is to
feed the equipment with unfiltered water. -
Outlet: may be on the lower or upper body of the equipment – see drawings. Its function is to
extract the product water from the equipment. -
Drainage: on the bottom of the equipment. Its function is to drain the equipment completely.
-
Vent: on the top of the equipment. Its function is to allow air to exit and enter the equipment.
-
Safety valve: on the top t op of the equipment (at the client’s request, this connection is the same
as that of the vent). Its I ts function is to relieve over-pressure in the equipment.
Note: it is recommended that the installation does not transmit forces to the connections; if
these exist, they must be reported to the design department for their calculation. Note: Extraordinary circumstances (operating conditions outside the design, incorrect
maintenance operations, …), can lead to the appearance of solids downstream of the cartridge filters. order to avoid any damage to the downstream equipme equipment, nt, the installation of a coarse filter is In recommended.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
3 3.1 3.1.1
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Commissioning Critical points and functioning Hammer blow
A hammer blow is an over-pressure in the installation due to the immediate closure of a valve, which generates a violent and instantaneous thrust of the fluid still in movement. This effect can break pipes or components in the equipment. To prevent this, it is necessary to ensure that the inlet/outlet flow in the filter varies slowly. It is recommended that slow opening and closing values and/or static starters or frequency shifters be used in the feed pumps. If manual valves are used, the operators must take special care when operating them, especially with butterfly valves or lever-operated ball valves since the flow variation takes place rapidly with a small opening percentage. 3.1.2
Excess operating pressure
Excess pressure (above the design value) can break or permanently deform the equipment. It is necessary to install safety valves or rupture discs rated at the equipment’s nominal pressure to avoid this. In addition, as further protection, it is recommended that pressure switches or pressure alarms be installed that stop the operation of the system if the maximum forecast operating pressure is exceeded. 3.1.3
Excess operating temperature Excess temperature degrades the mechanical properties of the plastic materials. IMPORTANT: The typical design parameters of the equipment are shown in the IMPORTANT: The properties plate carried on all equipment.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
3.2
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Prior cleaning of the filter
The filter must be clarified to clean it of dirt accumulated during transport. transport. 3.2.1
Opening of cover
Open the cover to give the filter a prior cleaning – see maintenance maintenance sections 4.3 and 4.4.1. 3.2.2
Remove support tubes (only the first time)
Since this is the first time the equipment is opened, temporary support tubes must be removed before removing the tightening plate, as shown in the following diagrams: IMPORTANT: This step is only carried out if the equipment is delivered without the
cartridges placed.
3.2.3
Remove the cartridges
FTP BL filters are usually dispatched with cartridges and internals already installed. To avoid dirtying the cartridges prematurely, these should be removed. See maintenance section 4.4.2. IMPORTANT: This step is only carried out if the equipment is delivered WITH the cartridges
placed.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
3.2.4
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Close the cover Close the cover before cleaning the equipment. See maintenance section 4.4.4.
3.2.5 Cleaning the equipment equipment Carry out an initial cleaning of the equipment. The resulting water flow may contain a high solids content and must be sent to the drain. Never feed a sensitive system (e.g., osmosis membranes) with the effluent generated during this phase. This clarifying must be carried out for some minutes until no dirt is seen in the outlet to the drain.
3.3
Clarifying of wound cartridges
If the cartridges are wound, they should be clarified for some minutes before being put into operation. In this case, install the equipment. equipment. 3.3.1
Open the cover
To install the equipment and fill with cartridges, open the cover. See maintenance sections 4.3 and 4.4.1. 3.3.2
Insert cartridges Follow the steps in maintenance maintenance section 4.4.3 to insert the cartridges.
3.3.3
Close the cover Before the rinse close the cover See maintenance sections 4.4.4.
3.3.4
Clarifying of wound cartridges
The water from this clarifying must be discharged to the drain. Foam may be generated, in which case the clarifying must last for long enough for the foam to disappear.
3.4
Filling and venting
Once the filter is completely full of water, start the installation in nominal operating conditions, completely purging (with the vent valve on top of the equipment) the air in the filter. If a vacuum occurs in the filter, it is essential to install an accessory that breaks the vacuum – e.g., double effect vents – that also act as an automatic air purge. We have to check for leaks and that the equipment functions correctly.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
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4.1
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Maintenance Filter body
These filter casings require no special or regular maintenance. However, we recommend that each time the cartridge is changed, a visual inspection be made of the recipient to check that all the parts are in perfect condition. It is possible that corrosion may appear in the closure bolts over time, or even on the legs if they have received impacts that have lifted the surface treatment. To prevent corrosion from appearing on the bolts, we recommend that anti-corrosion grease or oil be used. For the legs, if any signs of corrosion are seen, the affected area should be sandpapered sandpapered and a C-5M treatment applied locally.
4.2
Cartridges (filtering element)
When designing the installation, it is important to remember that a minimum free space is necessary from the main flange for replacing the cartridges. This distance is equal to the length of the cartridges plus a safety distance for handling the filtering element. This distance may vary depending on the replacement system used in the installation.
