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FILTRES INTENSIV

Zone Ecopole Route de Sarrelouis 57320 BOUZONVILLE


Tel : 03 87 78 32 22 Fax : 03 87 57 96 97

















OPERATING
INSTRUCTIONS
for
INTENSIV-Sleeve Round Filter

Type Filter ITEM
IFJC 21/1-3 RBX S12 35 01, S14 02 01
IFJC 9/1-1 RX S12 18 01


Customer: POLYSIUS / 1513 ECFACOM
Order number: 32012535/610/GL
Supplied: FILTRES INTENSIV
Order number: 7158/13

OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 1
INDEX
1 Technical data 1
2 Safety regulations 4
2.1 Remark 4
2.2 General notices of danger 4
2.2.1 Industrial safety symbol 4
2.2.2 Attention reference 4
2.2.3 Explosion Protection 4
2.3 Industrial safety instructions 5
2.4 Additional safety instructions at inflammable dusts 7
2.4.1 General instructions 7
2.4.2 Dust explosion and fire protection 7
2.4.3 List condition (Division in zones) 9
2.4.4 Protective concept against explosion 10
3 Construction features 11
3.1 Types of construction 11
3.2 Designation key 12
3.3 General description 12
3.4 Constructive design 13
3.5 Constructive design, details 14
3.6 Filter function 15
3.7 Filter operation-filtration 16
3.8 Filter operation-cleaning 17
3.9 Filter sleeves 19
3.10 Filter support cages 21
3.11 Two-stage filter sleeve cleaning system 23
3.12 Switch valves for filter sleeve cleaning 24
3.12.1 Diaphragm valve 2-stage model: C41 and C51 24
3.12.2 Diaphragm valve 2-stage model: C50 and C80 26
3.13 Pilot valves for filter sleeve cleaning 28
3.14 Sealings 29
3.15 Inspection openings 29
4 Electrical equipment 30
4.1 Constructive design 30
4.2 Function 30
4.3 Electrical connections 32
5 Pneumatic equipment 33
5.1 Compressed air supply 33
5.2 Compressed air sets 35
5.3 Remarks 36
6 Filter sleeve differential pressure 37
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 2
7 Delivery 38
7.1 Delivery 38
7.2 Packing 38
7.3 Designation 39
7.4 Painting 39
8 Filter installation 40
8.1 Filter installation on platforms provided by the customer
or in buildings 40
9 Maintenance platform with railing 41
10 Putting into operation 42
10.1 General 42
10.2 Switch-in sequence of the filter aggregates 43
10.3 Operation 43
10.4 Putting out of operation 44
11 Maintenance 45
11.1 Rectifying Faults 46
12 Maintenance 49
12.1 Protective measures during maintenance work 49
12.2 Installation and removal of injector tubes 50
12.3 Installation and removal of the C-Injectors 51
12.4 Mounting and removal of filter supporting cages 52
12.5 Installation of the inlet nozzle 55
12.6 Removal of the inlet nozzle 55
12.7 Assembly of multipart supporting cages 56
12.8 Dismantling of multipart supporting cages 57
12.9 Filter sleeve removal 58
12.9.1 Installation of the filter sleeves 58
12.9.2 Removal of the filter sleeves 61
12.10 Replacement of valve covers, diaphragms and silencers 62
12.10.1 Diaphragm valve - model: C41 and C51 62
12.10.2 Diaphragm valve - model: C50 and C80 64
12.11 Overhauling the pilot valves 66
13 Spare parts and customer service 68
13.1 Stockkeeping of spare parts 68
13.2 Ordering of spare parts 68
13.3 Customer service 68
13.4 Addresses of customer service and spare parts 69
14 Separate documentation 70
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Safety regulations 4
2 Safety regulations
2.1 Remark
The safety regulations are a supplement to the Operating- and Maintenance Instructions of
the filter and great attention must be given to them. If the equipment is used for purposes
for which it is not intended, incorrectly operated and insufficient or poor maintenance is
carried out, then damage to the filter and injury to personnel may arise.
2.2 General notices of danger
2.2.1 Industrial safety symbol
This symbol is put in all important industrial safety instructions of
these operating instructions where there is the danger of life of
persons. Kindly pay attention to these instructions and comport
yourselves in these cases especially carefully. Kindly pass on all
industrial safety instructions also to other users. Besides the
instructions of these operating instructions the general safety- and
accident preventing prescriptions of your legislator have to be
considered.
2.2.2 Attention reference
Attention is stated at points in these operating instructions which
have to be paid attention to, in particular that the rules, prescriptions,
Attention references and the correct performance of the works will
be maintained and a damage and demolition of the installation and/
or of the accessories will be avoided.
2.2.3 Explosion Protection
Important notes on Explosion protection
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Safety regulations 5
2.3 Industrial safety instructions
- The operator must first have read the filter operating instructions and must also have
understood them before installation, operation, maintenance and repair of the filter is
carried out.
- The responsibility for the installation, operation, maintenance and repair of the filter should
be delegated to personnel who are competent to undertake this work. Under the safety
aspect no doubts regarding competences may arise.
- Before the installation of the filter takes place, any binding laws or regulations that are
applicable to the place of installation must be strictly adhered to.
- During the transportation and installation of the equipment the relevant accident preventing
requirements and the admissible carrying loads of transport means and hoists must be
strictly adhered to.
- The support structures which are provided for the filters must not be modified or used for
carrying any additional loads.
- The operator must take full responsibility for the strength and stability of any buildings or
structures which are used by the operator for the installation of the filters and ensure
that they comply with any relevant Local requirements and conditions.
- Before putting the filters into operation, the operator must ensure that they are being used
for the purpose for which they are intended.
- Before putting the filters into operation, the operator must ensure that any protection
devices, protection guards and interlocking of the equipment has been correctly carried
out.
- Protection of personnel at filter inspection- and operating doors must be provided by the
operator and must be in accordance with the relevant Local regulations.
- In case of bag round filters the accident preventing prescriptions for the safe access to
enclosed vessels have to be considered.
- During the operation of the filters the operator must continuously check-up the residual
dust content of the cleaned gases to ensure that it is in accordance with the Local
regulations.
- For the continual safe operation of the filters, the operator must ensure that the filters are
operated, maintained and repaired in accordance with the operating instructions.
- When the filters are working with dusts which are dangerous to health, the operator must
ensure that in particular any maintenance and repair work is carried out in accordance with
the Local safety and accident prevention regulations that apply for the type of dust
involved.
- When handling the dust that is collected in the filters, the operator must ensure that the
disposal of this dust is done in accordance with any Local regulations that apply for the
type of dust concerned.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Safety regulations 6
- When disposing of spare parts which have been in contact with the dust to be filtered, in
particular filter media, the operator has to take care that this will be done in accordance
with any Local regulations that apply for the type of dust concerned.
- When operating the filters the operator must ensure that no inflammable objects, such as
cigarettes, cigars, sparks or other inflammable materials, such as paper, cardboard, clean-
ing rags, plastics or other wastes can inflame the filter sleeves. Otherwise the filters have
to be equipped in addition by the operator with appropriate fire protection devices,
consulting, however, the fire protection experts.
