(File 1) PF1032 - IOM - EN [PDF]

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INSTALLATION OPERATION MAINTENANCE



PF1032



Original Instructions: English



B100232FI



DOC23605 Rev. B 29.2.2012



Outotec Larox® PF PF144/144 M60 1 60 Minera Escondida



Outotec (Filters) Oy P.O. Box 29 FI-53101 Lappeenranta Finland Tel +358 (0) 20 529 4236 Fax +358 (0) 20 529 4439 E-Mail [email protected] [email protected]



Original Instructions: English



B100232FI



DOC23605 Rev. B 29.2.2012



Service /MKy



Outotec Larox PF Quick start guide



Only for general information. Do not replace manual. 30.8.2011



2 (10)



Safety When operating a filter, it is extremely important that safety is always taken into account since filters include systems operating at high pressures, high voltages and high temperatures. Automated moving parts can also be hazardous. The following is a short introduction to safety when operating Outotec Larox filters. -



Never start any maintenance or repair work whilst the filter is being operated.



-



Never open the filter protection doors whilst the filter is being operated.



-



Before starting the filter, make sure that there are no foreign objects between the filter plates.



-



Make sure that the pressure pipelines are not damaged to avoid the danger of spraying high pressure oil and slurry.



-



Notice that the force inside the plate pack is 960 tons (equal to pressure of 16 bars over an area of six square meters.)



-



Be aware of all moving and rotating parts, such as cloth, plate pack and rollers.



-



Personal protection equipment must be worn at all times: a hard hat, goggles, overalls with long sleeves and high cut steel toe shoes.



-



Be careful when working at heights. The surface of a filter can be slippery and you could fall. Be careful also that nothing falls.Always use service platforms and safety harnesses.



-



The dry cloth must be moisten before starting to run it. There is a DANGER OF EXPLOSION due to static charging in same space with any hazardous gases, dust or any other explosively sensitive materials.



-



Never bypass the sensors or other control components. This may result in improper operation and a safety risk.



-



Be sure that electrification cables are not damaged. Damaged cables may cause a safety risk due to dangerous voltages or faulty filter operation.



Only for general information. Do not replace manual. 30.8.2011



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Before maintenance:  Stop the filter at the end of the cycle, lock the plate pack, close the manual valves, and switch off the electricity from the main switch S700. Use the local Lockout - Tagout procedure to make the disconnection for electricity, hydraulics, pneumatics and liquids.  Only persons with sufficient skills to perform electrical installations should open the control panel/terminal boxes due to dangerous voltages inside the cabins/boxes.  When performing plate pack maintenance at the top of the filter, drive the plate pack to its open position and lock the top pressing plate to the columns with locking pins.  Only properly qualified and trained persons who are familiar with the functions of the filter may carry out filter maintenance tasks.  Check the plate pack suspension plates after any maintenance work with the plate pack. Follow your local safety instructions at all times. -



Always use the appropriate tools only. Remember that when the handheld test unit is removed from the bracket and activated, the filter can only be operated through this unit. The handheld unit can be used for testing the actuators and other functions allowing for maintenance and adjustments tasks. Before operating the filter with the handheld unit, remember to ensure that no one is within the danger zones.



-



Emergency-Stop switches are situated: on the control panel and on the side of the cloth conveyor unit casing, hydraulic unit and handheld unit. Also, opening the filter protection doors activates the emergency-stop circuit. Emergency-Stop switches stop the filter immediately.



-



Before opening any pressurized line, process line of hydraulic line, ensure that the pressure has been fully released.



-



It is absolutely forbidden to use the filter and its automatic devices in the manufacturing process if any fault has appeared.



-



Good housekeeping and maintenance prevents accidents.



-



Follow the instructions of Manual.



For more information about safety regulation, see instructions in the Manual. Should you feel uncertain in any situation, please do not hesitate to contact your nearest Outotec Service office.



Only for general information. Do not replace manual. 30.8.2011



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Daily Tasks Some regular tasks are necessary to keep the filter in the best possible condition. Good daily care improves filter performance and product quality. -



-



At the beginning of the shift check the filtration parameters and the recipe in use. Check that cake and any foreign objects are removed from between the filter plates and from the filter cloth. Check the filter cloth for holes and folds, as well as cloth tracking. Observe filter functions during the first couple of filtration cycles from the user interface. Check the filtration results and that the set values are being realized. Ensure that auxiliary equipment is operating correctly and providing the required utilization. Check that the cake thickness is even in all the plates. If it is not, there could be a blockage in the feed line. Keep the filter clean; scrapers, rollers and plates. A dirty filter equals unreliable and poor performance and a short lifetime for consumables. For the best results, wash the entire filter at the end of the shift. Check for leakages o In the process (plate pack, slurry and filtrate lines) o In the hydraulics (oil leakages) For more information about daily maintenance, see instructions in the Manual. The reliable operation and long life of the Outotec Larox PF filter largely depends on the proper care and on following the operation and maintenance instructions.



Only for general information. Do not replace manual. 30.8.2011



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Preventive Maintenance Preventive maintenance maximizes the utilization of the filter and guarantees constant output. With preventive maintenance you can optimize your total cost per ton produced. Ensure that an adequate stock of spare parts is always available. Note: These preventive maintenance instructions represent minimum guidelines and should not replace your specified preventive maintenance plan. Weekly Maintenance: -



Visually inspect scraper adjustment for optimum cloth performance, cleaning and tracking. Check that the emergency stop functions. This is vital for your personal safety. Adjust the sensors for trouble free operation. Check the hydraulic oil temperature and that the hydraulics operate smoothly without pressure shocks. o For more information, see instructions in the Manual. Observe the condition of the slide pieces for optimum cloth tracking. Grease the bearings. Inspect the condition of the distribution pipelines and hoses, as well as their connections, for wear and tear. Follow your weekly maintenance plan.



Monthly Maintenance: -



-



Inspect the filter plates, seals and diaphragms. Filter plates should be straight, seals and diaphragms should be leak proof. Check that the filter plates are straight and in line. Check o The hydraulic hoses o The hydraulic cylinders and fixtures o The operation of locking pins o The chains and sprockets o The seam thread of the filter cloth Follow your monthly maintenance plan.



Three times per year Maintenance: -



-



Analyze the quality of the hydraulic oil. o Change or fine filtrate the oil if necessary. o Oil impurities are the most common reason for faults in the hydraulic system. o For more information about hydraulic systems, see instructions in the Manual. Follow your three times per year maintenance plan.



Only for general information. Do not replace manual. 30.8.2011



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Optimization These optimization instructions are only guidelines and possibilities. Actual optimization depends on the special nature of your application. The following instructions offer an idea of how to find the optimum filtration parameters for your own application. Auxiliaries settings/ performance



Upstream process Input Slurry properties



Filter settings/ performance



After a certain pressing/drying time, the moisture content no longer decreases significantly. The longer the pressing/drying time, the lower the capacity of the unit.



Moisture content, %



Cake thickness, mm



A few optimization tips After a certain feeding time, the cake thickness no longer grows significantly…



Output



The OUTPUT of Outotec Larox filters depends highly on INPUT i.e. the upstream process and characteristics of the performance auxiliaries. Particle size and shape, the solid content of the slurry and other characteristics have a strong impact on filter performance.



Pressing/ Drying time, min



Feeding time, min



After a certain washing time, the washing result no longer improves significantly. The longer the washing time, the lower the capacity.



Capacity, ton



Washing result, mS



…and you have reached the optimum point. After that your capacity is going to drop.



Feeding time, min



Washing, min/ m3



Only for general information. Do not replace manual. 30.8.2011



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Optimizing a filtration system is not just about optimizing the filter itself. Filter performance depends highly on previous steps in the process. Also, the following process may limit the performance of the filter. Therefore, all three areas should be considered in terms of optimization. -



-



-



Optimization of upstream process: o Variations in solids and liquid properties o Variations in flocculants/ crystallization/ precipitation o Variations in slurry thickening/ mixing o Filtration conditions:  Slurry properties (temperature, d.s. content, psd, pH, viscosity, etc.)  Wash liquid properties (pH, conductivity, viscosity, etc.) o Temperature variation o Stabilize the process part that affects particles Optimization of the filter and auxiliaries o Filtration parameters and mechanical operation of the filter o Cake discharge o Cloth washing (proper washing against blinding) o Filtration variables (times, pressures, flows, weights/volumes, temperatures, etc.)  Slurry feeding (capacity, feeding profile)  Pressings (cake moisture)  Cake washing (wash results, way of washing)  Air drying (cake moisture, way of drying) o Filter auxiliaries operations:  Slurry pump (ramping for optimum cake forming)  Air compressor and receivers (enough air for proper drying)  Pressing air/water station Optimization of downstream process o The best possible ways to handle process products for further processes o Optimizing the cake moisture suitable for downstream process equipment (cake breaker, extruder, conveyers, track fortation, etc.)



Only for general description. Do not replace manual. 30.8.2011



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Operating Steps The following represent possible operating steps. Please refer to the process-technical documents for an exact summary of the various steps and processes. 1. Filtration When the filter plate pack has been closed, slurry is pumped into the filter and fed simultaneously into each filter chamber through the distribution pipes. Filtrate flows through the cloth into the filtrate collection area, then out through the discharge pipe. The filtered material is collected on the cloth surface forming the filter cake.



4. Diaphragm pressing II (optional) The wash liquid remaining in the chamber after the washing stage is pressed out of the cake as in stage two (Diaphragm pressing I). 5. Air drying The final drying of the cake is carried out using compressed air. Air flows through the distribution pipe filling the filter chamber, raising the diaphragm, and forcing the pressing air/water above the diaphragm out of the filter. The air flow through the cake reduces the moisture content in the cake to the optimum level and, at the same time, empties the filtrate chamber.



2. Diaphragm pressing I Pressing air/water flows in behind the rubber diaphragm. The diaphragm presses the cake against the cloth surface and forces the filtrate from the cake through the cloth.



3. Solid washing (optional) Wash liquid is pumped into the filter chambers in the same way as slurry. As the liquid fills the filtration chamber, the diaphragm is lifted and air/water is forced out from the upper side of the diaphragm. The wash liquid flows into the discharge pipes after passing through the filter cake and the cloth, and replaces the mother liquid.



6. Cake discharge When the air drying has been completed, the plate pack is opened and the cloth moving mechanism started. The filter cake on the cloth is discharged automatically from both sides of the filter.



Only for general description. Do not replace manual. 30.8.2011 Outotec Support -



-



-



Outotec Service is working together with our customers on day-to-day basis to ensure  Safety  Maximum availability  Minimum operating costs  Optimum process results We offer a comprehensive range of support  Technical services  Spare parts  Modernizations and upgrades We provide our services globally for  Outotec Larox PF  Outotec Larox CC  Outotec Larox DS  Outotec Larox FP  Outotec Larox FFP  Outotec Larox RT and RB  Outotec Larox LSF  Outotec Larox SC



For more information, contact your nearest Outotec Service office.



-



For more information about our company, visit our website  www.outotec.com



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Only for general description. Do not replace manual. 30.8.2011



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This guide is intended solely as a general introduction to the filter, and includes only a broad outline concerning necessary safety, maintenance, optimization and process steps. This guide is neither adequate nor the right document for ensuring the safe and proper operation, maintenance, control and upkeep of the equipment. This document must not be used for any purposes other than to provide general information about the equipment. All information and instructions relating to the equipment must be obtained from the appropriate and correct manuals, which are prepared especially for the safe, proper and correct operation, maintenance, control and upkeep of the equipment. All actions (including but not limited to the operation, maintenance, control and upkeep) relating to the equipment must be carried out in accordance with the instructions that have been specifically prepared for such purposes. Outotec prohibits anyone from using this guide for any purpose other than to obtain general information about the equipment. Outotec does not accept any obligations or responsibilities relating to this guide, and shall not be responsible for any damage to property or for personal injuries or deaths caused by this guide.



IOM MANUAL B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



29.2 2012



TABLE OF CONTENTS



1



Introduction to the machine



2



Safety



1. IOM MANUAL



3



Machine description



2. SPARE PART BOOK



4



Installation



3.1 OEM REXROTH



5



Operation



4. MDR



6



Maintenance



7



Special instructions



8



Optional devices



9



Appendices



3. OEM



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



29.2.2012



Table of Contents 1.



Introduction to the machine ............................................................................................................. 2 1.1. Unit identification .................................................................................................................... 2 1.1.1. Product identification....................................................................................................... 2 1.2. Manuals and documentation ................................................................................................... 3 1.2.1. Purpose of the document ................................................................................................ 3 1.2.2. Original documents ......................................................................................................... 3 1.2.3. Additional copies and copyright of the document ............................................................ 3 1.2.4. Scope of the document ................................................................................................... 4 1.3. Intended use........................................................................................................................... 4 1.4. Recommended operating conditions....................................................................................... 6 1.5. Warranty information .............................................................................................................. 7 1.5.1. Warranty terms ............................................................................................................... 7 1.5.2. Warranty claim ................................................................................................................ 8 1.6. Prohibited uses of the filter ..................................................................................................... 9 1.7. EC declaration by manufacturer ........................................................................................... 10 1.8. Warning and safety symbols used in this manual ................................................................. 11 1.8.1. Safety symbols ............................................................................................................. 11 1.9. Contact information .............................................................................................................. 17 1.10. Revision history .................................................................................................................... 17



IOM MANUAL PF1032



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



1.



29.2.2012



INTRODUCTION TO THE MACHINE To safely install, operate, maintain and decommission this machine you must read and fully understand the installation, operation, maintenance and safety instructions. Only qualified personnel may install, operate, maintain or decommission the machine.



1.1.



Unit identification



1.1.1.



Product identification Product name



Press Filter



Type designation



PF60



Serial number



PF1032



Year of construction



2012



The product information is presented in the product plate on the machine.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



1.2.



Manuals and documentation



1.2.1.



Purpose of the document



29.2.2012



This manual describes the installation, use and maintenance of the product. Only personnel with proper training are allowed to carry out maintenance and repair work, operate or install the product. This manual must be read and understood by all personnel involved in the operation, installation, maintenance or repairing of the product. This manual contains important information for the safe installation, use and maintenance of the product. Following these instructions will help you avoid risks, reduce repair costs as well as downtime, and improve the reliability and lifespan of the product. 1.2.2.



Original documents All information in this document has been written with our present experience and insight, to the best of our knowledge. The original version of this manual may have been written in another language. Details about the original document version and translation are written on the front cover. All illustrations and drawings in this document only serve as a general illustration, as their details are not always decisive for construction. This document and its appendices must be kept throughout the lifespan of the product. Attach any further changes to the document and keep it clean and accessible for whenever it is needed. If the document is damaged, immediately order a new one. If the product is sold, the new owner must be provided with the document.



1.2.3.



Additional copies and copyright of the document Additional copies of these documents can be ordered from the manufacturer. Please note that additional copies are not free of charge. All rights reserved. The reproduction of the document or the communication of its contents is not permitted without written consent from Outotec (Filters) Oy.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl 1.2.4.



29.2.2012



Scope of the document This manual and its appendices contain the following important information:



1.3.







general information about the purpose and content of the manual, instructions for reading the manual and warranty information







information about safety







information for the installation, operation and maintenance of the machine



Intended use The machine is intended for indoor professional automatic use in the mining and chemical process industries. It is an automatic operating pressure filter for efficient solid/liquidseparation. The machine can be operated remotely from a control room or locally from the control panel. The main operating stages of the PF filter include filtering, diaphragm pressing, cake washing and compressed air drying.



DANGER It is strictly forbidden to use this machine in any other way or for any other purpose, other than those specified in this instruction manual and its appendices.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



29.2.2012



The filtration area can vary depending on the model, as shown in the table below.