It is difficult to predict the service life of the filtering elements given that this varies according to the analytical parameters of the unfiltered water entering the equipment.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third parties without the written consent of Fluytec.
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Date: 28-02-2019
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The parameter that warns that the cartridges must be changed due to clogging is the differential pressure, a value show in the cartridge’s data sheet. The maximum differential pressure allowed in the equipment is 2 bar. For Fluytec cartridges, the recommended replacement value for the cartridges is 1.2 bar. For cartridge replacement instructions, instructions, see section 4.4, “Replacement of internal parts.” Note: as a safety measure during the movement of hanging loads, it is recommended that
nobody remains under them, to prevent accidents.
4.3
Preparation of internal parts
Follow these instructions for the proper replacement of internal parts (consumables and long-life components). -
Firstly: isolate the recipient by closing the inlet and outlet valves. To prevent accidents, it is recommended that the feed pump be stopped or, alternatively, ensure that the valves do not open during the operation – e.g., using valve lockouts.
-
Secondly: open the drainage and vent valves to empty the equipment.
Special care must be taken during all the processes to avoid losing small parts that are temporarily out of their normal working position, such as rings, nuts, gaskets and similar parts.
4.4 4.4.1
Replacement of internal parts Open the cover Step 1: remove the retaining ring for access to the upper lid.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
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Step 2: remove the upper lid. Aquí / here
Before
After
Step 3: remove the nuts from the plate, taking t aking special care not to lose them since they are small.
4.4.2 Extract cartridges Step 4: remove the tightening lid.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
Revision: 01
Date: 28-02-2019
Step 5: remove the springs.
Step 6: remove the lugs.
Step 7: remove the cartridges one by one, pulling them vertically.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
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4.4.3
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Insert cartridges Step 8: insert the cartridges in the lugs in the false bottom plate one by one (to facilitate the entry
of the lug into the cartridge, turn the cartridge supported on the lug so that the latter enters). It is very important to check that all the cartridges are aligned and at the same height, making a visual inspection before continuing with the next step.
Step 9: place the lug marked “Up” towards the exterior of the cartridge and the other part of the
lug in the form of a wire must be inserted into the cartridge elements for proper sealing.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
Operation and maintenance manual FTP BL XS O&M Manual FTP BOLTLESS
Revision: 01
Date: 28-02-2019
Step 10: insert each of the springs.
4.4.4 Close the cover Step 11: fit the fixing plate, aligning the holes in the plate with all the rods.
Step 12: fit all of the nuts to guarantee the sealing of the lugs.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
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Step 13: fit the upper lid.
Aquí / here
Before
After
Step 14: fit the retainer ring.
Step 15: with the filter closed, open its inlet, outlet and purge valves.
The valves should be opened/closed slowly (since these are normally manual ball valves, operations could be almost instantaneo instantaneous) us) to avoid hammer blows. When the pressure in the filter has stabilised, read the inlet and outlet pressure gauges – the difference between them is the load loss of the clean filter. Keep the filter in operation until the pressure difference between the pressure gauges and the increased pressure over the clean filter reaches that recommended recommended for changing the cartridges.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third thi rd parties without the written consent of Fluytec.
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Do and don´t table
DO
Transport and store
DON’T
Check the condition of the packaging and compliance with the instructions.
Do not roll the filter. Do not drag the filter.
Do not transport the equipment “General handling, transport, storage and preservation” preservation” procedure. when full.
Installation
Install in a totally flat and stable Do not install in a sloping or place. unstable place.
Do not install the internal parts Check the proper condition of the without checking them and starting internal parts. the commissioning of the equipment. Commissioning Carry out a washing before putting Do not commission without into operation. checking the start-up conditions (see section 3.2 and 3.3).
Do not use the equipment without water. Check regularly. Functioning
the
filter’s
pressure
Do not exceed the maximum working pressure.
Change the cartridges when the Do not exceed the maximum differential pressure is greater than working temperature. that given in the data sheet sheet - 1.2 bar bar (for Fluytec cartridges). Do not use highly concentrated chemical products that may damage the filter’s components.
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third parties without the written consent of Fluytec.
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Troubleshooting Problem
Filter breakage
Possible cause
Solution
Hammer blow
Avoid opening opening and closing valves valves quickly. Install Install static starters or frequency shifters on the feed pumps.
Excessive differential pressure
Install and check a differential pressure gauge (check the operating conditions).
Excessive relative pressure
Install safety elements: safety valve/rupture disc, pressure switch, pressure alarms, etc.
Insufficient closure
Apply the indicated indicated tightening torque (see section section 4.4.4).
Gasket damaged
Replace the gasket.
Cartridge clogged
Check the differential pressure; replace the cartridges at the indicated pressure.
Water leaks
Drop in filtered water flow
Solids passing through the filtering elements
Filtering elements incorrectly installed
Stop and open the filter as per the instructions. Visual check of the location of the cartridges and all internal parts.
Note: if Note: if the above problems cannot be solved, contact the Fluytec technical department. E-mail:
[email protected] Telephone: (+34) 94 467 61 50 50
The information herein is confidential and the property of Fluytec, SA and must be treated as such. It must not be disclosed in any way to third parties without the written consent of Fluytec.