- The filters, which are provided, are only to be used for the collection of dusts from the types
of gases which are stated in our contract specification "Technical Data". If the filters are
used on other dusts and gases, then the filters will fall outside our warranty terms, and the
operator must carry sole responsibility for risks resulting from this use. Filters of standard
execution must never be operated with combustible or explosive dusts and gases. For this
type of use the filters must be of special design and construction and fitted with special
explosion protecting devices.
- The electrical installation of the filters must only be done by qualified electricians.
- If the operator has any doubts regarding the installation, operation and maintenance of the
filters, then he must contact FILTRES INTENSIV regarding these matters and avail himself
of FILTRES INTENSIV services.
- The filters must be operated in accordance with the Local safety and accident prevention
regulations that apply for each specific application.
- The guarantee/warranty obligations of FILTRES INTENSIV are governed by the
order/contract. These will neither be increased or limited by these safety instructions.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Safety regulations 7
2.4 Additional safety instructions at inflammable dusts
2.4.1 General instructions
a) Inflammable dusts are:
-fire hazardous in quiescent condition
-explosion hazardous in whirled-up condition.
b) In case of inflammable dusts the filters have to be equipped with safety devices against
dust explosions. The electric devices are also included here.
2.4.2 Dust explosion and fire protection
The operator has to take care that no ignition sources from other areas could lead into the
filter
Examples for potential ignition sources are:
- Hot surfaces
- Flames and hot gasses
- Sparks and glowing nests
- Sparks generated mechanically
- Welding and cutting
- Spontaneous ignition
- Electrical recources
- static electricity
- Thunderbolt
People who work in areas where there is a risk of explosions should not be dangerously
charged. Through the respective conductive protective clothing and floors, charges can be
avoided.
- If there is danger of dust burnings the operator has to check-up whether the local condi-
tions will be sufficient for a necessary fire extinction (qualified staff, works fire station, local
fire station).
- For the design of explosion- and fire protection equipment for the filters special knowledge
will be necessary. These safety devices must therefore not be revised without having
official authority.
- If this protection equipment against dust explosions and dust fires will not or not completely
be ordered together with the filters with Messrs. FILTRES INTENSIV and be required for
delivery the operator has to take care for the completeness of this equipment.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Safety regulations 8
- Protection equipment against dust explosions and dust fires will be determined individually
basing on the relative prevailing dangers. In case of modifications in the functioning of the
filters, as e.g. due to changes at the pre-arranged units, modification of the dust type or
fineness of the dust, of the operating temperatures or other conditions, a check-up of the
protection devices by experts will become necessary.
- All questions regarding dust explosion and fire protection Messrs. FILTRES INTENSIV as
an expert enterprise can be consulted or the hereafter mentioned institutes:
FILTRES INTENSIV
Zone EcopoIe - Route de SarreIouis
57320 BOUZONVILLE
FRANCE
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Safety regulations 9
2.4.3 List condition (Division in zones)
The filter is in accordance with category 3 and can be used in areas with explosive dusts.
The following zone-concept for the filter was based on in accordance with EN 1127.
2 inside filter-Clean gas chamber Zone 22
3 outside the filter: Zone 22 (in the periphery of 1m)
Additional electrical or not electrical pieces of equipment must be suitable for the respective
zone.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Safety regulations 10
2.4.4 Protective concept against explosion
1 The stability of the filter is designed for a reduced explosion pressure in connection with
pressure relief at atmospheric pressure.
Flames and pressure waves caused by an explosion will be transmitted in connected pipe
lines and components and could cause severe damage there.
It must be insured that explosions in a filter do not lead to any secondary explosions with
impermissibly high pressures.
The filter unit is only to be used with suitable components in the
dirty gas or the clean gas line as well as in the discharge area..
If this is not done, the chance of deadly explosions can not be
excluded.
In the case of a fire or an explosion the filter, including all discharge
organs and topped dust transportation ways, fan, filter cleaning
system, etc. must be put out of operation immediately to avoid any
dust clouds and transfer of inflammable materials into adjacent
components. (Use signal e.g. by bursting sensor of the bursting disk
or response signal of the decoupling systems and/or by the fire
protection system for triggering)
Execution of the filter:
Pressure shock resistance [bar ]: 2,5
Explosion isolation clean-gas sided:
- To be provided by customer-the responsibility lies in the area of the manufacturer of the
complete plant
Explosion isolation dirty-gas sided:
- To be provided by customer-the responsibility lies in the area of the manufacturer of the
complete plant
Explosion isolation product discharge:
- To be provided by customer-the responsibility lies in the area of the manufacturer of the
complete plant
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 11
3 Construction features
The INTENSIV Sleeve Round Filters are filtering dust separators with a fully automatic
2-stage-injector cleaning system by means of compressed air impulses. They are used for
the dry recuperation of dusts from off-gases resp. from the outgoing air.
3.1 Types of construction
The following types of construction of the INTENSIV Sleeve Round Filters comply with the
required conditions of use:
Figure 1: Types of construction
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 12
3.2 Designation key
Figure 2: Designation key
3.3 General description
The INTENSIV Sleeve Round Filters are built in standard execution for normal applications.
They are, however, mainly and individually designed and manufactured for certain
conditions. These are special requirements with regard to:
- constructive design and execution
- higher operating pressures or vacuum
- special materials, such as special steel and aluminium
- special construction- and acceptance conditions.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 13
3.4 Constructive design
Figure 3: Constructive design of the INTENSIV-Sleeve-Round Filter
Designation
1 Dust gas chamber 12 Supporting cage
2 Clean gas chamber 13 Sleeve bottom
3 Dust coleection chamber 14 Inlet nozzle
4 Dust gas inlet 15 Injector row
5 Clean gas outlet 16 C - injector
6 Dust-/product outlet 17 Compressed air tank
7 Filter-housing 18 Diaphragm valve
8 Maintenance door 19 Valve box
9 Inspection valve 20 Differntial pressure gauge
10 Carrying claws 21 Compressed air set
11 Filtersleeve 22 Control unit
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 14
3.5 Constructive design, details
Figure 4: Constructive design of the INTENSIV-Sleeve-Round Filter Head
Designation
1 Dust gas chamber 14 Injector row
2 Filter housing 15 Valve tube
3 Filter sleeve 16 Compressed air tank
4 Supporting cage 17 O-ring
5 Intermediate ring 18 Diaphragm valve
6 Inlet nozzle 19 Control unit
7 Tension bar 20 Valve box
8 Bolt 21 Compressed air set
9 Special nut 22 Valve box
10 Sleeve bottom 23 Differential pressure gauge
11 Clean gas chamber 24 Connection pipe
12 Injector 25 Nipple
13 Injector-Fastening
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 15
3.6 Filter function
Figure 5: Filter function
The dust being in the raw gas will be separated at the surface of the filter sleeves and is
cleaned by the fully automatic filter cleaning system by short compressed air impulses.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 16
3.7 Filter operation-filtration
Figure 6: Filtration phase
Designation
1 Dust gas chamber
3 Filter sleeve
11 Clean gas chamber
4 Filter supporting cage
The dust loaden gases flow from the exterior to the interior through the filter sleeves (3), and
the dust is deposited uniformly onto the outside of the filter sleeves (3), and the thus cleaned
gases leave as cleaned gas the filter via the clean gas chamber (11) and the clean gas duct.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 17
Figure 7: Filter sleeve section (filtration phase)
Due to the pressure difference between filter sleeve outside and inner side the
filter sleeve (3) is drawn onto the supporting cage (4) in the shape of a star.