PF M60 Model



60



72



84



96



108



120



132



144



Filtration area (m²)



60



72



84



96



108



120



132



144



Filter plates (pcs)



10



12



14



16



18



20



22



24



Filter plate size (mm)



1 500 x 4 010



Main dimensions, length (mm)



6 800



Main dimensions, width (mm)



5 040



Main dimensions, height (mm) Weight (metric tons)



5 120



68.5



5 820



71.5



77



6 520



80.0



Required floor area (m²)



110



Max. pressure (bar)



16



Filter cloths, width (m)



1.7



Filter cloths, length (m)



62.5



73.5



84.5



95



7 220



85.5



88.5



94.0



97.0



105.5



116.5



128



136



Electric motors (400V, 50 Hz) Hydraulic unit (kW-r/min)



90 - 1 500



110 – 1 500



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



29.2.2012



GENERAL MARKING PRINCIPLE for filters: Company, Brand, Filter family, Size specification(s)/series, Material, Extra parameters, options Outotec PF 144/144 M60 1 60 Larox



PF



144



144



M60



1 60 Chamber height Construction material Filter series Frame size (max. filtration area) 2



Filtration area [m ] Pressure Filter



Construction material (material of parts in direct contact with slurry or filtrate): 1. AISI 304L, used in processes in which pH = 4-14 2. AISI316L, used in processes in which pH = 2-4 3. ASTM NO8904L, used in strongly acid processes in which pH = 1-2 5. Other steel material Chamber height: 45 =



45 mm chamber



60 =



60 mm chamber



75 =



75 mm chamber



Filter Series:



1.4.



M=



Mining & metallurgy



C=



Chemical processing



Recommended operating conditions 



Ambient temperature:



0°C … 50°C



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



1.5.



Warranty information



1.5.1.



Warranty terms



29.2.2012



Warranty terms of the delivered goods are in accordance with the "contract" or the "contractual purchase order" or if otherwise not specified, then in accordance with general terms NL 85 and NLM 84 with the exception of the below mentioned amendments and additions: The warranty does not cover: -



Wearing parts such as filter cloths, diaphragms, seals, slide pieces, valve balls and sleeves, V-belts, chains, scrapers, grids, closing device, hydraulic hoses and hydraulic seals.



-



Direct or consequential damages which have been caused by structural alterations or use of such parts, which are not of original manufacture.



-



Any filter or part of the filter that has been resold by the original contractual purchaser unless agreed in writing with Outotec of the transfer of the remaining warranty period to the new owner.



The claims against the warranty must be made by the purchaser in writing, within a reasonable time after the damage has been discovered. The following information must be indicated on the claims: -



The serial number of the filter



-



Date when the damage was discovered



-



Operational data of the filter when the damage was discovered



-



Full details of the damage



The damaged part must be sent with the claim to Outotec, freight prepaid. If the mentioned terms are not followed properly, the purchaser may loose his right to the warranty. Unless otherwise stated, the warranty of the repair work and/or replacement parts shall expire simultaneously with the warranty of the filter.



Outotec (Filters) Oy



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl 1.5.2.



29.2.2012



Warranty claim WARRANTY CLAIM Customer’s name/Contact Address



CLAIM



RETURNED GOODS



DATE:



Affiliate or distributor Outotec (Filters) Oy P.O.Box 29 FIN-53101 Lappeenranta, Finland



Country Phone



E-mail



Phone



+358 20 529 4236



E-mail:



[email protected]



Fax



Fax



+358 20 529 4439



Internet:



www.Outotec.com



Filter type



Model



Principal part involved



Part No.



Filter No.



Date of failure Operating cycles or time



For Outotec’s use only Type of operation Business unit Description of the case, place, circumstances, etc.



Goods to be returned Component delivered to customer with filter other delivery date: Qty. Code Description



Signature



For Outotec´s use only Actions To be repaired



Warranty status Warranty period



Yes Date



By



No



Rejected Date of credit



Credit invoice



Claim returned for completion To be scrapped



To be delivered to supplier for inspection



Claim accepted Date



By



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



1.6.



29.2.2012



Prohibited uses of the filter



DANGER It is strictly forbidden to use this machine in any other way or for any other purpose, other than those specified in this instruction manual and its appendices.



WARNING Crushing hazard. Falling filter plates can cause death or serious injury. Do not place body parts between the filter plates without first securing the hanging plates. 



Do not use the feed hoses or filter plates for climbing.







Do not take samples from the solids flow when the machine is discharging.







Do not change the process operation parameters in the PLC. This can cause product related problems, such as blocking and blinding of the feed lines. This can also lead to mechanical failures of the filter elements.







The slurry used in the machine may only be in accordance to the original technical specification. Use of other slurry may cause corrosion, mechanical wear, chemical hazards etc.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



1.7.



29.2.2012



EC declaration by manufacturer The machine can be delivered in two alternative executions according to the definition by the EC Machinery Directive 2006/42/EC as follows: (a) as “complete machinery” (ref. Directive 2006/42/EC, Article 2 (a)) with the following declaration: EC Declaration of Conformity of the Machinery (Directive 2006/42/EC, Article 5, Annex II, Sub A) NOTE!



CE-mark fixed on the machine by manufacturer.



(b) as “partly completed machinery” (ref. Directive 2006/42/EC, Article 2 (b)) with the following declaration: Declaration of Incorporation of Partly Completed Machinery (Directive 2006/42/EC, Article 5, Annex II, Sub B) NOTE!



Machine delivered without a CE-mark.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



1.8.



29.2.2012



Warning and safety symbols used in this manual The warnings in this manual have been divided into the following categories. The term “DANGER” indicates a hazardous situation which, if not avoided, will result in death or serious injury. The term “WARNING” indicates a hazardous situation which, if not avoided, could result in death or serious injury. The term “NOTICE” indicates a situation which, if not avoided, could result in damage to property.



1.8.1.



Safety symbols The safety symbols found in this manual may also be posted on the machine. All personnel involved in the operation, installation, maintenance or repairing of the machine must observe and be familiar with all safety symbols, labels and instructions.



Keep safety instructions and safety labels clean and visible at all times.



Replace any illegible or missing safety instructions and safety labels before operating the machine.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



29.2.2012



Hazard The black symbol inside a yellow triangle with a black border describes the hazard. Prohibition The black symbol inside a red ring with a diagonal red bar describes the action that should not be taken. Mandatory action The white symbol inside a blue circle describes the action that must be taken to avoid a hazardous situation.



Hazard symbols These symbols are used in warnings to indicate a hazardous situation or action. Hazard symbols are divided into five categories according to nature: 



Mechanical hazards







Electrical hazards







Radiation hazards







Material/substance hazards







Ergonomic hazards







Second Heading



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29.2.2012



Mechanical hazard symbols The hazard symbols related to each hazardous situation are presented in the following table.



Falling load hazard



Squashing hazard



Flying material hazard



Crushing hazard - feet



Crushing hazard - hands



Cutting hazard



Entanglement hazard



Entanglement hazard



Entanglement hazard



Falling hazard



Trip hazard



Skin injection hazard



High pressure injection hazard



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



29.2.2012



Electrical hazard symbols



Electrical hazard



Dangerous electrical voltage



Electrical shock / Electrocution hazard



Radiation hazard symbols



Radioactive hazard



Laser hazard



Material / Substance hazard symbols



Hot surface hazard



Explosion hazard



Flammable hazard



Hazardous / Poisonous material hazard



Chemical burn hazard



Silica / dust hazard



Ergonomic hazard symbols



Lifting hazard



Environment pollution hazard



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29.2.2012



Prohibited action symbols These symbols are used in warnings and notifications to indicate an action that should not be taken. The prohibited action symbols are presented below.



No climbing



No smoking



No open flames



Do not touch



Limited or restricted access



Do not weld



Do not remove safety guard



General symbol for prohibited action



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29.2.2012



Mandatory action symbols These symbols are used in warnings and notifications to indicate an action that must be taken. The mandatory action symbols are presented below.



Wear safety gloves



Wear eye protection



Wear safety helmet



Wear safety harness



Wear ear protection



Wear steel toed safety boots



Wear close fitting overalls



Wear high visibility vest



Wear respirator



Disconnect from power source



Switch off and lock equipment



Read the manual or instructions



Use cardboard for locating leaks



General symbol for mandatory action



IOM MANUAL PF1032 B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



1.9.



1.10.



29.2.2012



Contact information Manufacturer



Outotec (Filters) Oy



Adress



P.O. Box 29 53101 Lappeenranta



Telephone



+358 20 529 4236



Fax



+358 20 529 4439



Internet



www.Outotec.com



Revision history Revision



Date



Change



A



24.10.2011



Draft



B



29.2.2012



Final



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Table of Contents 2.



Safety.............................................................................................................................................. 2 2.1. Main safety risks and residual risks related to the installation, use and maintenance of the machine .......................................................................................................................................... 2 2.2. Personnel requirements......................................................................................................... 5 2.2.1. Instruction form ............................................................................................................. 5 2.3. Fire safety.............................................................................................................................. 6 2.4. Danger zones ........................................................................................................................ 6 2.5. Emergency stops and stopping devices ................................................................................. 8 2.5.1. Emergency stops .......................................................................................................... 8 2.5.2. Protective door system ................................................................................................ 10 2.6. Location of the main switch ................................................................................................. 11 2.7. Personal protective equipment ............................................................................................ 12 2.8. Installation and maintenance of the pneumatics .................................................................. 13 2.9. Installation and maintenance of the hydraulics .................................................................... 14 2.10. Installation and maintenance of the electrical system...................................................... 15 2.11. Safety during welding and grinding ................................................................................. 16 2.12. Safety equipment ............................................................................................................ 17 2.13. Vibration value ................................................................................................................ 17 2.14. Lubricants and other chemical substances ..................................................................... 17 2.15. Original spare parts ........................................................................................................ 17 2.16. Making modifications to the product ................................................................................ 18



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2.



SAFETY



2.1.



Main safety risks and residual risks related to the installation, use and maintenance of the machine



Make sure there are no unauthorized persons in the danger zones during use.



Always use personal protective equipment, such as a safety helmet, goggles, protective overalls, protective footwear and safety gloves when working with the machine. Other protective equipment, such as ear protection, a respirator etc. must also be used whenever needed. When carrying out maintenance or repair work, make sure the machine cannot accidentally be turned on. Use the appropriate lockout-tagout procedure.



Observe local laws, rules and regulations whenever applicable.



To avoid potential damage or injury, carefully plan your work beforehand.



Keep all warning labels on the machine clean and visible at all times.



All discovered defects or faults must immediately be brought to the attention of the operator or an authorized person.



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DANGER



It is strictly forbidden to remove or disable any safety feature before starting the machine. When the machine is in use, all safety features must be in place and operational.



Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Stop the machine completely before maintenance, repairs or disassembly. Do not touch the machine unnecessarily when it is use. Electrocution hazard. Electrocution will cause serious injury or death.  



Connect the grounding points on the frame of the machine to an earth before connecting the machine to a power supply. Cut the power supply to the machine before maintenance, repairs or disassembly and use the appropriate lockout-tagout procedure.



Falling load hazard. Falling loads will cause severe injury or death. Never stand under a lifted load.



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WARNING High-pressure air injection hazard. High pressure air spray can cause death or serious injury. Ensure the pneumatic system is not pressurized before maintenance, repairs or disassembly. High-pressure oil injection hazard. Compressed hydraulic oil can cause death or serious injury. Ensure the hydraulic system is not pressurized before maintenance, repairs or disassembly. Slipping/tripping hazard. An untidy work area can cause severe injury or death. Keep the machine and the area around the machine accessible and clean. Clean up spilled liquids and oils immediately. Cutting hazard. Sharp edges or corners on the machine can cause severe injury or death. Wear the appropriate protective equipment when working near the machine. Burning hazard. May cause severe injury or death. Some surfaces of the machine or substances used in the process may be hot. Wear protective overalls and gloves and do not unnecessarily touch the machine.



Fire hazard. Fire can cause death or serious injury. Keep heat sources, ignition sources and all forms of open fire away from the machine.



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2.2.



2.2.1.



29.2.2012



Personnel requirements 



Only reliable personnel may carry out installation, operation, maintenance or decommissioning work on the machine.







Personnel must be trained or instructed to carry out their duties. Ensure that only authorized personnel are working with the machine.







Clearly define the responsibilities and accountabilities of each member of personnel.







Only an experienced person may train and instruct personnel or supervise apprenticeships.







Electrical work may only be carried out by a qualified electrician or by an instructed person who is under the supervision of a qualified electrician.







Only qualified personnel with experience may carry out work on the hydraulic/pneumatic system.



Instruction form The following instruction confirmation form can be used to ensure personnel have been familiarized with important information concerning the filter.



Instruction Confirmation



_____________________ Name of the person to be instructed No. Instruction item



1.



To read the Operating Instructions and to clarify all possible questions.



2.



The operation method of the filter



3.



Pictographs and information signs



4.



Safety equipment of the filter



5.



Personal protective equipment



6.



Changing the filter cloth



7.



Work regulations



8.



Additional operating instructions



9.



Cleaning instructions



_____________________ Function of the person to be instructed Date Signature of Signature of instructed instructor person



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2.3.



29.2.2012



Fire safety



WARNING In the event of a fire, immediately evacuate the area to reduce the risk of injury from flames, heat, hazardous vapors, explosion, or any other hazard that may arise.



Follow your local rules and regulations in the event of a fire.



2.4.



Danger zones



Do not unnecessarily touch the machine when it is in use.



A danger zone is any space within and/or around the machine in which a person can be exposed to hazards. The danger zones have been recognized during the design phase of the machine (risk assessment process) and the risks have been minimized by design and by the use of safety guards and/or safety devices. When the safety instructions in the manuals are observed and all safety features are in place and operational, moving inside the “Danger zones” is safe and allowable. The danger zones are presented in the following illustration.



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29.2.2012



1 2



3



4



1



DANGER ZONE A



2



DANGER ZONE B



3



DANGER ZONE C (Both sides)



4



DANGER ZONE D (Both ends)



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2.5.



Emergency stops and stopping devices



2.5.1.



Emergency stops



Make sure the emergency stops are accessible at all times.



Check operation of the emergency stops and protective doors weekly.



The filter is equipped with several emergency stop buttons. In case of danger, the filter can be stopped immediately by pressing the emergency stop button. When the button is pushed, the filter stops and all of its functions cease. An emergency stop message is displayed on the screens in the control room. After all emergency stop buttons are released, the emergency stop circuit can be reset by pressing the alarm acknowledgement push button.



NOTE!



When the filter is equipped with protective door system, all filter protective doors must be closed in order to operate the filter automatically. If any door is opened during automatic operation, the filter stops immediately.



NOTE!



Only test mode functions are possible with doors opened



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The location of the emergency stop push buttons are displayed in the following illustration.



1 2 6



7 4 S701 S710S708S733S713S780S755 S700



0IT 7 M A IN S W C H



5 3



1. 2. 3. 4.



EMERGENCY STOP S707 EMERGENCY STOP S702, ON HAND HELD UNIT CONTROL PANEL EMERGENCY STOP S701, ON CONTROL PANEL



NOTE!



5. 6. 7.



ALARM RESET PUSH-BUTTON EMERGENCY STOP S705, IN HYDRAULIC UNIT HYDRAULIC UNIT



Reset the emergency stop push button by pressing the alarm reset push-button (5) on the control panel (3). Do not release emergency stop button until it is safe



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29.2.2012



Protective door system NOTE!



All protective doors must be closed in order to operate the filter automatically.



The filter is equipped with protective doors which are monitored with safety switches. All the safety switches are connected to the safety controller. The machine will be brought to a safe state (stop category 0) following actuation of any of the safety switches (i.e. opening a protective door). As a result, all electrical power is disconnected from actuators. If any of the doors are opened during automatic operation, the filter will stop immediately. If any of the protective doors are open, only test mode functions are possible. If a protective door is opened during filtering, it must be acknowledged before filtering can be restarted. The acknowledgement buttons on the filter (2 pcs) are situated on the left and right sides of the filter. The acknowledgement must be done in two parts. Firstly, by pressing the acknowledgement button on that side of the filter at which the protective door was opened. And secondly, after acknowledging the protective door alarm at the filter, the alarm must also be acknowledged from the main filter control cabin within 60 s.