3.8 Filter operation-cleaning
Figure 8: Cleaning phase
Designation
3 Filter sleeve 15 Valve tube
4 Supporting cage 16 Compressed air tank
6 Inlet nozzle 18 Diaphragm valve
12 C-injector 19 Control unit
14 Injector row 20 Valve box
A Compressed air B Network
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 18
The sleeve-round filters are equipped with a fully automatically operated filter sleeve
cleaning system. The cleaning of the filter sleeves is effected by pulses of compressed air
or other pressure gases together with secondary air by means of a 2-stage injector system.
During this process the cleaning air flow is blown via the inlet nozzle (6) into the filter sleeves
(3) causing a sudden reversal of pressure opposite to that of the filtration flow in the cleaning
air flow.
Figure 9: Filter sleeve section (cleaning phase)
Due to this sudden change in pressure, the filter sleeve which took up the shape of a star
around its support cage is suddenly inflated into a circle and the reverse flow of cleaning air
blows the dust off the outer surface of the filter sleeves which falls into the dust collection
hopper.
The operation of the filter sleeve cleaning has to be supervised by
regular checkings!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 19
3.9 Filter sleeves
Figure 10: Filter sleeve
The filter sleevces are designated by the following data:
- nominal diameter "D"
- nominal length "L"
- type of material
- other (e.g. special details regarding manufacture - due to the individual manufacture
necessary for each type of material the stated dimensions of the filter sleeves may not be
absolutely identical to the finished sizes.)
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 20
The filter sleeve material quality is of decisive importance to the function of the filter and is
selected according to each individual application.
The ruling factors are:
-Type of dust, dirty gas composition and grain distribution in the raw gas flow.
- Plant- or process technique of the plant to be dedusted.
- Required residual dust values in the clean gas.
The following may be detrimental to the function of the sleeve-round filter:
- incorrect selection of the filter material
- incorrect or inexpert manufacture
- poor storage facilities
- damage due to inexpert storage or installation.
When using other filter sleeves which do not correspond to the FILTRES INTENSIV original
execution there is the risk of injuries to health to the personnel working in the influencing
area due to an insufficient exhaust capacity of the filter plant, or due to exceeding the legally
determined admissible residual dust values in the clean gas.
Only filter sleeves which correspond to the original execution of
FILTRES INTENSIV have to be used!
Pay attention to the exhaust capacity of the sleeve-round filter!
Pay attention to the admissible residual dust values in the clean gas!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 21
3.10 Filter support cages
Figure 11: Multipart and one-part supporting cages
Designation
1 One-piece cage
2 Split end ring
3 Supprting cage bottom
4 Support cage upper part
5 Support cage lower part
6 Intermediate ring
7 Filter sleeve
Types of executions:
Where there is sufficient headroom, one-piece cages are used.
If there is insufficient headroom and long filter sleeves are used, the use of two-piece cages
is essential. The two pieces are joined together with an intermediate ring.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 22
Figure 12: Splitting of the intermediate rings
The ends are split to allow the inlet nozzles and intermediate rings to be clipped into position.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 23
3.11 Two-stage filter sleeve cleaning system
Figure 13: Filter sleeve cleaning
First stage Second stage
1 "Coanda"-Injector 9 Secondary air
2 Injector tube 10 Jet stream
3 Compressed air 11 Inlet nozzle
4 Circular cavity 12 Filter sleeve
5 Circular slot 13 Reverse air flow
6 Axial stream 14 Dust
7 Secondary air 15 Filtration stream
8 Jet stream
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 24
Stage 1
Compressed air is fed into the circular cavity (4) of the "Coanda" injector (1) via the injector
tube (2) and escapes through the circular slot (5) causing an axial stream (6) down the inside
surface of the injector. This induces secondary air (7) into the injector (1).
Stage 2
This combined compressed air and secondary air leaves the injector (1) and enters the inlet
nozzle (11) at high speed inducing a further supply of secondary air (9). This total reverse
air flow causes a sudden inflation of the filter sleeves (12) which blows the accumulated dust
from its outer surface.
3.12 Switch valves for filter sleeve cleaning
3.12.1 Diaphragm valve 2-stage model: C41 and C51
Figure 14: Diaphragm valve C41 and C51
Components designation Pneumatic feeds and blow-outs
1 Valve block A Valve seat
2 Valve tube B Valve tube - exhaust
3 Diaphragm valve cover C Diaphragm valve exhaust
4 Compression spring D Valve space (main valve)
5 Diaphragm E Control air - exhaust
6 Control line (pneumatic) F Valve space (control diaphragm)
7 Control valve cover G Valve seat (control valve)
8 Diaphragm for control valve
9 Silencer
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 25
Diaphragm valve function
Diaphragm valve closed (lower half of illustration):
- Blow-out C is blocked (e.g. solenoid valve).
- The pressure is higher in the valve spaces (D and F) than it is in the valve tube exhaust (B)
and in the control air exhaust (E).
- Diaphragm (5) is pressed against valve seat (A) and diaphragm (8) is pressed against
valve seat (G).
- Blow-out (B) closed.
Diaphragm valve opened - switching process (upper half of illustration):
- Air in valve space (F) is evacuated through exhaust (C).
- Control diaphragm (8) opens.
- Air in valve space (D) is evacuated.
- Main diaphragm (5) opens.
- Compressed air/compressed gas flows through the valve seat (A) into the injector row.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 26
3.12.2 Diaphragm valve 2-stage model: C50 and C80
Figure 15: Diaphragm valve C50 and C80
Components designation Pneumatic feeds and blow-outs
1 Valve block A Pressure release hole (main diaphragm)
2 Valve tube B Valve seat
3 Diaphragm valve cover C Valve tube - exhaust
4 Compression spring D Diaphragm valve exhaust
5 Main diaphragm E Valve space (main diaphragm)
6 Silencer F Pressure release hole
7 Control valve cover (control diaphragm)
8 Compression spring for control valve G Valve space Valve space
9 Diaphragm for control valve (control diaphragm)
10 Control line (pneumatic) H Valve seat (control valve)
J Control air - exhaust
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 27
Diaphragm valve function
Diaphragm valve closed (lower half of illustration):
- Blow-out D is blocked (e.g. solenoid valve).
- The pressure is higher in the valve spaces (E and G) than it is in the valve tube exhaust
(C) and in the control air exhaust (J).
- Diaphragm (5) is pressed against valve seat (B) and diaphragm (9) is pressed against
valve seat (H).
- Blow-out (C) closed.