IOM MANUAL PF1032 B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



2.6.



29.2.2012



Location of the main switch The main switch (1) is located on the cover of the control panel (2).



2



1



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29.2.2012



Personal protective equipment The following protective equipment must be made available to all personnel involved in the installation, operation and maintenance of the machine.



Wear protective gloves.



Wear steel toed safety boots.



Wear a helmet.



Wear close fitting protective overalls.



Wear protective eye wear when handling possibly hazardous substances and applied media.



Wear ear protection.



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2.8.



29.2.2012



Installation and maintenance of the pneumatics



Only qualified personnel are allowed to carry out installation, maintenance and repair work on the pneumatic system.



Wear safety goggles when maintaining, repairing or disassembling the pneumatic system.



The customer must provide a device with which the machine can be disconnected from the pneumatic supply. The device must be clearly marked and lockable to prevent accidental switch on.



WARNING High-pressure air injection hazard. High pressure air spray can cause death or serious injury. Make sure the pneumatic system is not pressurized before maintenance, repairs or disassembly. 



Perform a visual check of all pipes, hoses and screw fittings for leaks and visible damage daily and regularly check the condition more thoroughly. Repair any damage immediately.







To locate leaks in the pneumatic system, use a piece of cardboard.







Lay and install all lines and connections correctly. Fittings, lengths and hose pipe qualities must correspond to requirements.



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2.9.



29.2.2012



Installation and maintenance of the hydraulics



Only qualified personnel are allowed to carry out installation, maintenance and repair work on the hydraulic system.



Wear safety goggles when maintaining, repairing or disassembling the hydraulic system.



The customer must provide a device with which the machine can be disconnected from the hydraulic supply. The device must be clearly marked and lockable to prevent accidental switch on.



DANGER Hydraulic fluid injection hazard. High-pressure hydraulic fluid spray can penetrate the skin and will cause death or serious injury. Make sure the hydraulic system is not pressurized before maintenance, repairs or disassembly. 



Perform a visual check of all pipes, hoses and screw fittings for leaks and visible damage daily and regularly check the condition more thoroughly. Repair any damage immediately.







Lay and install all lines and connections correctly. Fittings, lengths and hose pipe qualities must correspond to requirements.







Avoid skin contact with the hydraulic fluid.



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2.10.



29.2.2012



Installation and maintenance of the electrical system Only qualified personnel are allowed to carry out the installation, maintenance and repair work of the electrical system.



The customer must provide a device with which the machine can be disconnected from the electrical supply. The device must be clearly marked and lockable to prevent accidental switch on.



DANGER



Electrocution hazard. Electrocution will cause severe injury or death. Cut the supply voltage before performing work on the electrical system.



NOTICE Stop the machine immediately if electrical failure occurs.



Only use original Outotec (Filters) Oy fuses with the correct intensity of current.



If it is absolutely necessary to work on live parts, ensure there is a second person present to actuate the main switch or emergency stop. Appropriately close off and clearly mark the working area. Only use appropriate, insulated tools and devices.



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2.11.



29.2.2012



Perform a visual check of the condition of the electrical equipment daily and regularly check the electrical equipment of the machine more thoroughly. Repair all defects immediately. Examples of typical defects: loose connections or damaged cables.



Safety during welding and grinding Before starting welding, determine the material to be welded, the appropriate method of welding and the consumables.



Carry out welding, firing or grinding on the machine only if it is permitted.



DANGER



Explosion hazard. Explosions will cause severe injury or death. Clean all dust and flammable substances from the machine and its surroundings and ensure sufficient ventilation.



Poisonous gas hazard. Poisonous gases will cause severe injury or death. Maintain and check the working order of the ventilation installations regularly.



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2.12.



2.13.



29.2.2012



Safety equipment 



Emergency stop push buttons







Protective door system (if applicable)







Safety rails







Safety covers and plates







Warning labels







Working platforms



Vibration value The highest root mean square value of weighted acceleration does not exceed 0,5 m/s2.



2.14.



Lubricants and other chemical substances



Materials and supplies are to be used and disposed in accordance with the manufacturer’s instructions.



Use appropriate personal protective equipment when handling chemical substances.



WARNING Hot materials hazard. Hot materials and supplies can cause severe injury or death. Observe extreme caution and wear appropriate personal protective equipment when handling hot materials or supplies.



2.15.



Original spare parts Only original spare parts or Outotec (Filters) Oy approved parts may be used for replacement. NOTE!



Any damage that occurs by using other than original or Outotec (Filters) Oy approved spare parts or accessories rules out all liability and warranty on the suppliers’ behalf.



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2.16.



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Making modifications to the product



DANGER It is strictly forbidden to modify this machine or use it in any other way or for any other purpose, other than those specified in this instruction manual and its appendices. Unauthorized changes and modifications may affect operation and/or safety and may result in damage to property, personal injuries and even death.



Any modifications to the product may only be carried out by trained personnel with written consent from Outotec (Filters) Oy. If an unauthorized modification has been implemented, it’s effect on warranty liability will be considered and may result in the rejection of warranty applications. Outotec (Filters) Oy reserves the right to make alterations to the product at any time, in order to: 



improve the product;







update the product to comply with changed applicable standards;



if the need for modifications is recognized by Outotec (Filters) Oy.



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Table of Contents 3.



Machine description ........................................................................................................................ 2 3.1. Technical description ............................................................................................................. 2 3.2. Process operations ................................................................................................................ 2 3.2.1. Plate Pack ..................................................................................................................... 3 3.2.2. Process Piping .............................................................................................................. 6 3.3. Auxiliary operations ............................................................................................................... 7 3.3.1. Closing mechanism ....................................................................................................... 7 3.3.2. Cloth ............................................................................................................................. 8 3.3.3. Pressing air pipe ........................................................................................................... 9 3.3.4. Cloth drive mechanism ................................................................................................ 10 3.4. Control operations ............................................................................................................... 12 3.4.1. Control panel ............................................................................................................... 12 3.4.2. Hydraulic power system .............................................................................................. 14 3.5. Functional Description of the Filter....................................................................................... 21 3.5.1. Principle of pressure filtration ...................................................................................... 21 3.6. Description of Controls and functions .................................................................................. 26 3.6.1. Control panel ............................................................................................................... 26



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MACHINE DESCRIPTION Technical description Type OUTOTEC PF 60 SERIES Filtration area Frame size Plate size Number of filter plates Chamber volume Main dimensions (with service platforms) Required floor area Weight (Filter without auxiliary equipment) Filter cloth



length width height



width length



Electric motors (460 V, 50 Hz) - hydraulic unit Pressures - Slurry feed - Pressure air - Pressure air (valve actuators) - Air blow drying - Cloth wash water



3.2.



mm pcs 3 m mm mm mm 2 m t



144/144 144 144 1500 x 4010 24 8.64 6800 5040 7220 110 97



mm m



1700 136



kW - r/min



110 - 1500



bar bar bar bar bar



2.2 - 1500 2.0 - 10.0 2.0 - 16.0 6.0 – 12.0 4.0 - 12.0



m



2



Process operations



DANGER Hazardous moving parts. The plate pack consists of several moving parts, which can cause serious injury or death. Never touch the plate pack during operation



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WARNING High-pressure liquid injection hazard. Compressed liquid can cause death or serious injury. As a result of seal damage or foreign objects between the plate pack, liquid squirts are possible. When the pack is closed, always be careful.



3.2.1.



Plate Pack The filter plate consists of three main parts: the filtrate chamber (1), base plate (2) and frame (3). Note that all feed channels must be open to ensure that both sides of the plate are under equal pressure during all operation stages. Otherwise the plate bends and causes leakages in the plate pack and damage the filter cloth.



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D D



A



A



9



2



7



1



6



8



7



10



D-D



1. 2. 3. 4. 5. 6. 7. 8. 9. 10.



4



2



3



4



4



5



FILTRATE VAT BOTTOM PLATE FRAME GRID DIAPHRAGM SEAL FILTRATE COLLECTOR SLIDE PIECE LONGITUDINAL GUIDANCE SLIDE PIECE LATERAL GUIDANCE COLLECTOR SEAL



A-A



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Filtrate chamber (1) The filtrate chamber collects the filtrate and leads it out through the collectors attached to the corners of the chamber. Bottom plate (2) The bottom plate is a frame part in which all parts of the filter plate are attached. The pressing air channel is led through the bottom plate. The bottom plate and diaphragm form the pressing air chamber. Frame (3) The frame works as a fixing element for the diaphragm. The plate pack seal is fixed to the lower surface of the frame. The feed channels leading into the filtration chamber have been led through the frame. Grid (4) The grid supports the cloth and forms an outlet for the filtrate. Diaphragm (5) The rubber diaphragm acts as a pressing element. The cake is pressed against the filter cloth and the grid by means of pressurized air. As a result of the pressure, the liquid is removed from the cake through the filter cloth into the filtrate chamber. Pressure may rise above 16 bar, but as far as the durability of the diaphragm is concerned, it’s much more recommendable to start with a pressure of 8 bar. And when the pressure is rising, the effect of the pressure rise on the pressing time and the residual moisture should be observed. In this way the most suitable pressure for each process and slurry can be determined. In temperatures above + 60 °C, a strong aging phenomenon affects to rubber. If the slurry to be filtered is hotter than + 60 °C, pay special attention to the temperature and follow the manufacturer's instructions. Observe the condition of the diaphragms continuously. In case the consumption of pressurized air has increased and it flows into the chamber even at the end of pressing stage, change the damaged diaphragm immediately. Seal (6) The seal is fixed to the frame on the chamber's side in order to prevent slurry leakages. There is no seal below the cloth, but the cloth and plastic surface are face to face. If a counterpressure forms a space below the cloth, the filtrate starts to leak from the plate pack.



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Filtrate collector (7) The filtrate collectors form the channels through which the filtrate is discharged from the plate pack in the "pack closed" position.



Observe the collectors’ alignment. Removing the collectors causes leakage in the line. Correct their position.



The wear of slide pieces and/or removing the filtrate chamber is causing these changes. Refer to paragraph "Adjustment of slide pieces", 3.5. 3.2.2.



Process Piping The Outotec (Filters) Oy PF filter includes two pipelines, which are directly in contact with the filtration process; the feed pipe and the filtrate pipe.



Filtrate pipe The purpose of the filtrate pipe is to remove the filtrate or the wash liquid (filters with cake washing) which has penetrated through the cake. Feed pipe The slurry as well as drying air is led through the feed pipe into the filter chambers. Also in filters with a cake washing option the same route is used for the washing liquid. All these different operations can be accomplished with pinch valves. Slurry is pumped through the lower end, drying air and the possible washing liquid through the upper end of the feed pipe.



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3.3.



Auxiliary operations



3.3.1.



Closing mechanism



29.2.2012



General The closing mechanism comprises quick action cylinders (1), sealing cylinders (2) and locking pins (3) as indicated in the enclosed drawing. The closing of the plate pack takes place in two stages: first the plate pack is closed by means of quick action cylinders (1) and after closing, the plate pack is sealed with sealing cylinders (2). Quick action The plate pack is open after previous cycle. The plate pack closes when the top pressing plate (5) is driven to its lowermost position by means of quick action cylinders (1). After this, the locking pins (3) fix the top pressing plate (5) to the columns (6) that have been fixed to the base plate (7). The filtration chambers have thus been formed, and the plate pack is now surrounded by the pressing plates, base plate and columns. Sealing After locking, the filtration chambers are sealed tightly by pressing the plate pack (4) between the pressing plates by sealing cylinders (2) fixed to the base plate (7). When the sealing cylinders (2) reach the pressure required for closing the plate pack, automatically controlled locking valves shut off their oil connecting elements. The purpose of these valves is to secure that the cylinders stay in place. After filtration, the plate pack opens for cake discharge. The sealing cylinders (2) return to their initial position, after which the locking pins (3) are drawn to their "open" position, which releases the top pressing plate (5) for quick opening. When the filter is stopped for maintenance, make sure that the plate pack is in its upper position and the pressing plate is fixed with locking pins (3) to the columns (6).



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3.3.2.



29.2.2012



Cloth The cloth operates both as a filtering element and as a conveyor belt transporting the cake out of the filter. Besides having a good filtering ability, the cloth must be able to withstand heavy pulling. Only special type of fabrics can be used. The most commonly used material is a multifilament fabric which is lengthwise (warp) stronger than crosswise (weft). Pay special attention to possible holes in the cloth. Patch the holes immediately; solid matters entering through the holes wear the filtrate channels heavily especially during drying when the air flow speed is high.



Cloth wash To sustain the cloth's filtering properties, a part of the cloth is spray-washed by pressurized water after every filtration cycle. The washing takes place automatically and simultaneously with the cloth travel. Make sure that all the nozzles stay open and that the sprays are directed towards the cloth in a correct angle. No unwashed stripes must be left on the cloth. If necessary, rinse the wash liquid filter located in the wash liquid piping. The wash water consumption is comparable to the available pressure according to the curve presented below. The consumption of water is fractional - it is used only when the cloth is moving.



NOTE!



Due to the efficient operation of the nozzles, the pressure recommendation is 10-14 bar.



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Pressing air pipe The pressing air pipe distributes pressing air in the diaphragms. The operation is carried out with the pressing air and controlled by pressing air inlet valve V03 and return valve V04.



V24



V03



3



1



2



V04



1 Pressing air in 2 Pressing air out 3 Diaphragm lifting up V03 Valve closes on failure of actuating energy V04 Valve closes on failure of actuating energy V24 Valve closes on failure of actuating energy



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29.2.2012



Cloth drive mechanism To remove the cakes and to wash the cloth, the cloth is moved by means of drive rollers between filtering cycles. A spring-loaded pressing roller presses the cloth against the drive roller in order to maintain the tension.



1. 2. 3. 4. 5. 6. 7.



Vat roller Main drive roller Pressing roller Centering roller Impulse roller Tensioning roller Guide roller



8. 9. 10. 11. 12. 13.



Auxiliary drive roller Cloth scraper Roller scraper Cloth wash nozzles Cake Spread roller



Cloth travel adjustment An encoder attached to the roller measures the length of cloth travel. The discharge length (plates) must be defined so that the filter is discharged completely. Check that the clipper seam finds its right position on the guide roller, i.e. outside the sealing surface.



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Cloth tensioning device The change in the cloth length, that takes place during the opening of the plate pack and cloth travel is compensated by means of tensioning device. A torque, which is brought about by means of hydraulic motor tightens a pair of chains fixed to the tensioning roller. Observe the pressure used by the tensioning device motor and compare it to the pressure used during the start-up. You may increase the torque by raising the pressure and decrease it by lowering the pressure. Cloth tracking Cloth tracking operates automatically by means of a roller movable at its other end. The cloth may also be tracked manually with the help of push-buttons to a desired direction. Due to manufacture, there are slight bends on the cloth to avoid the cloth drifting slightly to the sides while moving. When tracking the cloth manually, let the cloth circulate several times and make sure that it does not drift to either side systematically. If the cloth does not stay centered, the cloth seam is inclined or one of the rollers does not rotate.



Observe that the cloth stays in the center area.



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3.4.



Control operations



3.4.1.



Control panel



29.2.2012



The control panel contains a programmable logic (PLC) which enables an automatic control of the filter. The operator interface terminal is formed of a DIGITAL touch screen unit which is connected to the programmable logic via a serial connection port. Information exchange between PLC and the touch screen unit is automatically affected by the touch screen unit.



DANGER Explosion hazard. Explosions will cause severe injury or death. Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous.



Explosion hazard. Explosions will cause severe injury or death. When in hazardous locations, turn off the power before replacing or wiring the modules.



A window provided with a lock protects the operator interface; this window should always be kept locked when the display screen is not used. Similarly, the control panel door must always be closed, unless maintenance measures otherwise require. NOTE! The changes in the PLC program are only allowed when accepted by the manufacturer



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It is not allowed to add or remove any components from the control panel without the manufacturer's permission. All components replaced during maintenance must fulfill at least all the same technical requirements as original parts.



DANGER Electrocution hazard. Electrocution will cause severe injury or death. It is not allowed to use the control panel power supply for any other external equipment



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Hydraulic power system The Hydraulic Power Unit (HPU) contains all elements to provide hydraulic power generation including fluid pressure and flow control. It also accommodates hydraulic fluid storage, filtration and temperature control. The HPU is a complete unit and may be situated in a separate space from the Outotec pressure filter.



1. 2. 3. 4. 5. 6. 7. 8.



OIL COOLER ELECTRICAL MOTOR COUPLING PRESSURE ACCUMULATOR HYDRAULIC PUMP P1 HYDRAULIC PUMP P3 RETURN FILTER OIL LEVEL / TEMPERATURE



9. 10. 11. 12. 13. 14.



THERMOMETER HYDRAULIC OIL HEATER OIL LEVEL INDICATOR AIR FILTER PRESSURE FILTER MANIFOLD BLOCK



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Reservoir The reservoir, volume of 600 liters (161 GAL) provides the storage of the hydraulic fluid. The fluid level is monitored with transmitter B501 and the temperature with transmitter B601. Transmitters B501 and B601 are integrated into the same apparatus. Safety switch S601 stops the pump if the oil temperature is too high. The hydraulic fluid temperature is controlled with an oil cooler (45). Transmitter B601 controls the cooling by activating either fan motor M05 or cooling water circulation. This depends on the type of hydraulic unit. The return fluid into the tank is passing through the filter cartridge RF. The cartridge condition is monitored by differential pressure switch S410. In the head side is situated thermometer TM and level indicator LE, and for dusty conditions is available an air breather.



M05



OC



AF



LH B501 TM TH B601 °C



65°C



HE R04



SV3 SV1 S821



°C



S601



S823 L P1



Rkv



A



L P3



Y PR01



S410 RF



5 B



600L



Alternative water cooler. Cooling water flow is controlled with thermostat.



W2 W1 OC



S410 RF



A



B



5



Alternative air breather provides air filtration when fluid level changes



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Hydraulic pumps The fluid pressure is generated with two radial piston pumps, which are driven by one constant speed 3-phase electric motor M01.



Y11



HV1



PR01 PR1



13O bar



290 bar S210



PG1 MP1



Y31



HV3



PR3



220 bar



50 l/min



FC3 1



S215



S215



MPP1 S210



MP2 B403



PP1



S412



MPP2 DR PP2



ACC



PG3



10l Precharge 100 bar



PGO ACCU



B401



P1 M01



P3



SV1 S821



SV3 S823



A variable displacement pump P1 produces pressure to primary hydraulic circuit. The maximum displacement of the pump is 250 cm³/rev and its maximum pressure and maximum flow are electrically controlled by a p/Q amplifier. The amplifier controls a servo solenoid valve in the pump(P1) pilot circuit. The pump control system uses following signals: -



Pressure set point signal Up (0...10 VDC) from Outotec control system



-



Flow set point signal UQ (0...10 VDC) from Outotec control system



-



Feedback signal from system pressure transmitter B411 (4...20 mA)



-



Feedback signal from pilot stage (servo solenoid valve spool) position transducer (10VDC)



-



Feedback signal from stroke ring position transducer (displacement) (10VDC)



Pump P3 produces fluid power to accumulator circuit. It is a variable pump with maximum displacement of 45 cm3/rev. The suction sides of both pumps are connected to the reservoir with reinforced rubber hoses.



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Valve Unit The valve unit is attached on to the top of the hydraulic oil reservoir. The unit includes hydraulic accumulator AC and its control circuits, pressure relief valves, pressure transmitters and pressure gauges. The hydraulic fluid from pump P1 enters the valve unit through port PP1. Pressure is measured with two pressure transmitters, one of which (B411) is only for pump control feedback signal and is not connected to the PLC system. Pressure gauge PG1 shows the primary circuit pressure. The primary circuit pressure relief valve PR1 limits the system pressure to the pre set value (290 bar). The hydraulic fluid from pump P3 enters the valve unit through port PP2 and is used in accumulator circuit. See Accumulator circuit for functional description. Ports P1 and P3 are the pressure connections to the pressure filter. Port T1 returns the fluid back to reservoir. P1



P3



Y11



T1



HV1



PR01 130 bar



290 bar



PR1 S210



PG1 MP1 Y31 S215



HV3



PR3



MT



50 l/min



FC3.1



S215



MPP1



S230 S210



PP1



220 bar



MPP2 PP2



S230



DR TB



ACC 10l



Precharge 100 bar



PG0 ACCU



TC



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Accumulator Circuit The circuit is equipped with accumulator (AC) to provide hydraulic pressure during power failures. The accumulator also provides the minor operations while the hydraulic pump is idling. The accumulator has a steel shell with rubber bladder, and it’s pre-filled with nitrogen gas to appropriate pressure. The accumulator pressure is monitored with pressure transmitter B403 and pressure gauge PG0, and the maximum pressure is limited by means of pressure relief valve PR03. The circuit pressure is controlled with pressure reducing valve PR01 and monitored by means of pressure gauge PG3. Accumulator charging is controlled with displacement of pump P3 and with pressure relief valve PR03. Displacement of the pump P3 is adjusted close to zero when system is not chargin the accumulator. The accumulator pressure and recharging are monitored with the alarm circuit. See B403 for details. P1



P3



T1



PR01 130 bar



Y31



HV3



PR3



50 l/min



FC3.1 S230



MPP1



MPP2 DR PP2



S210



PP1



MP2 B403



MT



220 bar



PG3 PG0 ACCU



ACC



S230



TC



TB 10 l Precharge 100 bar



M05 OC P3



SV3 S283



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Filling the oil container Before filling the oil container, ensure that the container is completely clean inside. The container is filled to the upper limit of the oil level gauge with oil according to the recommendations. Filling must take place by using a separate filtration pump unit, which is provided with a max. 5 um abs. full flow filter. The filling quick coupling in the hydraulic unit is located in connection with the return filter. Filling with an open vessel is forbidden. Note!



The barrel oil delivered by oil companies is not clean enough for the hydraulic system. If the barrel oil is used without separate filtration, the oil filter will be blocked within few days.



The blocking of the oil filter will cause informative alarm by means of pressure switch S410 and high pressure oil filter pressure switch S411.



Filtration pump unit for filling the hydraulic unit.



Oil filling quick coupling in the hydraulic unit



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Start up Before the start-up of the hydraulic system, the following items must be checked: -



Check that the hydraulic piping or components have not been damaged during transportation.



-



Check that the supply voltage and frequency are correct.



-



Check that the rotation direction of the pump is according to the arrow.



Note!



Pay attention when starting the axial piston pump. When the oil temperature is below 10 °C, an incorrect procedure during start-up may damage the pump within few seconds. Pay special attention with the oil viscosity class 46 cSt. Before starting the motor, the immersion heater of the container must warm up the oil until its temperature is at least 10 °C.



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3.5.



Functional Description of the Filter



3.5.1.



Principle of pressure filtration



Filtration When the filter plate pack has been closed, the process slurry is pumped into all filter chambers simultaneously. The solids (cake) begin to form as the filtrate is displaced by more slurry entering the chamber. As the solids build, the pumping pressure increases, and filtrate is forced through the cloth until the required solids thickness is achieved.



Pressing I Pressing air inflates the rubber diaphragms located at the top of each chamber. The diaphragm presses the solids (cake) against the cloth surface squeezing the solids (cake) to remove more filtrate through the cloth.



Washing (optional) The wash liquid is pumped into the filter chambers in the same way as the slurry. As the wash liquid fills the filtration chamber, the diaphragm is lifted up and the air is forced out from the upper side of the diaphragm. The wash liquid flows into the discharge pipes after passing through the solids (cake) and the cloth.



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Pressing II (optional) The diaphragms are re-inflated, forcing the wash liquid uniformly through the solids (cake) as in stage 2 above.



Air drying Compressed air is blown through the solids (cake) for final dewatering. In other words, the air is entered through the distribution pipe filling the filter chamber, raising the diaphragm and forcing the pressing air above the diaphragm out of the filter. The air flow through the solids (cake) optimizes the moisture content and, at the same time, empties the filtrate chamber.



Solids (cake) discharge When the air drying process has been completed, the plate pack opens, cloth moving mechanism starts and the dewatered solids are conveyed out of each chamber on the moving filter cloth. The solids on the cloth are discharged from both sides of the filter.



NOTE!



The four-stage (short) program does not include washing and second pressing stages.



IOM MANUAL PF1032 B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



29.2.2012



Main assembly drawing NOTE!



The filter plates are numbered from bottom to top



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2



1



4



1. 2. 3. 4.



Column no. 1 Column no. 2 Column no. 3 Column no. 4



5



6



8



7 3



5. 6. 7. 8.



HC51 Hydraulic cylinder no.1 HC52 Hydraulic cylinder no.2 HC53 Hydraulic cylinder no.3 HC54 Hydraulic cylinder no.4



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3.6.



Description of Controls and functions



3.6.1.



Control panel The Control Panel is used to facilitate the operation of the OUTOTEC Pressure Filter. All the main controls, which are required for the operation, such as switches, push buttons and the operator interface terminal are located in the control panel. Each push-button, switch and indicator lamp is provided with a label briefly describing the function of the device. 1



2



3



4 8 5 6



9



7



1. 2. 3. 4. 5.



Alarm signal light Touch screen Mode selection Hydraulic unit mode switch Alarm reset push-button



6. 7. 8. 9.



Stop push-button Start push-button Emergency stop push-button Main switch



Alarm signal light (1) In case of an alarm, the alarm signal on top of the panel as well as the S733/H733 button (5) start flashing and an alarm message appears on the display.



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Touch screen (2) The flow diagram is located in the display of the operator interface terminal. The indicator lamps show the present state of the actuator or motor in question.



Mode selection (3) Test mode can be selected only with key switch S780. After activated, the handheld test unit can be used Hydraulic unit mode switch (4) The hydraulic unit is automatically started and stopped according to control system, when the switch S755 is turned to position 1 Alarm reset button (5) When S733/H733 is pushed once the alarm signal will stop flashing. The second push acknowledges and eliminates the cause of the activated alarm



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



S701



S710



EMERGENCY STOP



START / RUN



29.2.2012



S708



STOP/STOPPED



S780 AUTO / TEST



S733



ACKNL / ALARM



0



S755 HYDRAULIC UNIT



0



1



TEST



A



S701



S710 S708 S733



S780



S755



S700



MAIN SWITCH



S700



Stop button (6) Pushing the stop button S708/H708 stops the filter. When the button is pushed once, it illuminates indicating that the filter has stopped Start button (7) To start the filter from the present stage, push the start button S710/H710 once. When the filter is running, the button is illuminated. When the S710/H710 is flashing slowly, it indicates that the filter is ready for operation Emergency stop button (8) The filter is equipped with several emergency stop buttons. In case of danger, the filter can be stopped immediately by pressing the emergency stop button. After all emergency stop buttons are released, the emergency stop circuit can be acknowledged by pressing the alarm reset/acknowledgement push button (S733) EMERGENCY STOP push buttons are not illuminated Main switch (9) The main switch S700 is used for switching on and off the electric supply of the pressure filter



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Table of Contents 4.



Installation and decommissioning instruction................................................................................... 2 4.1. Main Package Dimensions and Weights ................................................................................ 3 4.2. Lifting Instructions.................................................................................................................. 4 4.3. Installation Instructions .......................................................................................................... 6 4.3.1. Installation and connections .......................................................................................... 6 4.3.2. Installation of partially dismantled filter .......................................................................... 9 4.3.3. Installation readiness check list ................................................................................... 12



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4.



29.2.2012



INSTALLATION AND DECOMMISSIONING INSTRUCTION Before starting installation, use the packing list to check that all the items for the filter and all the accessories have been supplied completely and are free of damage. Immediately contact Outotec (Filters) Oy if there are any missing or damaged parts.



IOM MANUAL PF1032 B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



4.1.



29.2.2012



Main Package Dimensions and Weights



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4.2.



29.2.2012



Lifting Instructions 



  



Use appropriate and certified lifting equipment, such as cranes, hoisting slings and hoisting chains for lifting the filter. Ensure that the condition and lifting class of the lifting equipment is sufficient. Carefully plan your work beforehand. The transport accessories (plywood frame, steel supports and tarpaulin) must be kept on the machine while lifting. Lift very slowly and leave enough room around the filter. The filter will not rise quite horizontally. When it is lifted off the platform it tends to move towards its longitudinal axis.



Plan the lifting so that changes of the fixing are at the minimum. Make sure that the condition and lifting class of the cranes are sufficient. Even a “slight” swing or collision may cause severe damages to people or equipment. The main dimensions, weight, lifting points and the centre of gravity of the pressure filter can be seen in manufacturer’s drawing. The pressure filter must be lowered to the platform very slowly because it tends to move slightly towards its longitudinal axis. Once the filter is in its place, the transport supports can be removed.



DANGER Falling load hazard. Will cause severe injury or death. Do not stand under a lifted load.



Squashing hazard. A moving hoisted load will cause severe injury or death. Make sure no unauthorized personnel are in the vicinity of a lifted load.



WARNING Falling hazard. Falling can cause severe injury or death. Moving on the pressure filter (when fixing and loosening lift chains) requires special attention and caution. Water or ice can make the painted surfaces extremely slippery.



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NOTICE Incorrect hoisting may also cause damage to the machinery. Do not damage leads, cables and other components when fixing and loosening the lifting equipment



NOTE!



The shafts of the quick action cylinders (4 pieces) are covered with plastic pipes in the factory. Check that they are in place. Prevent the shafts from being damaged.



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4.3.



Installation Instructions



4.3.1.



Installation and connections



29.2.2012



Before lifting the filter check that the installation site is as level as possible and that the positions of the fixing holes, pipe inlets and cake chutes of the filter frame are according to manufacturer’s drawings Follow the specific lifting instructions for this machine. The pressure filter is installed on a concrete or steel foundation with dimensions as indicated in the confirmed drawings supplied as enclosures to the order confirmation. The filter auxiliary equipment related to the operation of the filter are measured and installed according to the documentation of such equipment. Install the filter in a horizontal position. Check the correct position of the filter by leveling the columns, which must be in a vertical position ( 1mm/m). This instruction does not apply to the operator panel. The filter is delivered fully assembled or in parts depending on the size of the filter and the installation conditions. Screw joints may loosen during transportation. Check all screw joints and if necessary, tighten them before the start up. The piping, which is not included in the delivery, is constructed and connected by the customer according to the Outotec's instructions. The inlet and outlet pipes must be connected to the filter piping flanges or valve ends. The filter is connected to the electrical network according to the cabling instruction drawing (ref drawing in Folder 2 “Electrification”). The cleanliness of the hydraulic system is very important. When installing the hydraulics, make sure that there is no dirt between or inside the components and joints. In case the filter is in a stock for a longer time (2 months or more), it might be reasonable to protect it against corrosion. The procedure of the protection depends on the circumstances. Please contact OUTOTEC to get more information about the current procedure. In case of an extended shut down, (1 day or more) drive the plate pack up and the locking pins out. In this case the corrosion protection has the same rules as above. Before installation it must be checked that all parts mentioned in the packing list have arrived. A seizing deterrent must be used in all screw joints unless otherwise instructed. The tensioning torques of screw joints can be found on the next page. During lifting, general precaution must be observed and all pieces must be protected. Especially the quick action cylinder rods must be covered until the plate pack is moved. The pieces are lifted at the points indicated in the drawings and instructions. Any surface damage must be repaired.