Diaphragm valve opened - switching process (upper half of illustration):
- Air in valve space (G) is evacuated through exhaust (D).
- Control diaphragm (9) opens.
- Air in valve space (E) is evacuated.
- Main diaphragm (5) opens.
- Compressed air/compressed gas flows through the valve seat (B) into the jet tube.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 28
3.13 Pilot valves for filter sleeve cleaning
Figure 16: Pilotventil
Components designation Pneumatic feeds and blow-outs
3 Valve 1 Valve intake
4 Coil 2 Valve exhaust
5 Electrical connection
6 Seal for the housing
7 Nut
8 Valve piston
9 Valve seal
Function: Closed in neutral position
Pilot valve closed (basic function)
- Closed without electrical current, i.e. the valve piston (8) and valve seal (9) countersunk at
its end are pressed against the valve seat with spring pressure so that the path from (1) to
(2) is interrupted.
Pilot valve opened (switching function)
- The coil (4) is placed under voltage by the switching impulse of the control unit. The valve
piston (8) is raised up by means of electromagnetic power from the valve seat and clears
the path from intake (1) to exhaust (2).
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Construction features 29
3.14 Sealings
Figure 17: Sealings
The good function of the filter depends mainly from the sealing. For sealing of the filter flat
sealings will be used (see sketch). Sealing points which are not shown have to be treated
similarly.
3.15 Inspection openings
All inspection- and maintenance openings at the sleeve-round filters in the area of dust
conveying equipment, such as dust rotary valves and flaps, are provided with haxagon
screws thus preventing that one can get into movable machine parts involuntarily. These
lockings can only be opened by means of corresponding tool. (wrench). When opening
voluntarily it is presumed that the corresponding plant part will be switched-off. Thus the
sleeve-round filter plants have therefore only to be operated with tightened openings.
Should for the operators works other safety philosophies and prescriptions or additional
warnings be applicable these should be considered by the operator at the sleeve-round filter
operation.
Sleeve-Round Filters must only be operated with tightened
openings!
There is the risk of danger due to movable machine parts!
Before opening the inspection door in the crude gas area, switch off
the drives for the discharge parts as well as the heating for the
housing and let them cool off for 15 minutes.
If this is not done, dust fires or explosions due to ignition by hot
surfaces cannot be excluded.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Electrical equipment 30
1 Electrical equipment
1.1 Constructive design
Figure 1: Scheme of the electric control
Designation
1 Sleeve filter
2 Valve box
3 Terminal box (in case of multi-compartment filters several)
4 Control unit
5 Supply line
6 Line for additional function (fault indication, differential pressure switching)
1.2 Function
Figure 2: Diagram of the filter sleeve cleaning
The function of the electric control of the filter sleeve cleaning will be determined by the
following times:
- pulse time
- cycle time (interval time)
- cleaning cycle
The following times are preset by standard:
- pulse time (electrical): 50 ms
- cleaning cycle: 120 s
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Electrical equipment 31
The cleaning cycle has to be understood such that the filter sleeve rows will be cleaned each
one at an interval of 120 s.
The clock time (interval time) can be established as follows:
e.g.: filters with 3 filter sleeve rows
cleaning cycle 120 s
clock time = ------------------------------------ = --------- = 40 s
number of sleeve rows 3
filters with 5 filter sleeve rows
cleaning cycle 120 s
clock time = ------------------------------------ = --------- = 24 s
number of sleeve rows 5
filters with 5 filter sleeve rows
cleaning cycle 120 s
clock time = ------------------------------------ = --------- = 12 s
number of sleeve rows 10
In case of bigger filters the number of the cleaned filter sleeve rows will be distributed to the
10 existing connections of the control unit so that in these cases one or more sleeve rows
will be cleaned in parallel. The cleaning cycle of 120 s will, however, also be maintained
here. The clock-time, and thus also the cleaning cycle, can be adjusted on request to the
local conditions, considering, however, the resulting consequences. These settings assume
professional knowledge and should only be done after having consulted the experts of the
manufacturer. In case of a modification of the cleaning cycle the following should be
considered:
a) Shortening of the cycle time
- the compressed air consumption increases in the same ratio
- cleaning of the filter sleeves will be more intensive
b) Prolongation of the clock time
- the compressed air consumption decreases in the same ratio
- the efficiency of the cleaning decreases also according to the local conditions
The pulse time is set in the control unit and sealed up. This setting may not be modified,
-in special cases only by experts-. The use of various types of control units is possible.
A separate operating instruction has to be considered.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Electrical equipment 32
1.3 Electrical connections
The sleeve-round filters will be supplied completely wired. All cables have identification
numbers. The customer has to install the electronic control unit. An easily accessible place
should be chosen for the place of installation. If possible, the control unit should not be
installed at the filter, since due to the shaking of the pneumatic cleaning system the function
can be affected. The connection to the valve- resp. terminal boxes arranged at the sleeve-
round filter and the current supply of the control unit has to be installed by the customer.
To ensure the correct function of the sleeve-round filters it is necessary to provide the
electric connections according to the terminal plans pertaining to each individual filter type.
All electric works must only be effected by qualified personnel according to the DIN / VDE
standards as well as to the local conditions.
Modifying the pulse- and clock times without having official authority may endanger the
correct function of the filter plant and must only be effected - if at all - only by the technical
expert personnel.
Filter plants with electric installation in normal execution may not be operated in hazardous
locations and critical against vapours or dusts. For these purposes other types of electric
installations with special protection types are necessary.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Pneumatic equipment 33
2 Pneumatic equipment
2.1 Compressed air supply
Figure 3: Scheme compressed air supply
Designation of components
1 INTENSIV-Sleeve-Round Filter
2 Compressed air reservoir
3 Shut-off valve
4 Compressed air distribution pipe
5 Compressed air set
6 Safety valve
7 Compressed air supply line
8 Compressor
9 Main shut-off valve - compressor
10 Works ring main
11 Main shut-off valve - ring main
12 Compressor drain
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Pneumatic equipment 34
The necessary compressed air for the filter sleeve cleaning will be supplied by:
- works network (10)
- compressors (8).
A compressed air set (5) is provided before each sleeve-round filter (1).
This air set meets the following functions:
- separation and filtration of dirty particles, oil and water with automatic drainage
- regulation of the adjusted cleaning pressure.
The cleaning pressure to be adjusted can be taken from the point "Technical Data".
If the pressure in the supply line (7) will be higher than the admissible pressure in the
compressed air reservoir (2), the compressed air system of the filter has to be protected by
a safety valve (6). A shut-off valve (3) is provided at each compressed air reservoir (2)
between the distributing main (4) and the compressed air reservoirs (2) in order to
epressurize the compressed air reservoir when effecting e.g. repair-or control works.
The main shut-off valves (9 or 11) permit a switch-off of the total compressed air system.
The sections of the supply lines (7) provided by the customer have to be chosen big enough
(in case of short supply lines one nominal width bigger than the connection at the compres-
sed air set). At longer supply lines the sections of the same have to be adjusted to the local
conditions. The condensate arising obligatorily at the compressor plant will be let off by the
compressor drainage (12).