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Due to the height of the filter, a passenger hoist or scaffolding is required for the installation. The weights of different pieces are indicated in the installation instructions and packing lists. Special care and cleanliness must be observed during installation of hydraulics. The pipes/hoses and actuators must be kept plugged until connected. The instructions for the Hand Held operations should be read through carefully before testing any hydraulic functions. Assembly directions of the disassembled filter parts: Even if the filter is delivered ”fully assembled”, there are often some parts that are removed from the assy, for transportation packing. Then, these disassembled parts, i.e. some of the side covers (safety doors and shields) and slurry and filtrate hoses are fixed either into the main filter packing or, as usual, packed in a separate box. For assembling of these or other removed parts of the filter assembly, see the details from assembly and spare part drawings and their parts lists, which are an integral part of Outotec (Filters) Oy filter complete supply. Control panel In case the control panel is separated from the filter, it will be delivered in a plywood box. The control unit weighs about 200 kg. The lifting loops are situated on top of the control panel. The fixing holes of the control panel are inside the control panel. The bag containing moisture aspirating material should be left in its place inside the control panel until the startup. The gadget window must be kept closed. If the piping etc. installation work is carried out near the control panel, it must be covered against dust and dirt.



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Ref. Hydraulic piping, joints ASSEMBLY TORQUE TABLE FOR STEEL TUBING Tube O.D.



Min.



Max.



in.



mm



in. lbs.



daNm (mkg)



in. lbs.



daNm (mkg)



1/4” 5/16” 3/8” 1/2”



6 8 10 12 14 15 16 18 20 22 25 30 32 38



90 135 205 290 380 420 470 570 690 830 1060 1420 1600 2000



1 1,5 2,3 3,2 4,2 4,7 5,2 6,4 7,7 9,3 11,9 16 18 22



130 210 310 420 570 630 710 890 1060 1150 1600 2220 2500 3110



1,5 2,4 3,5 4,8 6,4 7,1 8 10 12 14 18 25 28 35



5/8” 3/4” 7/8” 1” 1.1/4” 1.1/2”



Ref installation/assy of Outotec PF 60 – 144 TORQUE FOR SCREWS AND NUTS Pre-stress approx. 80% of minimum yield limit. Thread



M6



M8



M10 M12 M14



Strength class



Tensioning torque Nm (Nm 0.1 kp m  0.1 kgm)



A4-80



7,8



19



36



65



8.8



11



25



48



80



M16



M18



M20



M22



M24



M27



M30



M36



103



160 230



320



445



570



840



480



850



125



190 265



350



480



590



960



1290



2270



The values in the table require a friction coefficient of 1 = 0.12, 2 = 0.12, which correspond to a lightly oily surface – seizing deterrent must be used in all screw joints unless otherwise instructed.  1= friction coefficient of the thread  2= friction coefficient between the base and the screw (nut) head NOTE!



The screws for the filter plate/frame have their own torque value.



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Installation of partially dismantled filter The filter is delivered partially dismantled. 1. Check: -



The positions of foundation bolts - carry out crosswise measurement



-



That the foundation is horizontal. If needed, adjust the shimming pieces under the frame



2. Fasten the top ends of the columns and lift the upper frame into its place.



Weight 2.2t



2300



1400



700



4.3.2.



29.2.2012



2850 5800



Wooden beam 100x100, l = 2000 (3 pcs)



3. Check that the columns are vertical. If needed, you can adjust the position of the filter with a hydraulic jack (30 - 50 t). The lifting lugs for the jack are situated in the same place as the foundation bolts at the side of the U-bar frame. 4. Lift the cloth tensioning device into its place.



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Dwg. 316223



Wooden beam 100 x100, l=2000 (3 pcs)



5050



3t



2700 NOTE!



Dimension 5050 in the picture is for PF 96. Corresponding dimensions for other filter sizes: PF 72: 4350 PF 120: 5750 PF 144: 6450



5. Install the quick action cylinders into their places, fasten the hydraulic hoses and connect the electric cables. Carry out the bleeding of the quick action cylinders according to the Instruction manual. Now you can lift and lower the top pressing plate hydraulically.



6. Install the process pipelines. 7. Install the suspension parts, conductors and slide pieces of the plate pack. 8. Install the feed hoses and pressing air hoses.



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9. Install frame beams of the platforms.



FILTER



2275



2160



4665



COLUMN



2275



A



1195



A



1300



2080



1800



A-A



10. Install the service platforms. A



B



FILTER



4665



B



6508 4100



A



± 0 I FILTERI 2275



A-A



2275



B- B



11. Install the side covers. 12. Check the operation of the limit switches as well as all the operations by test drive. 13. Connect the filter into the customer's piping. 14. Install the filter cloth.



IOM MANUAL PF1032 B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



4.3.3.



29.2.2012



Installation readiness check list



1.



Filter shipment arrived at site



2.



Shipment inspected and possible damages reported to Outotec



3.



Site transportation of the filter components and auxiliaries available



4.



Foundation ready and matches with Outotec foundation drawings



5.



Lifting equipment (e.g. overhead crane) available



6.



Tools (according to Outotec tools list) available



7.



Scaffolds and ladders available



8.



Electric power for lifting equipment and tools available



9.



Compressed air for pneumatic tools available



10.



Office including, heating/cooling, lighting, telephone, furniture and toilet



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Table of Contents 5.



Operation instructions .................................................................................................................. 5-3 5.1. Starting the Filter ................................................................................................................ 5-3 5.1.1. Start up inspection ..................................................................................................... 5-3 5.1.2. Checks before start up ............................................................................................... 5-4 5.1.3. Start up measures ...................................................................................................... 5-4 5.1.4. Adjustments ............................................................................................................... 5-4 5.1.5. Checks after start up .................................................................................................. 5-5 5.1.6. Maintenance .............................................................................................................. 5-7 5.2. Operation panel .................................................................................................................. 5-8 5.3. Operator interface............................................................................................................. 5-10 5.3.1. Screen selection....................................................................................................... 5-10 5.3.2. Operator interface structure...................................................................................... 5-11 5.3.3. Cleaning the display ................................................................................................. 5-12 5.3.4. Drive mode ............................................................................................................... 5-13 5.3.5. Process .................................................................................................................... 5-14 5.3.6. Filter ......................................................................................................................... 5-15 5.3.7. Recipe ...................................................................................................................... 5-17 5.3.8. Change the recipe .................................................................................................... 5-18 5.3.9. Parameters .............................................................................................................. 5-22 5.3.10. Messages................................................................................................................. 5-25 5.4. Switching on the voltage ................................................................................................... 5-26 5.4.1. Description of the indicator light functions ................................................................ 5-27 5.5. Test mode ........................................................................................................................ 5-28 5.5.1. Using the remote test functions ................................................................................ 5-29 5.5.2. Emergency stop description: .................................................................................... 5-31 5.5.3. Emergency stop functions: ....................................................................................... 5-32 5.5.4. Indications and alarms in safety relay KA100 ........................................................... 5-35 5.5.5. The test selector S714 has several functions ........................................................... 5-36 5.5.6. Restrictions in testing the actuators. ......................................................................... 5-37 5.5.7. List of symbols in handheld test unit: ........................................................................ 5-38 5.5.8. Test selector S712 ................................................................................................... 5-39 5.5.9. Push button S765..................................................................................................... 5-40 5.5.10. List of symbols in top test unit .................................................................................. 5-40 5.6 Operating the Filter ........................................................................................................... 5-41 5.6.1 Operational modes ................................................................................................... 5-41 5.7. Man mode (Manual mode) ............................................................................................... 5-42 5.8. Auto mode (automatic) ..................................................................................................... 5-44 5.8.1. How to stop the filter................................................................................................. 5-45 5.8.2. How to restart the filter with automatic drive ............................................................. 5-45 5.9. End mode (Stop at the end of the cycle) ........................................................................... 5-46 5.10. Reset mode (Sequence reset) ..................................................................................... 5-47 5.11. Malfunctions and alarms .............................................................................................. 5-48 5.11.1. General .................................................................................................................... 5-48 5.11.2. Alarm acknowledgement .......................................................................................... 5-48 5.11.3. Troubleshooting ....................................................................................................... 5-49 5.11.4. Troubleshooting ....................................................................................................... 5-50 5.11.5. Alarm functions ........................................................................................................ 5-53 5.12. Operation stages in automatic operation ...................................................................... 5-63 5.12.1. SBR01 Pressure release .......................................................................................... 5-63 5.12.2. SBR02 Plate pack opening....................................................................................... 5-63



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SBR03 Cake discharge ............................................................................................ 5-63 SBR04 Restart operation ......................................................................................... 5-63 SBR05 Plate Pack closing ........................................................................................ 5-63 SBR06 Pre-Filtration ................................................................................................ 5-63 SBR07 Filtration (Slurry feed) ................................................................................... 5-64 SBR08 Pipe washing................................................................................................ 5-64 SBR09 Hose washing .............................................................................................. 5-64 SBR10 Pressing 1 ................................................................................................ 5-64 SBR11 Cake washing (optional) ........................................................................... 5-64 SBR12 Pressing 2 (optional) ................................................................................. 5-64 SBR13 Drainage of distribution Pipe ..................................................................... 5-64 SBR14 Cake air drying ......................................................................................... 5-64



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5.



OPERATION INSTRUCTIONS



5.1.



Starting the Filter



5.1.1.



Start up inspection



29.2.2012



Make sure all safety features have been fitted to the filter and to the ancillary equipment before startup.



In order to carry out the start up without unnecessary delays certain things have to be ready and completed. -



Filter installed



-



All dismantled (for packing and transportation) components assembled to the filter; also pipelines including limit switches



-



All hydraulic hoses loosened for packing connected



-



Pipelines built according to Outotec design instructions



-



Cake can be discharged from the filter, and the conveyor(s) meets Outotec recommendations



-



Voltage connected to control panel



-



Voltage connected to filter„s motors



-



Cables connected (Please see the cabling diagram)



-



Cloth wash water available



-



Cake wash water (liquid) available



-



Compressed air available for cake drying, and capacity meets Outotec recommendations



-



Slurry pump installed



-



Slurry available



-



Hydraulic filter aggregate equipped with a 3-5µm filter available for hydraulic oil filling (Please see the manual, Section 6 – Maintenance)



-



Hydraulic oil available (for quality and quantity, please see the manual)



-



Test cloth installed in to the filter and production cloth available



-



Start up spare parts kit available



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5.1.2.



5.1.3.



29.2.2012



Checks before start up -



Check the condition of the filter cloth seam



-



Make sure that the times of different operational stages correspond to the optimum times achieved in test filtration or test runs



-



Check the surroundings of the filter and make sure that no ladders or other objects are leaning on it



Start up measures 1. Open the manual valves of the pipelines leading to the filter 2. Make sure that the cake discharge conveyor works properly 3. Make sure that the slurry feed pump works properly 4. Make sure that the separate pump for cloth wash works properly (if in use) If the stage timings and the "ready for operation" lights are blinking, filtering can be started NOTE!



if any of the alarm lights is on or the "emergency-stop" button is pushed down, the "ready for operation" light does not illuminate



5. Start the filter by discharging



NOTICE Pieces of cake left in between the sealing surfaces might damage the filter cloth. Make sure that the spaces between the plates are clean before the plate pack is closed



6. Turn the selector switch to "AUTO" position. From now on the operation of the filter proceeds automatically onwards to "plate pack closing", "filtering" etc.



5.1.4.



Adjustments Observe the variables listed below and adjust the filter and the process according to different situations in order to reach the best results in all stages of the process. NOTE!



The exact adjustment gives the best result



The factors effecting to the filtration results -



filterability of the feed



-



condition of the cloth



-



openness of the filtrate channels



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The amount of the cake also depends on -



solid contents of the feed



-



feed pressure



-



filtration time



The dryness of the cake also depends on -



particle size of the feed



-



pressing pressure



-



drying air pressure



-



air drying time



The washing result also depends on



5.1.5.



-



wash liquid pressure



-



washing time



-



wash liquid properties



-



cake permeability



Checks after start up In order to reach the best possible results with minor possible problems, always pay attention to following: -



When the slurry valve opens, observe the pressure reading. If the pressure does not start rising, there are either closed valves on the feed pipeline, a pipe is blocked or the pump is not working properly



-



If there is too much leakage between the plates during the filtering stage, a seal has been damaged or the filtrate piping has become clogged



-



Observe the pressure of the water station



-



When washing the cake, watch the wash liquid pressure reading (for the same reason as when pumping slurry)



-



When drying with air, an air blow requires a sufficient amount of air. Check that at the beginning of the drying phase the pressure of the distribution pipe reaches at least 3 bar, which ensures that there is a sufficient amount of compressed air for all the chambers



-



When the filter discharges, make sure that there is a cake formed on each filter plate. An empty space is a sign of a blockage either in the feed hose or in the feed joint of the filter plate



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NOTICE Blockages can cause the empty filter plates to bend under the pressure. Clear all blockages before carrying on with filter operation.



NOTE!



Check the condition of the filter cloth. An acid washing is necessary in certain processes occasionally



-



Observe the cloth to be sure it remains undamaged. A damaged cloth must be mended immediately to prevent the particles for escaping through a broken cloth out of the filtrate flow channels



-



Observe the diaphragms. They must remain undamaged



-



Always use the lowest possible pressure to achieve the desired filtering result. An unnecessarily high pressure shortens the life of the diaphragm and other wearing parts



-



Do not feed too much material into the filter (The maximum cake thickness is 40 mm for 45 mm high chambers, and 55 mm for 60 mm chambers): the feed pipe may get clogged, cake discharge become more difficult or, if the material is heavy, the cloth can break.



Do not feed too much material into the filter to avoid damage



-



Do not let the feed hoses to block up. An empty filter chamber under pressure causes the plate to bend. A bent plate causes leakage, makes holes in the cloth and hampers the cake discharge



DANGER Hazardous moving parts. The plate pack consists of several moving parts, which can cause serious injury or death. Never push anything in between the plates while the filter is in operation. -



Avoid high temperatures when a standard filter is in question. In temperatures above + 60 °C, a strong aging phenomenon affects to the rubber and the operating life of the rubber parts becomes shorter. When operating in temperatures over +60 ºC, the manufacturer's instructions must be strictly followed.



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29.2.2012



Do not direct the pressure-water spray directly at the electrical devices when washing the filter



5.1.6.



Maintenance Maintenance of the standard parts -



According to the instructions given by the sub-suppliers attached to this manual.



General -



Flush the filter from outside when necessary, when the filter is not in operation.



-



Keep the filter and its surroundings tidy and free from any unnecessary objects.



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5.2.



29.2.2012



Operation panel The Control Panel is used to facilitate the operation of the Outotec Larox Pressure Filter. The Control Panel incorporates switches, push buttons and an operator interface terminal, which are required for the operation. Each push-button, switch and indicator lamp is provided with a label briefly describing the function of the device. The flow diagram is located in the display of the operator interface terminal. The indicator lamps show the present state of the actuator or motor in question.



Operator interface terminal with a flow diagram. The Operator Panel is illustrated on the following page.



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5.3.



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Operator interface Controlling and observing the operation of the filter, choosing the required filtering program, changing parameters and testing actuators are operated through the operator interface. In addition, the operator interface gives clear text information about alarms.



5.3.1.



Screen selection Touch buttons are used to select screens.



Do not use objects like a screwdriver, pencil etc. to activate a touch button



The screen needs to be touched lightly and shortly only. Some menus may seem to have a slight delay before performing the function requested, so it is a good idea to have a pause before touching again.



2



1



The HELP touch button ? (1) locates stationary* in the top right hand corner of the display. When the button is touched, a screen containing the requested information is displayed.



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To quit any HELP screen, use the PREVIOUS SCREEN touch button (2). This touch button locates stationary* in the top left hand corner of the display. * The button is available on every selected screen



5.3.2.



Operator interface structure The available menus of the operator interface are illustrated in a form of a diagram in the figure below



PROCESS HELP



FILTER HELP



PROCESS



FILTER



MODE POP-UP



RECIPE HELP



PARAMETER HELP



REPORT HELP



TOOLS HELP



RECIPE



PARAMETER1



REPORT



TOOLS



ALARM & ALARM HISTORY HELP



ALARM 1 HELP ALARM 1 HELP ALARM 1 HELP ALARM 1 HELP



ALARM HELP



PARAMETER2 DIRECT ACCESS SCREENS*



HELP



PRESSURE GRAPHS



HISTORY



INPUT STATUS



OUTPUT STATUS



SCREEN CLEAN



ALARM HISTORY



LAST ALARM HELP



PASSWORD



CALIBRATE HYDRAULICS



PASSWORD



SYSTEM CONFICURATIO N



*) Direct access screens (inside the grey frame) can be accessed directly from any screen inside the frame or linked to it.



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5.3.3.



29.2.2012



Cleaning the display NOTE!



To clean the display, use a soft cloth or paper towel and any ordinary window cleaner



It is an essential part of the unit‟s maintenance to keep the display clean. Even if a great care is taken to touch the display with clean hands only (this is not necessary), dirt will still collect on the display surface. For cleaning the display (since all screens have been active), a Screen cleaning CLS function has been programmed into the display unit. The function is accessed from the TOOLS menu. After a selected time the display will automatically return back to the FILTER menu.



To help prevent marring the plastic sheet on the surface of the display, carefully clean off any abrasive particles on the display surface, and then clean as advised above.



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5.3.4.



29.2.2012



Drive mode



The MODE touch button is used to select a drive mode. The following drive modes are available:



AUTO



The filter operates using the preset stage times.



MANUAL



The filter can be operated one stage at a time. This mode is used e.g. for optimizing the stage times.



END



When this mode is selected, the filter stops at the end of the cycle. This is used whenever the operator wishes to stop a filter running in auto mode.



RESET



Is used to e.g. stop a filtering cycle. In this case the filter starts filtering in a controlled manner from the very first stage.



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5.3.5.



29.2.2012



Process



The PROCESS screen displays the main devices of the filtering process as well as the process diagram. In addition to the filter, the slurry tank with level information, feed slurry pump, and cake conveyor are displayed. The rest of the basic screens can be accessed by means of the touch buttons in the lower part of the display. The drive mode can also be selected directly from this screen. List of symbols on the PROCESS screen: M109 M08 M102 M15 V02 V03 V04 V05 V06 V07 V09 V12 V14



Cloth washing pump motor Cake conveyor motor Slurry feed pump motor Cake wash water pump motor Slurry inlet valve Pressing air inlet valve Pressing air outlet valve Cake wash water inlet valve Drying air inlet valve Manifold drain valve Cloth wash liquid inlet valve Slurry inlet valve Diaphragms lifting up valve



V16 V17 V24 V27 V39 V139 V239 B415 B419 B491 OK LOW WEIGHT



Flow control valve Manifold drain valve Ejector line valve Feed manifold ventilation valve Plate pack wash valve(optional) Rollers wash valve(optional) Cake chute wash valve(optional) Feed manifold pressure Pressing manifold pressure Wash water pressure Slurry tank level OK Slurry tank level, min. The filter weight (optional)



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5.3.6.



Filter



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List of symbols on the FILTER screen: M01 R04 Y11 Y31 M05 B401 B601 B403 B472 B501



Hydraulic unit motor Hydraulic oil heater Hydraulic oil cooler valve Hydraulic pump 3 flow control valve Hydraulic oil cooler motor Hydraulic pressure transmitter Hydraulic oil temperature transmitter Hydraulic accumulator pressure transmitter Plate pack sealing pressure Hydraulic oil level



Y52 Y61 Y62 Y71 Y72 Y81 Y82 Y91 Y92 Y41



B505



Plate pack position



Y42



B415 B419 B503 B504 S332 S838A S839A S26* S16* B505M B505D B505C B472 S171 Y51 Y511



Feed manifold pressure transmitter Pressing manifold pressure transmitter Cloth position Cloth tracking cylinder position Cloth seam detector Cloth alignment limit switch, left Cloth alignment limit switch, right Locking pins locked Locking pins unlocked Plate pack open (maintenance) Plate pack open (discharge) Plate pack closed Plate pack sealed Seal plate down (unsealed) Plate pack opening Plate pack balancing



V02 V03 V04 V05 V06 V07 V09 V12 V14 V16 V17 V24 V27 V39 V139 V239



Plate pack closing Locking pins unlocked Locking pins locked Unsealing Sealing Cloth slackening Cloth straining Cloth drive forward Cloth drive reverse Cloth tracking cylinder out (the cloth to left) Cloth tracking cylinder in (the cloth to right) Slurry inlet valve Pressing air inlet valve Pressing air outlet valve Cake wash water inlet valve Drying air inlet valve Manifold drain valve Cloth wash liquid inlet valve Slurry inlet valve Diaphragms lifting up valve Flow control valve Manifold drain valve Efector line valve Feed manifold ventilation valve Plate pack wash valve(optional) Rollers wash valve(optional) Cake chute wash valve(optional)



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5.3.7.



29.2.2012



Recipe



The RECIPE screen displays the filtering recipes the filter is provided with. The preset recipes (max. 10 pieces) can be scrolled, modified and activated. The [PREV] and [NEXT] touch buttons are used to scroll the recipes. The title of the recipe is displayed in the RECIPE field above the [ACTIVATE] button (the first 18 digits). To modify the control data, enter password from the keyboard and push [ENT]. The cursor will now move to the time value of the first stage. A new value is set accordingly. Use the arrow keys in the numerical keyboard in order to move to the previous/next stage. [CLR] is used to delete the field indicated by the cursor. If password is configured not to be in use, there is no need to enter it.



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5.3.8.



29.2.2012



Change the recipe



The displayed recipe is activated by the [ACTIVATE] button. Confirmation screen is now displayed. Push [YES] to accept and [NO] to disregard. The text field RECIPE (SELECTED FOR USE) in the upper part of the RECIPE screen displays the selected recipe. The selected recipe will be selected for use at the end of the „plate pack closing‟ stage. The rest of the basic screens can be accessed directly by means of the touch buttons in the lower part of the display.



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Recipe data Recipe data values are determined during start-up. 01 PRESSURE RELEASE Data 1 Data 2



Min 0001 0001



Typ 0060 0005



Max 9999 9999



Unit sec sec



Function Release through cake duration V07 open duration



Data 1 is used to determine the duration of the pressure release through the filtration cake. All valves (except filtrate valve) closed. Data 2 value provides the time for valve V07 to be kept open. After this time the sequence proceeds to next step. 02 PLATE PACK OPENING Data 1 & 2 are not used 03 CAKE DISCHARGE Data 1 Data 2



Min 3 10.0



Typ 5 45.0



Max 99 100.0



Unit Plate lengths %



Function Cloth drive length Cloth wash speed



Data 1 value indicates how many PLATE LENGTHS the cloth will advance during the entire DISCHARGE stage. This includes the initial cake discharge, cloth washing and seam placement. Data 2 value indicates the relative cloth drive speed during CLOTH WASH (STEP03) in range of 20.0...100.0%. This value will adjust the hydraulic FLOW accordingly. 04 RESTART OPERATIONS Data 1



Min 0



Typ 3



Max 9999



Unit seconds



Function Restart Delay



Data 1 value indicates the duration of the RESTART delay in seconds. Data 2 not used 05 PLATE PACK CLOSING Data 1 & 2 are not used



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07 FILTRATION Data 1 Data 2



Min 0001 0.1



Typ 0075 5.0



Max 9999 16.0



Unit Sec Bar



Function Stage duration Max Pressure



Data 1 is used to determine the duration of the actual filtration step during this stage. Data 2 value provides pressure setpoint for maximum pressure measured from transmitter B415 located in the feed manifold. If this pressure is reached or exceeded during filtration, the step is aborted and the sequence proceeds to next step. 08 PIPE WASHING Data 1



Min 0001



Typ 5-10



Max 9999



Unit sec



Function Stage duration



Data 1 is used to determine the duration of the actual pipe wash step during this stage. Data 2 not used 09 HOSE WASHING Data 1 Data 2



Min 0001 0.1



Typ 0015 5.0



Max 9999 16.0



Unit Sec Bar



Function Stage duration Minimum Pressure



Data 1 is used to determine the duration of the actual hose wash step during this stage. Data 2 value provides pressure setpoint for minimum pressure measured from transmitter B415 located in the feed manifold. The step will not continue until this pressure is reached regardless the time (Data 1) setpoint. If the pressure is not reached within a delay set to B415T2 timer (typically 30.0 Sec), an alarm B415HALM LOW HOSE WASHING PRESSURE is produced. This function can be disabled by setting the Data 2 value to zero (0.0 Bar). 10 PRESSING 1 (OPTIONAL) Data 1



Min 0001



Typ 0120



Max 9999



Unit sec



Function Stage duration



Data 1 is used to determine the duration of the actual pressing step after the minimum pressing pressure is achieved. Data 2 is not used.



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11 CAKE WASHING (OPTIONAL) Data 1 Data 2



Min 0001 0.1



Typ 0060 5.0



Max 9999 16.0



Unit Sec Bar



Function Stage duration Minimum Pressure



Data 1 is used to determine the duration of the actual cake wash step during this stage. Data 2 value provides pressure setpoint for minimum pressure measured from transmitter B415 located in the feed manifold. If the pressure is not reached within a delay set to B415T3 timer (typically 30.0 Sec), an alarm B415CALM LOW CAKE WASHING PRESSURE is produced. This function can be disabled by setting the Data 2 value to zero (0.0 Bar). 12 PRESSING 2 Data 1



Min 0001



Typ 0120



Max 9999



Unit sec



Function Stage duration



Data 1 is used to determine the duration of the actual pressing step after the minimum pressing pressure is achieved. Data 2 is not used. 13 PIPE DRAIN Data 1



Min 0001



Typ 0030



Max 9999



Unit sec



Function Stage duration



Data 1 is used to determine the duration of the actual pipe drain step during this stage. Data 2 is not used. 14 AIR DRYING Data 1 Data 2



Min 0001 0.1



Typ 0120 5.0



Max 9999 16.0



Unit Sec Bar



Function Stage duration Minimum Pressure



Data 1 is used to determine the duration of the actual air drying step during this stage. Data 2 provides a setpoint for minimum pressure measured from transmitter B415 located in the feed manifold, immediately after V06 and V16 are opened. If this pressure is not reached within 3 seconds, an alarm B415A DRYING AIR LOW PRESSURE is resulted.



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5.3.9.



29.2.2012



Parameters The PARAMETER screens display the filter control parameters that are valid for any recipe. The parameters are distributed between two screens, which can be scrolled by means of the PAGE 1 and PAGE 2 touch buttons.



Parameter 1



Parameter 2



To modify the values, enter password from the keyboard and push ENT. The cursor will now move to the value of the first parameter. A new value is set accordingly. Use the arrow key in the numerical keyboard in order to move to the previous/next parameter. CLR is used to delete the field indicated by the cursor. If the password has been entered in a RECIPE screen and a PARAMETER screen is selected next, there is no need to enter the password again. The RECIPE field of the PARAMETER screen displays the title of the active recipe. The rest of the basic screens can be accessed directly by means of the touch buttons in the lower part of the display. Drive mode can also be selected directly from this screen. Parameter data Recipe data values are determined during start-up. 01 RUNS TODAY RESET TIME (hhmm) The parameter used to reset the CYCLES TODAY counter in the HISTORY REPORT screen. 02 PRESSING END DELAY (s) (OPTIONAL) Delay before opening pressing air outlet valve during air drying.



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03 MAXIMUM OPERATING PRESSURE (bar) Parameter provides a setpoint to protect the filter against overpressure at any operating stage. The maximum operating pressure is typically 16.0 Bar. If this setpoint is exceeded either by reading from B415 or B419, an overpressure alarm is resulted. Min 0.1



Typ 16.0



Max 16.0



Unit Bar



Function Maximum pressure



04 MINIMUM PRESSING PRESSURE (bar) “MINPRPRE” provides a setpoint to start the pressing timer (DATA 1). If the pressure is not reached within a delay set to B419T2 timer (typically 30 Sec), an alarm B419PALM PRESSING MANIFOLD PRESSURE NOT REACHED is produced. Min 0.1



Typ 6.0



Max 16.0



Unit Bar



Function Minimum pressure



Unit Bar



Function Min. pressure



05 MINIMUM FEED PRESSURE (bar) Min 0.1



Typ 2.0



Max 16.0



06 G-POINT 1 PRESSURE SETPOINT (bar) “GPOINT1” provides a setpoint for the G-Point1 pressure in PRESSING 1. G-Point1 is a pressure where the feed manifold pressure (measured from B415) drops sharply during pressing stage. This is an indication that the cake is de-watered enough and the fluid bridge from pressing diaphragms to the feed manifold through the feed ports is discontinued. The G-poin1t value must be higher than 1.0 Bar and lower than normal pressing pressure. Min 0.1



Typ 5.0



Max 16.0



Unit Bar



Function G-Point 1 Pressure



07 G-POINT 2 PRESSURE SETPOINT (bar) “GPOINT2” provides a setpoint for the G-Point2 pressure in PRESSING 2. G-Point2 is a pressure where the feed manifold pressure (measured from B415) drops sharply during pressing stage. This is an indication that the cake is de-watered enough and the fluid bridge from pressing diaphragms to the feed manifold through the feed ports is discontinued. The G-point2 value must be higher than 1.0 bar and lower than normal pressing pressure setpoint. Min 0.1



Typ 5.0



Max 16.0



Unit Bar



Function G-Point2 Pressure



08 DRYING AIR PRESSURE “DRYAIRSP” cake drying air setpoint determines if the air pressure has decreased enough to stop the drying stage. Min 0.0



Typ 2.0



21 CLOTH LENGTH (m) Length of the cloth in metres



Max 16.0



Unit Bar



Function Ending Pressure



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22 B331 PLATE LENGTH (imp.) One plate length in pulses coming from encoder B331 23 NUMBER OF PLATES IN THE FILTER (pcs) Number of filter plates in filter. 24 END MODE CLOTH WASH (rev) Number of revolutions that cloth is driven and washed during ENDMODE 25 CAKE DISCHARGE SPEED (%) “CADISSPD” value indicates the relative cloth drive speed during CAKE DISCHARGE (STEP02) in range of 15.0...50.0%. This value will adjust the hydraulic FLOW accordingly. 26 B331 SEAM PLACE (imp.) Distance from seam sensor S332 to first roller in plate pack in pulses.



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29.2.2012



Messages



The Outotec Pressure Filter control system informs the operator about a number of operating situations by means of green coloured message runner in the middle of the screen. These kind of situations are e.g. such in which the filter seems to have stopped without any visible reason, like when waiting for a discharge permission or some level information. The message text tells the reason for the message. The messages automatically disappear as soon as the cause for a message is eliminated.



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29.2.2012



Switching on the voltage



1. Turn the MAIN SWITCH S700 to the ON (1) position. 2. When the main switch is turned ON, the S733/H733 button starts to flash and the S708/H708 button begins to illuminate. If not, check the main switch and the fuse(s) inside the panel. 3. Make sure that there are no foreign objects between the filter plates. 4. Switch off all "Emergency Stop" buttons. The status of indicator lamps should be as follows: S710/H710 = OFF S708/H708 = ON S733/H733 = FLASHING 5. Turn the HYDRAULIC UNIT switch S755 to position 1. The hydraulic unit is automatically started and stopped according to the drive mode. In Test Mode, if no actuator or function is activated within five minutes, the hydraulic unit will stop. The unit restarts as soon as any actuator or function is activated.



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Description of the indicator light functions



S701 EMERGENCY STOP EMERGENCY STOP push buttons are not illuminated



S701



EMERGENCY STOP



S710/H710 READY/RUN When flashing slowly, it indicates that the filter is ready for operation. When steadily illuminated, the filter is in operation (RUN) S710 / H710



START / RUN



S708/H708 STOP/STOPPED When illuminated, it indicates that the filter is stopped. S708 / H708



STOP / STOPPED



In case of alarm, the alarm signal on top of the panel as well as the S733/H733 button start flashing and an alarm message will appear on the display.