As to the compressor itself the operation instruction of the manufacturer has to be
considered.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Pneumatic equipment 35
2.2 Compressed air sets
Figure 4: Compressed air set connections 1/2" and 3/4"
Designation
1 Pressure adjusting screw
2 Manometer
3 Filter
4 Compressed air inlet
5 Condensate outlet
The relative operating instructions of the corresponding manufacturers have to be
considered for this.
The compressed air sets will be used to separate usual impurities in the compressed air
system as well as oil and water. The compressed air quality should be in the range of the
following values,
Compressed air purity classes according to ISO 8573-1:2001-02
referred to air in atmospheric condition.
In case of excessive solid matter- or condensate powerful units have to be provided which
correspond to these conditions.
Class Value

Solid particle class 6
Particle size < 5 m
Concentration < 5 mg/m
Humidity class 4 Pressure dewpoint < +3 C
Oil class 3 Concentration total oil < 1 mg/m
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Pneumatic equipment 36
2.3 Remarks
- The diaphragm valves need for closing a minimum pressure of 0,3 bar. In case of
difficulties during starting due to a pressure reducing at the diaphragm valves the
necessary closing pressure can be provided by a sudden opening of the main shut-off
valves or the individual shut-off valves arranged before the compressed air reservoirs.
- The filter sleeve cleaning process will be with unoiled compressed air.
DO NOT FILL IN ANY OIL !
At the operation of compressed air- resp. compressed gas plants the
prescriptions for compressed air reservoirs have to be maintained!
The compressed air reservoirs of the Sleeve-Round Filters may only
be operated with a pressure stated on the compressed air reservoir
nameplate. The operation of these units with a pressure higher than
the admissible pressure is not permitted according to the legal
prescriptions!
The safety valves are adjusted by the customer to the admissible
operation pressure and leaded. The lead seals may neither be
removed nor the valves readjusted arbitrarily!
The condensate arising during the compressed air supply has to be
completely collected and disposed according to the local
prescriptions. The condensate may not be let off into the sewerage!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Filter sleeve differential pressure 37
3 Filter sleeve differential pressure
Figure 5: Differential pressure measurement at the filter
Designation
1 Dirty gas room
2 Clean gas room
3 Filter sleeves
4 U-tube pressure gauge
5 Measuring sections
The supervison of the correct function of the sleeve-round filters will generally be by
measuring the filter sleeve differential pressure (filter sleeve resistance) with a U-tube
pressure gauge. This pressure gauge consists of a glass tube bent in form of an U which is
filled with a measuring liquid. Both tube legs are open and provided for the connection of
measuring hoses. A scale arranged behind the U-tube permits an actual value determi-
nation of the sleeve-resistance. The measuring result is the difference value between the
two liquid levels in the U-tube. The measuring hoses will be connected each one at the front
walls of dirty- and clean gas room.
Measuring procedure as shown on the sketch.
A correct measuring result assumes clean measuring lines. For this reason the measuring
line to the dirty gas room has to be cleaned in particular from time to time according to the
local requirements. The differential pressure set value pre-set for each filter can be taken
from point "Technical Data".
The correct function of a Sleeve-Round Filter is only guaranteed if
the filter sleeve differential pressure measured at the filter will not be
higher than the pre-set actual value. Unacceptable high differential
pressures indicate a not correct function of the filter so that
detrimental influences due to an insufficient exhaust capacity of the
filter cannot be excluded.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Delivery 38
1 Delivery
1.1 Delivery
The filter will be supplied completely mounted in unit. The pneumatic equipment such as
fittings, distributing main and compressed air reservoir have been completely mounted in
the works. The supporting structures for the filters have been desptached unassembled.
During transport and installation of the filters supplied in erection
units the lifting gears may only be mounted at the lifting eyes
provided by the supplier! The carrying capacity stated on each lifting
eye may not be exceeded! Transport carrying eyes have to be
removed before putting into operation!
1.2 Packing
The filter will generally be packed in so far as a safe transport will be possible.
The maintenance unit, the electronic control unit and small parts, such as screws and
sealing material will be supplied packed in cases resp. crates. For the safe transport of the
filters resp. construction- or erection groups safety devices will be necessary in some
particular cases, as e.g.:
- screwings and safety devices at inspection- and maintenance doors, in order to prevent an
unintentional opening of the same during transportation.
- Using of intermediate layers of cellular materials in case of a transport of filters in horizontal
position.
- Other transport safety devices, such as additional stiffenings, bases and parts for
loosening and the like.
All transport safety devices have to be removed before putting the
filters into operation!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Delivery 39
1.3 Designation
Nameplate
The filter will be designated by a maker's nameplate resp. by a type plate which has to be
arranged at a well visible place.
The plate indicates the following:
- Com.-no.
- Machinery-no.
- Type
The type plate necessary for the identification of the filters may not
be removed nor be made illegible!
CE-Plate
The sleeve-round filter is designated by a CE-plate according to EC-directive. This plate is
arranged underneath of the type plate.
Do not remove or make illegible the CE-plate!
1.4 Painting
If no special paintings are agreed in the contract all sheet steel parts will be provided with a
rust-protecting paint during transport.
The necessary corrosion protection paint or coating has to be provided for by the operator.
Attention has to be paid to a perfect corrosion protection, in
particular at supporting members!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Filter installation 40
2 Filter installation
The filter installation will be effected generally as follows:
- on supporting legs (in case of smaller filter types)
- on supporting structures
- in customer's buildings
All electrically conductive equipment parts have to be earthed.
The discharge resistance to earth has to be smaller than 10
6
.
Ignited dust fires or explosions due to electrostatic charges (spark
discharge) can not be ruled out when the earthing is carried out in a
disorderly fashion.
2.1 Filter installation on platforms provided by the customer
or in buildings
Figure 1: Filter with claws for the installation on platforms provided by the customer
or in buildings.
At the filter installation on platforms provided by the customer or in
buildings the supporting structure has to be provided according to the static requirements.
Attention has to be paid at the filter installation to the solidity and
stability of the platform structure!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance platform with railing 41
3 Maintenance platform with railing
For the support of the maintenance platform perforated flat steels are arranged at the filter
housing. For inspection- and repair works a maintenance platform has to be provided in the
area of the filter head. To protect the personnel the platform is provided with a protecting
railing.
Figure 2: Platform at filter
Figure 3: Round platform at filter
The access to the maintenance platform may be via ladders or stairs (according to the local
prescription).
Attention has to be paid to the correct execution and mounting of the
protecting railing!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Putting into operation 42
4 Putting into operation
4.1 General
Before putting into operation of the sleeve-round filters the following has to be checked-up
resp. to be executed:
1. General check-up and verification of the readiness for service.
2. Removal of transport safety devices.
3. Removal of all residues of erection (e.g. as screws, nuts welding electrodes remainders
or tools) from the discharge elements.
4. Operational test of all mechanical aggregates, such as rotary valves and dust discharge
valves.