When S733/H733 is pushed once the alarm signal will stop flashing, the second push will acknowledge it provided that the cause of the alarm has been eliminated. S733 / H733



ACKNL / ALARM



S713 / H713



TEST ACTIVATE



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Test mode The Test mode is used during troubleshooting and routine maintenance of the filter. All valves and motors present on the pressure filter can be individually actuated (with some restrictions) when the TEST Mode is selected. The Test Mode can be activated remotely through the handheld test unit when Test Mode from key switch S780 is selected.



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29.2.2012



Using the remote test functions



Before operating the machine, make sure that no one is near the danger zones of the filter.



Outotec pressure filter is provided with two test units. A Handheld test unit and a top test unit installed in terminal box X12 on the top of the pressure filter.The hand held unit can be connected to left or right side of the filter unit. This allows the handheld unit to be brought to the actuator to be tested facilitating thus maintenance and adjustments of the actuator. The handheld test unit has an emergency stop push button, test selector switch S714, and two push buttons S723 and S725. Test mode can be selected only with key switch S780. When the key switch S780 is turned to position test down, the hand held unit is activated. After activated, the handheld test unit can be used. When the key switch S780 is turned to position test top, the top test unit is activated. After activated, the top test unit can be used. When the test operation is over, turn the selector switch to position “A” in the handheld unit or top test unit. If hand held unit is used put the unit back onto its suspension hook. The filter is ready for normal process use. Select Auto-mode with the key switch S780 on the control panel.



Handheld test unit



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Filter is equipped with several emergency stop buttons. If there is any danger, filter can be stopped immediately by pressing emergency stop button. Never release emergency stop button until it is safe to do so. After all emergency stop buttons are released, emergency stop circuit can be acknowledged by pressing alarm acknowledge push button (S733). When filter is equipped with protective door system, all filter protective doors must be closed in order to operate filter automatically. If any door is opened during automatic operation filter will stop immediately. Only test mode functions are possible with doors opened. Emergency stop buttons and protective door limit switches and related safety functions must be tested regularly. Larox recommendation is once a week.



5.5.2.



Emergency stop description: Emergency stop sytem consists mainly of: -



Programable safety relay KA100



-



Expansion input unit KA101



-



Expansion relay unit KA102



-



Expansion relay unit KA112



-



Expansion relay unit KA110



-



Expansion relay unit KA111



-



Fieldbus unit to PLC KA130



Programmable safety relay, base unit, includes 20 digital inputs, 4digital semiconductor outputs and 2 relay outputs (potential free contacts). Expansion unit KA101 includes 8 digital inputs. Expansion unit KA110 includes 8 relay contacts. KA110 is used for hydraulic unit. Expansion unit KA111 includes 8 relay contacts. KA111 is used for equipments (pumps and motors) outside of filter. Emergency stop system includes also: -



Emergency Stop Push Buttons S7**



-



Door Switches S8**



-



Acknowledge Pushbuttons with signal lights for door alarms S741/H741 and S742/H742



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Enable Switch S790



Base unit KA100 includes the safety program. The inputs as well as KA101 inputs are used for controlling the safety signals from safety devices and safety control devices. The outputs are used for controlling the expansion safety relays (KA110, KA111, KA102 and KA112) and other devices. Fieldbus module KA130 is used for communication with PLC.



5.5.3.



Emergency stop functions: Auto mode: In Auto mode (Key Switch S780 in Auto mode), the Hand Held unit must be connected in Right Side, near to the terminal box X2. Enable Switch S790 must be connected to opposite corner of the filter and the Enable Switch S790 must be released. The doors must be closed and the door alarms must be acknowledged. When these conditions are true and all the safety relays are ON (KA110, KA111, KA102, KA112), the Auto Ready signal is sent to PLC. In Auto mode the PLC together with Safety System controls the functions of filter and auxiliary equipments. Test mode: In Test Mode (Key Switch S780 in Test Down or Test Top mode) it is possible to make the maintenance and test functions for the single devices of the filter. In Test mode the Hand Held can be connected on Right side or on Left side. When Hand Held is connected to Right side, the doors can be open on Right side and similarly when connected to Left side the doors can be open on Left side. If the doors are opened on the other side, there will become a door alarm to that side. In that case close the doors and acknowledge the alarm. If it is needed to open the doors on both sides, the Enable Switch S790 must be connected on the other side than Hand Held. After that it is possible to open the doors on both sides without alarm. In Test Down mode it is possible to test the devices on low level of the filter with Hand Held unit. In Test Top mode it is possible to test the valves on the top of the filter. The selection switch S714 in Hand Held unit must be in Auto mode. The doors on both sides can be open. The valve to be tested is selected by selection switch S712 and test activation will be done by Test Activate push button S765. The switches are located on the top of the filter in X12 or in X15.



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Alarms from safety system: If there are any alarms in safety system (“S70* EMERGENCY STOP”, “S8**LT DOORS LEFT SIDE NOT ACKNOWLEDGED” or “S8**RT DOOR RIGHT SIDE NOT ACKNOWLEDGED”), before any device or function can be activated the safety alarms must be acknowledged. All alarms are seen in OIU and can be acknowledged with push button S733. In case of door alarms (H741 or H742 illuminated), acknowledge it with Door Alarm Push Button S741 or S742 before acknowledge it from OIU with S733 (see chapter 2-9 Malfunctions and alarms). If H741 or H742 are flashing, door(s) are open. Expansion safety relay KA110: Emergency Stop Push Buttons are located in different units. S701 in Control cabin X1, S703 in pressing water station, S705 in hydraulic unit , S706 and S702 in Hand Held unit. There can be also some other Emergency stop Push Buttons. KA110 is controlled only by Emergency Stop Push Buttons. Expansion safety relay KA111: Expansion Safety Relay KA111 is reserved for motors and equipments outside of filter. All motors and equipments that supply water, slurry or some other material to the filter and equipments that can cause harm or danger to filter or people, must have contact from KA111 for stopping those devices. Expansion Safety Relay KA111 is not working in Test mode. In Auto mode it is ON every time when Auto ready conditions are True.



Feedback signal from MCC: Feedback signal from MCC must be ON before Emergency Safety Relay system is possible to get active. With this loop it is controlled that all the motors and equipments must be stopped before the safety system can be activated. If MCC loop is not ON after emergency stop (by doors or EMS buttons), Emergency Stop relay will have O_FAULT and alarm is seen in OIU “KA100 FAULT IN EMERGENCY STOP RELAY”, when trying to acknowledge the alarm.



Testing of devices: Testing of valves and hydraulic and pneumatic functions of the filter devices will be done with Hand Held unit. Later there is explanation of the Hand Held unit operation.



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Expansion safety relays KA102 and KA112: In terminal box X2 in the filter there is Emergency Stop Expansion Relay KA102. Via this relay the power is activated to solenoid valves and other devices of the low level of the filter. In Test Down mode. KA102 will be ON only when the Test Activate push Button S723 or S725 is pushed in HH unit. In terminal box X12 on the top of the filter there is Emergency Stop Expansion Relay KA112. Via this relay power is activated to solenoid valves of process valves on the top of the filter. In Test Top mode. KA112 will be activated only when the Test Activate push Button S765 is pushed in X12 or X15. If during Test Down mode the doors are open on both sides, in the other side another operator must use Enable switch S790. If the Enable Switch is connected, the doors can be opened without alarm. When the doors are open on both sides, the enable switch must be kept in middle position, before KA102 can be activated and any device or function can be activated . Safety in testing: Hand Held unit can be connected to both sides of the filter, normally the connectors are in opposite corners. Home place for HH unit is near to terminal box X2 and in Auto mode it must be connected to that side. Enable Switch S790 must be connected in Auto mode to opposite side. When operator is testing alone, the doors can be open on the side where the HH is connected. For safety reasons the doors on the other side must be closed. If it is necessary to open the doors on both sides, the other operator must use Enable switch S790. If Enable switch is connected to other side, it is possible to open the doors without door alarm. For testing it must be pressed first the Enable switch in middle position by one operator and after that the other operator can push the test activate push button in HH unit. The operator can stop the test function by releasing the Enable Switch.



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Indications and alarms in safety relay KA100 The RUN light must be on in relay. This means that the program is running. If there is some FAULTs in the system, the program will be stopped leading to safe condition. FAULT LED ON: External error on the base unit, leading to a safe condition, e.g. terminator not connected. The alarm can be seen in OIU. FAULT LED FLASHING: Internal error on the base unit. The alarm can be seen in OIU. I_FAULT LED ON: External error, leading to a safe condition, e.g. short across the contacts or error on safety mat input. The alarm can be seen in OIU. I_FAULT LED FLASHING: Internal error on the base unit. The alarm can be seen in OIU. O_FAULT LED ON: External error on the outputs of the base unit, e.g. short across the contacts, leading to a safe condition. The alarm can be seen in OIU. O_FAULT LED FLASHING: Internal error on the base unit. The alarm can be seen in OIU.



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The test selector S714 has several functions 1. When in AUTO position, the eventual alarms during testing can be acknowledged directly from the handheld test unit, the filter can run and top test unit can be used.



2. VALVE side positions permit the testing of the process valves as shown on switch S714. The left hand side push button S725 activates the valve V0*. The eventual parallel valve V1* can be activated by the right hand side push button S723.



3. HYDRAULIC side positions permit testing of the hydraulics and motors as shown on switch S714. Note that there may be two devices or two directions for each position of S714. In case of two devices, the left hand side push button S725 operates the device listed on the left and the right hand side push button S723 operates the device listed on the right. If there are two directions in which the device may operate, the left hand side pu button S725 runs the device either upwards or forward and the right hand side push button S723 runs the device either downwards or reverse.



Three positions between V and H are reserved for auxiliary equipment test functions and are indicated by X1, X2 and X3.



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S725/H725 Yellow illuminated push button (leftmost button) This push button activates the hydraulic cylinder or motor selected up or forward when S714 is positioned on the HYDR side, and the valve V0* when S714 is positioned on the VALVE side. This push button also operates as the ALARM ACKNOWLEDGE push button when S714 is in AUTO. S723/H723 Green illuminated push button (rightmost button) This push button activates the hydraulic cylinder or motor selected down or reverse when S714 is positioned on the HYDR side, and the valve V1* (parallel to V0*) when S714 is positioned on the VALVE side.



Testing continues as long as the push button is switched on. Note that cloth drive is provided with positions both with and without cloth tensioning.



5.5.6.



Restrictions in testing the actuators.  The quick action cylinders (up or down) will operate only when the locking pins are fully locked or unlocked.  The cloth drive will operate only when the plate pack is fully open (B505D must be activated).  Unsealing the plate pack does not work (lower pressing plate down) if there is pressure (pressure transmitter B419) in the pressing manifold.  There are several safety interlocks for opening pressing air inlet valve V03 (for example plate pack must be closed, locked and sealed) including some hardwired interlocks  Some of the valves can only be tested from the terminal box X12 (or X15,optional) located on top of the filter. See the electrical drawings for reference.



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List of symbols in handheld test unit: Label A HC5 HC6 HC7 HC10 HM8&9 HM9 HM8 HC4 Y11 M05



BAL BAL R4 BAL HC5 X3 X2 X1 V*0 V*9 V*8 V*7 / 17 V*4 / X4 V*3 / 13 V*2 / 12 V*1



Description Auto Mode Quick Action Cylinders Locking Pins Sealing cylinder Cake Chute Cover (optional) Cloth Drive and Tensioning Cloth Drive Only Cloth Tensioning Cloth Tracking Oil Cooler Water Valve Oil Cooler Motor (Optional) QA Balancing QA Balancing oil heater QA Balancing with Quick Action Spare Spare Spare Valve *0 Valve *9 Valve *8 Valve *7 Valve *4 Valve *3 Valve *2 Valve *1



S725 Function Alarm Acknowledge Opening (Up) Lock Upwards (sealing) Opening



S723 Function Filter Start Closing (Down) Unlock Donwards (unsealing) Closing



Forward



Reverse



Forward Loosing (Down) Cloth Tracking Cylinder Out (the cloth to left) Oil Cooler Water Valve Open



Reverse Straining (up) Cloth Tracking Cylinder In (the cloth to right) Oil Cooler Motor M05 Start



QA Balancing QA Balancing QA Balancing with QA Upwards



Hydraulic oil heater QA Balancing with QA Downwards



V00 V09 Cloth Wash V08 Wash Filtrate V07 Manifold Drain V04 Pressing Air Out V03 Pressing Air In V02 Slurry V01 Filtrate



V10 Slurry Recycle



V17 Manifold Drain V14 Air Mover V13 V12 Slurry V11



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5.5.8.



29.2.2012



Test selector S712



1.



When in AUTO position, the filter can run and handheld test unit can be used.



2.



VALVE side positions permit the testing of the process valves as shown on switch S712.



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Push button S765



This push button activates the valves V05, V06, V16 & V27, when S712 is positioned on the valve side.



S765 TEST ACTIVATE



NOTE!



5.5.10.



The testing continues as long as the push button is switched on.



List of symbols in top test unit Label A V05 V06 V16 V27



Description Auto Mode Process water valve Drying air valve Drying air control valve Feed manifold ventilation valve



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5.6



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Operating the Filter



5.6.1 Operational modes



The MODE touch button is used to select a drive mode. The following drive modes are available:



AUTO



The filter operates using the preset stage times.



MANUAL



The filter can be operated one stage at a time. This mode is used e.g. for optimizing the stage times.



END



When this mode is selected, the filter stops at the end of the cycle. This is used whenever the operator wishes to stop a filter running in auto mode.



RESET



Is used to e.g. stop a filtering cycle. In this case the filter starts filtering in a controlled manner from the very first stage.



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Man mode (Manual mode) The MAN mode can be used when the operator is searching for the optimal values of the process variables as well as when the sequence must be continued from a different point than from where it was stopped, or if the operator wants to run any stage longer than normally.



S701



S710 / H710



S708 / H708



S733 / H733



EMERGENC Y STOP



START / RUN



STOP / STOPPED



ACKN L / ALARM



1 turn the HYDRAULIC 1. Select MAN MODE from the touch screen and UNIT switch S755 to position 1. The MAN MODE field is now displayed. The field has the following 0 elements: S755



HYDR AULIC UNIT S700



? RECIPE STAGE MODE ELAPSED STATUS 



MAIN SWITCH Touch button to activate HELP-screen Displays the current program Displays the number of the current stage. Displays the current mode. MAN MODE. Displays the time elapsed in MAN MODE. Displays the current status, e.g. RUN, READY, ALARM, STOP Touch button to reverse. Touch button to forward.



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2. For PRESSURE RELEASE proceed to step 4. For any other stage, use the  <   or > touch buttons for scrolling through the stages. Note that the  <   touch button does not forward the sequence from the beginning to the end, where as the   > touch button rewinds the sequence from the end to the beginning. Note also that this kind of selection process is possible only when the filter is stopped. 3. To start the filter, push the START button once. Note that prior to starting the filter, the START button should be flashing indicating that the filter is ready to begin operations. In case it fails to do so, make sure that there is no active alarms. Once the filter is running, the START button is illuminated. The time elapsed during filter operations will be displayed in the TIME ELAPSED area. In MAN MODE time will COUNT UP from zero to show actual time elapsed in the stage currently running. 4. To proceed to the next stage, push the START button once. 5. To stop the filter, push the STOP button. When pushing the STOP button once, it illuminates indicating that the filter has stopped. 6. To restart the filter from the stage, where it was stopped, push the START button.



RESTRICTIONS 1. The filtration stage cannot be selected twice during one operation cycle. If filtration has been going on for 10 seconds or more and is stopped and restarted, the sequence will automatically skip over slurry feeding and continue from pipe and hose washing. 2. The process stages cannot be selected unless the plate pack is fully closed. 3. The discharge stage cannot be selected unless the plate pack is fully open.