5. Check-up of the sense of rotation at all dust discharge elements.
6. Test run of all mechanical aggregates.
7. Verifiacation of the filter sleeve cleaning:
- cleaning pressure
- function of the solenoid- and diaphragm valves
- clock time
8. Checking the explosion protection system
- Check the correct earthing of all electrically conductive components
- Check that all safety components are correctly installed and function as they should
according to the explosion protection directive
The explosion protection system has to be installed and activated
before the equipment is used.
If this is not done, the chance of deadly explosions cannot be
excluded.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Putting into operation 43
4.2 Switch-in sequence of the filter aggregates
1. Compressor
If the operating pressure has been achieved, release for the switch-in
of the following aggregates:
2. Dust screw conveyor in the filter
3. Filter sleeve cleaning (pneumatic)
4. Fan
After switch-in of the plant:
1. Verification of the filter sleeve differential pressure at U-tube pressure gauge.
2. Verification of the clean gas outlet with regard to residual dust outlet (visual check).
Possibly recording measuring units have to be used.
After some operating hours, possibly after the first shift check-up of the clean gas room with
regard to residual dust deposits.
Before putting into operation guarantee readiness for service !
Removal of all erection residues !
Attention has to be paid to the switch-in sequence !
After putting into operation check-up of clean gas by visual check!
In case of dust outlet the plant has to be put out of operation
immediately, and faults to be rectified!
4.3 Operation
The sleeve-round filters are designed for continuous operation. The supervision during
operation is therefore limited to the following points:
1. Supervision of the mechanical aggregates.
2. Supervision of the filter sleeve differential pressure.
3. Supervision of the clean gas regarding residual dust outlet.
Attention has to be paid to the filter sleeve differential pressure
during operation!
Clean gas has to be supervised!
In case of an excessive residual dust outlet the legally prescribed
residual dust values can be exceeded so that environmental
pollution cannot be excluded.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Putting into operation 44
4.4 Putting out of operation
The sequence of the shutdown of the sleeve-round filters is as follows:
1. Fan
2. Filter sleeve cleaning
3. Rotary valve
Depending on the type of dust and the local operating conditions an after-running of
the filter sleeve cleaning can be advantageous at shutdown of fan.The most favourable
after-running time has to be determined by the operator after putting into operation.
Generally the after-running time will be 10 to 30 minutes.
Attention has to be paid to the switch-off sequence during shutdown
of the plant!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 45
5 Maintenance
Leverlocks, manholes or inspection doors permit a simple control and maintenance of the
corresponding filter sections. The sleeve-round filters are designed for an operating method
which requires less maintenance.
Maintenance is therefore limited to the following areas:
1. Check-up of the filter sleeves after 500 operating hours at the latest.
2. Check-up of the differential pressure gauge, if necessary, to refill the measuring liquid or
to replace the same, possibly the measuring ductings have to be cleaned.
3. Check-up the filter in the compressed air set and condensate outlet, possibly clean or
replace filter.
4. Check-up and, if necessary, tighten the filter sleeve fastening (special nuts).
5. Check-up of the injector tubes and injectors with regard to proper fastening, possibly
tighten.
6. Check-up of all pneumatic ductings with regard to density, possibly repair leakages.
The correct function of the sleeve-round filter can be endangered by
insufficient or inexpert maintenance!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 46
5.1 Rectifying Faults
No Check Point
Period
in
Weeks
Type of Check Action
1 Differential
pressure
gauge
Daily Check sleeve diffe-
rential pressure
see point "Technical data"
(cleaning cycle) and "Filter
sleeve differential
pressure".
2 Filter sleeves 2


4
a) Check joints
between
mounting plate
and inlet nozzle
b) Check for wear
and damage to
the sleeves (dust
deposits on the
clean gas side
resp. at the inlet
nozzles or dust
trails in the
exhaust air
c) Check if sleeves
are stuck together
through dew-point
effects
a) Tighten capped nuts


b) Dismantle sleeves and
replace by new ones






c) Change sleeves and
clean dirty ones.
Investigate the causes
and effect the remedy
3 Supporting
cages
4 Check if supporting
cages are
conductive
connected
Restore Conductibillity
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 47
4 Solenoid val-
ves and con-
trol unit
4 Check if the warning
lights on the electro-
nic control unit go
out immediately after
lighting up for a
short time.
Fuse defect!
Short-circuit in the
control unit, sole-
noid coil or cabling.
Check if valve clo-
ses.
Check if compres-
sed air escapes con-
tinously from tubing.
Electronic component part
ok. If it fails to go out, there
is interference in the sole-
noid coil or in the connec-
ting cable. Change
solenoid coil.
Investigate cause.
Replace fuse.

Replace valve by a new
one.
Free solenoid valves of
possible foreign bodies
(chips). Replace defect
valve.
5 Diaphragm
valves
4







24
Check if compres-
sed air is escaping
continously. Observe
if the pressure on
the gauge is rising
back to its operating
pressure between 2
impulses.
Check of all dia-
phragms.
The release of compres-
sed air or drop in pressure
will be shown on the pres-
sure gauge:
change the diaphragm of
the valve.
6 Injector tubes 4 Check that O-rings
are o.k.
Install new O-rings.
No Check Point
Period
in
Weeks
Type of Check Action
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 48
Disturbances which influence the suction capcity or the residual
dust emission of the sleeve-round filters have to be rectified
immediately!
In case of auto ignitions, it is possible that dust deposits will
become to ignition!
6 Cleaning cycle 2 Check standard
adjustment.
If the cleaning is not
satisfactorily adjust-
ed, filter sleeve diffe-
rential pressure too
high, adjust the
cycle time new. Are
the cycle time lower
than in the "Techni-
cal data" check the
operating pressure.
Cleaning cycle of the filter
120s.
Adjust cycle time.
7 Sealings at
doors
4 Check if sealings are
brittle or damaged.
Renew sealings.
8 Air set 2 Check oil- and water
separator. Check
operating pressure.
Compressed air
operating pressure
must rise to full ope-
rating pressure bet-
ween 2 impulses.
If necessary unscrew filter
bowl and clean with water
or petrol. With pressure
drop on gauge, check
compressor output, possi-
bly an increase in cycle
time (see point "Function")
may be required. Re-
adjust to prescribed pres-
sure.
9 Dust in
the dust col-
lection room
2 Function of the dust
discharge elements
such as rotary val-
ves and flaps has to
be checked-up.
Investigate causes of
faults. Check-up electrical
resp. mechanical drives.
No Check Point
Period
in
Weeks
Type of Check Action
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 49
6 Maintenance
Avoid sparks with all repairs!

6.1 Protective measures during maintenance work
For maintenance work where there is a risk of ignition in areas at risk
of explosion or in areas where the work can result in a dangerous
explosive atmosphere arising, protective measures are necessary.
The employer or their representative must specify the location, start,
duration and extent of the necessary protective measures in work
instructions, usually in writing and must instruct the employees
accordingly (for the coordination of work see paragraph 6 of the
regulations for the prevention of industrial accidents "General
regulations" (German employers' liability insurance association
regulations BGV A1)).
Work may only start when the employer or their representative has
ensured that the protective measures have been carried out and are
effective. The effectiveness of the protective measures must be
monitored for the duration of the work. The employer or their
representative may only cancel the protective measures when the
maintenance work has been completed and there is no longer any
danger.
After the maintenance work is complete it must be ensured that the
explosion protection necessary for normal operation is effective
before operation is restarted.
Coordinating work
para. 6
(1) If an employer subcontracts work to another company then, if
necessary to avoid being a danger to one another, the employer
must nominate someone to be responsible for the coordination of
the work. The employer must ensure that this person has authority
over the subcontractor and their employees..
(2) If the subcontractor accepts jobs which are to be done at the
same time and place as jobs to be done by other subcontractors,
then they are obliged to coordinate with the other subcontractors as
far as is necessary to avoid presenting a danger to one another.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 50
6.2 Installation and removal of injector tubes
Figure 4: Injector tube
Designation
1 Injector tube 6 Hexagon screw
2 Compressed air reservoir 7 Bushing
3 Sealing 8 Special nut
4 Nipple 9 Support for injector row
5 O-ring 10 Valve tube
11 Connecting tube
The installation of the injector tubes will be in the following sequence:
- Screw nipple (4) with sealing (3) in the valve tube (10) of the compressed
air reservoir (2).
- Insert connecting tube (11) into the nipple (4).
- Insert O-ring (5) in the tube at the housing (filter exterior side) and connect same with the
connecting tube (11).
- Insert O-ring (5) in the tube at housing ( filter interior side ) and connect with the injector
tube (1).
- Screw injector tube (1) at the support for injector row (9) with the screw (6), bushing (7) and
special nuts (8).
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 51
Starting power for the screw connection: 40 Nm.
When dismantling the injector tube (1) the screw connections (6 and 8) have to be loosened,
and the injector tube (1) has to be pulled out of the tube at the housing by short right- and
lefthand turnings.
Attention has to be paid to correct O-ring sealings and proper
screwing of the injector tubes!
6.3 Installation and removal of the C-Injectors
Figure 5: C-Injector
Designation
1 Injector tube
2 C-Injector
3 Clamping strap
4 Hexagon nut (flanged nut)
5 Connecting trunnion
6 Disk
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 52
The C-injectors of the sleeve-round filters will be installed and removed as follows:
Installation:
- Put C-injector (2) with the connecting trunnion (5) in the corresponding hole of the injector
tube (1).
- Clamp the C-injector (2) with the tension bars (3) from both sides against the injector tube
(1). It has to be sealed by tighten of the hexagon screws (5).
- The screw starting torques for the screw connections: 21Nm.
- The C-injectors (2) must be tandem joined and angular aligned to the injector tube (1).
Removal:
The removal of the C-injectors will be effected in inverse sequence.
Attention has to be paid to the correct screwing of the injectors!
6.4 Mounting and removal of filter supporting cages
See separate Operating instruction
"Avoiding fire dangers resulting from electrostatic charge"
Protective components have to be earthed for discharge of electro-static charges.
Intensiv-Filter achieves earthing by the correct mounting of clamps.
Be careful to earth in an orderly fashion!
Ignited dust fires or explosions due to electrostatic charges (spark
discharge) can not be ruled out when the earthing is carried out in a
disorderly fashion.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 53

Figure 6: Mounting and removel of the filter supporting cages
Designation
1 Filter supporting cage 4 Special nut
2 Inlet nozzle 5 Injector tube
3 Tension bars, straight 6 Tension bars, cranked
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 54
The installation of the filter supporting cages has to be effected as follows:
- Insert filter supporting cage (1) with clamped on inlet nozzle (2) in the already installed filter
sleeve and screw with tension bars (3 and 6).
The removal has to be effected as follows:
- Detach screwing
- Pull out injector tube (5) and lay down
- Loosen special nuts (4), and turn tension bars (3 and 6) by 90.
- Get hold of filter supporting cage (1) at inlet nozzle (2) and pull same out of the filter sleeve.
Figure 7: Removal of filter supporting cages with auxiliary tools
To facilitate the removal of the filter supporting cage an auxiliary tool can be used according
to the above sketch.
Extras can be provided by the spare parts service.
When installing the filter supporting cages attention has to be paid
to a correct screwing !
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 55
6.5 Installation of the inlet nozzle
Figure 8: Installation of the inlet nozzle
The inlet nozzle is provided with 4 wedge-shaped ribs acting as erection aid.
For the installation of the inlet nozzle it will be placed on an even base, and the supporting
cage has to be pushed with a strong jerk over the inlet nozzle. As soon as the subdivided
end ring of the supporting cage snaps in the groove of the inlet nozzle the correct connection
has been established.
6.6 Removal of the inlet nozzle
Figure 9: Removal of the inlet nozzle
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 56
The inlet nozzle once installated at the supporting cage remains normally always in this
position. If a removal of the same will become necessary it has to be proceeded as follows:
- Put on mounting lever (included in the supply) (see figure), expand supporting cage and
remove inlet nozzle from hand. If no erection lever will be existing the expanding procedure
can also be effected by a squared timber. The supporting cages should not be bent
manually for the removal of the inlet nozzle, since uncontrolled deformations may lead to
damages of the filter sleeves.
6.7 Assembly of multipart supporting cages
Figure 10: Erection of the intermediate ring into the supporting cage lower part
During assembly of multipart supporting cages the intermediate ring will first be meshed in
the corresponding supporting cage lower part.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 57
Figure 11: Mounting of the supporting cage upper part into the intermediate ring
Then the supporting cage upper part will be inserted diagonally in the intermediate ring
(pay attention to the position of the moulding seam), and then the supporting cage locked
by turning.
6.8 Dismantling of multipart supporting cages
During the dismantling procedure only the supporting cage upper part each will be removed
from the intermediate ring, whereas the intermediate ring remains in the corresponding
lower part.
As to the operating procedures please refer to:
"Removal of the inlet nozzle" and "Assembly of multipart supporting cages" (during
this procedure the inverse sequence has to be considered).
Attention has to be paid during installtion and removal of the filter
supporting cages, as well as the inlet nozzles and intermediate rings
to the correct procedure !
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 58
6.9 Filter sleeve removal
The quick and simple sleeve changing at the sleeve-round filter will be effected from the
clean gas side.
6.9.1 Installation of the filter sleeves
For the installation of the filter sleeves the following procedures are required:
- Removal of the injector tubes
- Removal of the filter supporting cages
- Removal of the defect filter sleeves
Figure 12: Mounting of sleeve
- Place the folded filter sleeve (supply estate) through the corresponding hole in the sleeve
bottom. Unfold the sleeve due to reciprocating motions and lay with the top sealing ring on
the sleeve bottom.
- Align the longitudinal seams of the filter sleeves in the same direction such that they are in
alignment with the tension bars.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 59
After effected installation of the filter sleeves the following procedures have still to be made:
Figure 13: Mounting of filter supporting cages
- Push filter supporting cage with inlet nozzle into the filter sleeve.
Figure 14: Fastening of sleeve and supporting cage with tension bars
- Align tension bars in longitudinal direction of the injector tube.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 60
Figure 15: Screwing of tension bars
- Screw tension bars, however, avoid excessive tightening.
- Install injector tubes.
Pay attention to a correct screwing of the filter sleeve fastening!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 61
6.9.2 Removal of the filter sleeves
The removal of the filter sleeves will be effected in the reverse sequence. Before removal
the filter cleaning should be switched-in for such a long period until the filter sleeves are free
from dust. In certain cases, e.g. in case of dust types which are dangerous to health or
excessive heat it can be advantageous to let the fan of the filter plant operate in throttled
state. The thus penetrating fresh air through the sleeve bottom holes creates a better
atmosphere for the personnel. Useless filter sleeves have to be disposed according to the
local conditions considering the legal prescriptions.
When changing the filter sleeves only the filter sleeve quality has to
be used which has been designed for the dust to be filtered!
Accident preventing prescriptions have to be considered carefully!
If required by the local prescriptions protecting clothes have to be
used!
Breathing masks have to be used in general!
The prescriptions for disposal of filter sleeves which can no more be
used have to be paid attention to!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 62
6.10 Replacement of valve covers, diaphragms and silencers
6.10.1 Diaphragm valve - model: C41 and C51
Figure 16: Diaphragm valve C51
Designation
1 Valve block 8 Special nut (20 Nm)
2 Main diaphragm 9 Control diaphragm
3 Spring 10 Cover control diaphragm
4 Valve cover main diaphragm 11 Screw (8 Nm)
5 Silencer 12 Shut off valve
6 Screw (4 Nm) 13 Hose
7 Washer 14 Plug-in screw fitting
Replacing the main diaphragm
- Close the stop valve (12) and create a vacuum in the valve block (1) by carrying out several
dedusting procedures.
- Pull out sleeve (13) from the plug-in screw fitting (14) by sliding the locking mechanism
back (see direction of arrow in the illustration "Diaphragm valve C51").
- Remove cover (4) by unscrewing the cap nuts (8) and washers (7) from the valve block (1)
and replace the diaphragm (2) with the compression spring (3).
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 63
It should be noted here that the pressure build-up bore hole in the membrane engages with
the corresponding bore hole of the valve block!
Do not forget to install the compression spring (3)! Carry out a performance check!
The starting torque for the nut caps is 20 Nm!
Replacing the control diaphragm
- Unscrew the screws (11) from the cover (4), remove the cover (10), and replace the control
diaphragm (9).
The starting torque for the screws is 8 Nm!
Replacing the silencer
- Unscrew the screws (6) from the silencer (5) and replace the silencer.
The starting torque for the screws is 4 Nm!
Do not undertake replacement of the membrane until the valve block
is in a vacuum state!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 64
6.10.2 Diaphragm valve - model: C50 and C80
Figure 17: Diaphragm valve C50 and C80
Designation
1 Valve block 8 Special nut (20 Nm)
2 Main diaphragm 9 Control diaphragm
3 Spring 10 Cover control diaphragm
4 Valve cover main diaphragm 11 Screw (8 Nm)
5 Silencer 12 Shut off valve
6 Spring 13 Hose
7 Washer 14 Plug-in screw fitting
Replacing the main diaphragm
- Close the stop valve (12) and create a vacuum in the valve block (1) by carrying out several
dedusting procedures.
- Pull out sleeve (13) from the plug-in screw fitting (14) by sliding the locking mechanism
back (see direction of arrow in the illustration "Diaphragm valve C50").
- Remove cover (4) by unscrewing the cap nuts (8) and washers (7) from the valve block (1)
and replace the diaphragm (2) with the compression spring (3).
It should be noted here that the pressure build-up bore hole in the membrane engages with
the corresponding bore hole of the valve block!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 65
Do not forget to install the compression spring (3)! Carry out a performance check!
The starting torque for the nut caps is 20 Nm!
Replacing the control diaphragm
- Unscrew the screws (11) from the cover (4), remove the cover (10), and replace the control
diaphragm (9) with compression spring (6).
The starting torque for the screws is 8 Nm!
Replacing the silencer
- Unscrew the silencer (5) and replace it.
Do not undertake replacement of the membrane until the valve block
is in a vacuum state!
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 66
6.11 Overhauling the pilot valves
The pilot valves are built-in a explosion protected pilot box-housing.
Structural changes at the equipment or at parts of the equipment are notallowed.
Unused duct screwings must be plugged by means of blind plugs.Before opening the
equipment the operating voltage must be switched-off.
Before opening the equipment ist must be guaranteed that:
- no explosive atmosphere does exist and
- no dust deposits are on the equipment
Figure 18: Replacing the pilot valves
Designation
1 Valve
2 Coil
3 Pilot box housing/bracket
4 Seal
5 Nut
6 Hose
7 Coil connection
The installation and disassembly of the pilot valves is to be carried out as follows:
- Pull out hose (6) from the plug-in screw fitting by sliding the locking mechanism back.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Maintenance 67
- Loosen lock nut (5) and remove entire valve (1) upwards.
- Install new valve (1) and screw tightly with the lock nut (5).
Be careful to ensure that the seal (4) sits upright on the bracket!
Safe operation of the pilot valves is guaranteed only with the use of
original spare parts!
After operation of the equipment the housing cover must be
mounted dusttight.
- The unobjectionable condition of the cover seal must be checked
before assembly of the cover.
- The 6 screws of the housing cover must be tightened strongly.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Spare parts and customer service 68
7 Spare parts and customer service
7.1 Stockkeeping of spare parts
For a continuous function- and operation readiness and also for a correct repair of the
sleeve-round filters the stockkeeping of spare- and wear parts is an important condition.
7.2 Ordering of spare parts
The ordering of spare parts will be done generally according to the spare parts list.
The following indications have to be made:
- Com.-no.
- Machine-no.
- Type
- Spare part designation
- Spare part number
- Required number of pieces
- Exact despatch address (e.g. exactly designated place of installation, inventory number,
name of the person to whose attention the goods are supplied)
- Delivery date
It has to be considered that due to the variety and the special application of the sleeve-round
filters not all spare- and wear parts can be stored in any number of pieces. Therefore it is
strongly advised to keep a pre-planned number of pieces on stock.
7.3 Customer service
The FILTRES INTENSIV customer service can be consulted for all problems regarding
sleeve-round filters.
Attention has to be paid to a sufficient stock of spare- and wear
parts!
When using spare parts which deviate from the original execution
the correct function of the sleeve-round filters may be influenced or
even endangered.
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Spare parts and customer service 69
7.4 Addresses of customer service and spare parts
All requirements regarding spare parts or customer service can be directed to the following
addresses:
FILTRES INTENSIV
Zone Ecopole - Route de Sarrelouis
57320 BOUZONVILLE
FRANCE
Tel: +33 (0)3 87 78 32 22
Fax: +33 (0)3 87 57 96 97
E-mail: sthuringer@filtresintensiv.fr
OPERATING INSTRUCTIONS
for
INTENSIV-Sleeve-Round Filter
Model IFJC-R
BA 201.01E September 1995 Separate documentation 70
8 Separate documentation
1. Appendix
2. Control unit
3. Compressed air set
4. Compressor