NOTICE Overfilling can cause serious damage to the filter plates. When in manual mode, supervise the prefiltration and filtration stages.



WARNING Hazardous moving parts. The plate pack consists of several moving parts, which can cause serious injury or death. Never leave the filter running by itself in MAN mode



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Auto mode (automatic) AUTO MODE is the normal operating mode of the filter. All necessary operations to run the filter are automatically executed by the control system.



S701



S710 / H710



S708 / H708



S733 / H733



EMERGENC Y STOP



START / RUN



STOP / STOPPED



ACKN L / ALARM



1 1. Select AUTO MODE from the touch screen and turn the HYDRAULIC UNIT switch S755 to position 1. 0



S755



HYDR AULIC UNIT S700 MAIN SWITCH The AUTO MODE screen will be displayed. The screen has the following elements:



? RECIPE STAGE MODE REMAINING STATUS



Touch button to activate HELP-screen Displays the current program Displays the number of the current stage. Displays the current mode. AUTO MODE. Displays the time remaining in AUTO MODE. Displays the current status, e.g. RUN, READY, STOP



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2. To start the filter from the present stage push the START button once. Note that prior to starting the filter, the START button should be flashing indicating that the filter is ready to begin operations. In case it fails to do so, make sure that there are no active alarms. Once the filter is running, the START button is illuminated. The time remaining during filter operations will be displayed in the REMAINING area. NOTE!



In AUTO MODE, the time will COUNT DOWN from the preset to show the time remaining in each stage.



3. If you want to start from another stage, see instructions for program RESET in section RESET MODE and MANUAL START in section MANUAL MODE.



5.8.1.



How to stop the filter 1. To stop the filter push STOP button. When pushing the STOP button once, it illuminates indicating that the filter has stopped. NOTE!



The filter may be stopped due to an alarm or a voltage break.



If the filter has been stopped, and it has been idling for a long period of time, it is recommended that the filter to be driven in the discharge stage in MAN MODE until the full length of the filter cloth has been washed. Once the full length has been washed, the AUTO MODE can be switched on, to be able to operate the filter normally.



5.8.2.



How to restart the filter with automatic drive 1. If the filter has been stopped due to an alarm or if the STOP button has been pushed, proceed as follows: Locate and eliminate the alarm or malfunction prior to restarting the filter (see MALFUNCTIONS AND ALARMS). Push the START button once. The filter restarts from the stage it was stopped in and continues the automatic operation.



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End mode (Stop at the end of the cycle) The END mode is used to stop the filter automatically after complete cycle (after cake discharge and cloth wash), thereby freeing the operator from having to wait for the end of the present cycle. In this mode the filter will perform an orderly stopping after the end of cake discharge. All functions in END mode are similar to those in AUTO mode.



1. Select END mode from the touch screen. 2. The filter will continue its operation through the cycle as if in AUTO mode and stop after the end of cloth washing. At this time the filter will perform an orderly shutdown by closing the plate pack. The filter can be restarted at any time in either MAN mode or AUTO mode by pushing the START button (see MAN mode or AUTO mode). The filter will restart from PLATE PACK OPEN after END mode stop.



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Reset mode (Sequence reset) The RESET MODE is used to reset the program sequence back to the PRESSURE RELEASE stage and load into the operational area of the program any new data that has been entered. NOTE:



Before starting the filter from another point than where it was stopped, the program sequence must be reset.



1. Select RESET mode from the touch screen. The program then asks for a confirmation and requests you to stop the filter. 2. Push STOP button S708/H708 to RESET the filter program sequence. 3. The default starting stage after resetting the filter program sequence is PRESSURE RELEASE unless the plate pack is fully open. If the plate pack is fully open, the default starting point is CAKE DISCHARGE. To start the filter from another stage, see MAN MODE.



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5.11.



Malfunctions and alarms



5.11.1.



General



29.2.2012



Extensive diagnostic functions have been programmed into the control system of OUTOTEC Filter. Alarms that stop the filter immediately -



Emergency stop



-



Voltage break



Alarms that stop the filter after a preset delay



5.11.2.



-



Valve or sensor failure



-



Motor failure



-



Process pressures



-



Cloth drive



-



Plate pack movements



-



CPU battery low (If the CPU has a battery)



-



Failure in hydraulics



-



Level of process fluid tanks



Alarm acknowledgement When in state of alarm, the filter will stop immediately. The ALARM BEACON on top of the control panel and the ALARM RESET button S733 will flash informing alarm or malfunction existing in the filter. Push the ALARM RESET button once to stop the ALARM BEACON and the ALARM RESET button from flashing. The ALARM RESET button remains illuminated. Once the cause of the alarm has been located and eliminated, push the ALARM RESET button again to acknowledge the alarm. Then the filter can be restarted by pushing the START button S710.



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Determine the cause of alarm before restarting the filter



5.11.3.



Troubleshooting If the cause of alarm and its corrective measures are not known, the display screen can provide the operator with extensive help in determining the possible reasons for the alarm, and the measures that can be taken to correct it.



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Troubleshooting HOW DISTURBANCE APPEARS 1. Leakage between plates during filtering.



2.



Cake wetter than normal.



3.



Pressing water station low level alarms and stops the filter. (OPTIONAL ONLY WITH WATER PRESSING)



4.



Cloth slipping sideways off the rollers (displaced).



5.



Folding in the cloth.



6.



Cloth moves jerkily but without slipping on the drive roller.



CAUSE FOR DISTURBANCE



WHAT TO DO?



-Hardened of crystallized cake on seal surfaces under the cloth or foreign material between plates. -Defective seal. -Bent plate. -Local deflection which does not compensate. -Counter pressure in the filtrate side. -Slurry feed greater than the filter's hydraulic capacity. -Slurry properties have changed. -Damaged diaphragm. -Leakage in pressure water piping.



-Open plate pack, clean plates and wash the cloth.



-Damaged diaphragm.



-Filtering must not be by continued by adding water; the diaphragm must be changed. -Repair the cloth.



-Cloth seam not perpendicular to the edges. -Rollers not properly positioned. -Cake sticks to the rollers. -Bad seam in the cloth. Cloth seam gets caught on scrapers.



-Cloth scrapers retard the cloth. -Water is left in the pressing diaphragms and presses the cloth. (OPTIONAL ONLY WITH WATER PRESSING)



-Replace the seal. -Replace or straighten the plate. -Examine and straighten the sealing surface if necessary. -Check pipelines. -Decrease the slurry feed rate. -Install control equipment for slurry. -Replace the diaphragm. -Locate and stop the leakage.



-Adjust the rollers. -Adjust roller scrapers closer to the rollers. -Repair the clipper seam. -Check the scrapers and adjust if necessary. Check clipper seam and change the cloth if the seam is damaged. -Adjust the cloth scrapers. -Remove the water from the diaphragms.



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29.2.2012 CAUSE FOR DISTURBANCE



WHAT TO DO?



-The cloth slips on the drive roller due to insufficient cloth tensioning. -Too much water remains in the pressing diaphragms pressing the cloth thus preventing the cloth from moving. (OPTIONAL ONLY WITH WATER PRESSING) -Cakes are too thick.



-Adjust the tensioning pressure.



8.



Cake gathers on the rollers.



The cloth is insufficiently cleaned.



9.



Too high solid content in the filtrate.



-Hole in the cloth. -Cloth wash does not operate properly.



10.



Blocked grids.



Hole in the cloth.



11.



Filtrate outlets and pipes wear out fast.



Cloth wash does not operate properly.



12.



A very thin cake or no cake at all. Cloth guiding is difficult, cloth edges get frayed, cloth limits give an alarm. A roller does not rotate or rotates jerkily. The chains of the tensioning device do not stay on the sprockets. The pinch valve leaks.



Blocked slurry feed inlet.



13.



14. 15



16.



Slide pieces are worn or wrongly adjusted.



-Close the pack carefully in TEST mode and open V04. Adjust a longer drying time.



-Remove the cakes manually, check the plate feed inlets, check the slurry feed time. -Adjust the cloth scrapers closer to the cloth. -Adjust the roller scrapers. -Check the cloth wash system. -Always patch the hole immediately! -Check the cloth wash nozzles and their direction. Also check the direction of the nozzle pipes, clean or change clogged nozzles. Always patch the hole immediately! Check the cloth wash nozzles and their direction. Also check the direction of the nozzle pipes, clean or change clogged nozzles. Clean the slurry feed inlet and check the slurry sieve. Adjust the slide pieces or replace them if necessary.



Bearing fail due to damaged seal.



Change the bearing.



The chains have stretched.



Tighten the chains.



A broken pinch valve sleeve.



Change the sleeve and adjust the actuator.



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HOW DISTURBANCE APPEARS 17. Problems with the pressure water pump; wearing out, dropped pressure, increased cake moisture. (OPTIONAL ONLY WITH WATER PRESSING) 18. Cloth drive and centring is difficult and cloth life gets shorter.



19.



Faults in subsupplied parts.



29.2.2012



CAUSE FOR DISTURBANCE



WHAT TO DO?



Broken diaphragm.



Change the diaphragm and clean the water station.



-Ageing of rubber (drive, press and centring rollers). -Too high pressing force (between the drive and press rollers).



-Change the roller(s). -Adjust the coil springs of the press roller to the length of 55 mm and change the damaged roller(s). See the manufacturer's instructions.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



5.11.5.



29.2.2012



Alarm functions Name (Group) S70* EMERGENCY STOP (D)



Cause One or more of the emergency stop buttons is engaged.



Reason Emergency stop by the operator.



S801... S810 PROTECTIVE DOOR SENSOR (D)



Protective door sensor indicates that door is open.



POWER LOSS OR PLC RESTART (H)



PLC stopped and restarted.



-Protective door is open. -Sensor adjusted wrongly. -Sensor fault. -Main voltage break. -PLC has been in PROGRAM mode.



Measures -Find out the reason for the Emergency stop. -Make sure that it is SAFE to restart the filter and release the engaged button(s). Emergency-stop buttons are located in the control panel, filter and hand held unit. If possible do not leave the emergency stop button activated for a longer time, because the pinch valves may open, otherwise close the process line manual valves. -Close protective door. -Adjust/replace sensor. -Check electrical system.



Check the reason for PLC stop.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl Name (Group) PLC BATTERY LOW (H)



B331 CLOTH INCREMENTAL ENCODER (B)



S332 CLIPPER SEAM SENSOR (B)



S332D CLIPPER SEAM DISPLACED (B)



Cause Voltage level of memory backup battery in the Programmable Logic Controller (PLC) has dropped too low. Alarm activated when filter stops. No impulses from incremental encoder when cloth drive activated.



Seam not detected within one cloth revolution or detected in improper place. Clipper seam is displaced for closing the plate pack.



S838A OR S839A CLOTH DISPLASED TO LEFT OR RIGHT SENSOR (B)



The automatic cloth tracking system has failed to keep the cloth centered.



B503 CLOTH POSITION (B)



Transmitters value out of range (0…1000).



29.2.2012 Reason Battery is low.



Measures Change the backup battery. See PLC manufacturers instructions from the PLC operation manuals. NOTE! DO NOT REMOVE POWER TO THE FILTER WHILE THIS ALARM IS ACTIVE.



-Pressing roller is loose. -Cloth is cut or too long. -Tensioning mechanism inoperative. -Cakes are too thick. -Cloth cannot move forward. -Water remains in the pressing diaphragms. -Encoder has failed. Sensor not adjusted properly or has failed.



-Adjust the pressing roller. -Check the cloth, repair. -Check the cloth tension. -Check that the cloth can move freely. -Replace encoder.



-Sensor B331 has been faulted or resetted. -Clipper is inside of plate pack. -Cloth not adjusted properly. -Tensioning roller displaced. -Cloth seam not straight -Material has piled up on the rollers. -Scrapers are not adjusted properly. -Jammed roller(s) -Press roller not evenly adjusted. -Switch not adjusted properly or has failed. Transmitter B503 not adjusted properly or has failed.



Check the function of sensor B331.



Adjust/replace sensor.



-Center the cloth using the tracking roller (If the cloth is badly displaced, loosen the cloth in TEST mode and manually center the cloth). -Check tensioning roller. -Check rollers and scrapers. -Adjust press roller for even pressure against drive roller. -Adjust/replace switch.



Adjust/replace the sensor.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl Name (Group) B504 TRACKING ROLLER RANGE SENSOR (B)



B505M PLATE PACK POSITION SENSOR´S VALUE TOO SMALL (F)



B505C PLATE PACK POSITION SENSOR´S VALUE TOO HIGH (F)



B505S ABNORMAL MOVE OF PLATE PACK (F)



B505D PLATE PACK NOT IN DISCHARGE POS. (F)



Cause -The B504 transmitter is located on vicinity of the left end of the tracking roller. -Transmitters value out of range. -The B505 sensor is located in the center of the upper pressing plate, attached to the top frame. -The linear measurement wire is attached to the moving pressing plate and moves up and down with the plate -Abnormal signal from sensor B505. -The signal value is equal or less than value that indicates B505M minus 6 mm. -Abnormal signal from sensor B505. -The signal value is equal or greater than value that indicates B505C plus 6 mm. -Abnormal signal from sensor B505. -The signal is continuously monitored and compared to respective functions. Plate pack is not in cake discharge position when cake discharge stage is active.



29.2.2012 Reason Transmitter not adjusted properly or failed.



Measures -Adjust/replace transmitter. -Acknowledge the alarm and restart the filter.



-Sensor wire disconnected. -Sensor has failed. -Wiring has failed.



-Check the position of upper pressing plate. -Adjust/replace sensor and/or wiring. -Acknowledge the alarm and restart the filter.



-Sensor wire disconnected. -Sensor has failed. -Wiring has failed.



-Check the position of upper pressing plate. -Adjust/replace sensor and/or wiring. -Acknowledge the alarm and restart the filter.



-Upper Pressing plate not moving properly. -Hydraulic solenoid is jammed. -Hydraulic pressure too low. -Sensor wire disconnected. -Sensor has failed. -The plate pack has flown too down when filter has been stopped. -Sensor has failed. -Wiring has failed.



-Check movement and position of the upper pressing plate. -Check hydraulic solenoids. -Check hydraulic pressures. -Adjust/replace sensors.



-Check the position of pressing plate. -Drive the plate pack to up with hand held. -Adjust/replace sensor and/or wiring.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl Name (Group) S161…S164 LOCKING PINS UNLOCKED SENSORS (F) S261…S264 LOCKING PINS LOCKED SENSORS (F) S171 SEALING PLATE DOWN SENSOR (F)



S531 DIAPHRAGM LEAKAGE SENSOR (E) S532 V06 SLEEVES LEAKAGE (E) TARE MAX TARE ALARM (E) (OPTIONAL)



MINW MINIMUM WEIGHT ALARM (E) (OPTIONAL)



29.2.2012



Cause Abnormal state of the displayed sensor when operating the locking pins (locking or unlocking).



Reason -Locking pin jammed in the mid position. -Hydraulic pressure too low. -Mechanical failure. -Sensor not adjusted properly or has failed.



Measures -Inspect locking pin assembly. -Test locking pin movement. -Check hydraulic pressures. -Adjust/replace sensor.



Abnormal state of the sensor S171 when driving down (unsealing) or up (sealing) the sealing cylinders HC7. S531 sensor is detecting moisture (slurry or water) in pressing manifold. S532 sensor is detecting moisture (slurry or water) V06 sleeves. Measured weight is greater than max tare weight after plate pack closing stage. Cake weight after pressing is less than set minimum cake weight in parameters.



-Sealing plate not moving properly. -Hydraulic pressure too low. -Sensor not adjusted properly or has failed. -Diaphragms are leaking. -Sensor S531 has failed. -Diaphragms are leaking. -Sensor S532 has failed. -Extra mass has been piled up to filter. -Weight sensor or amplifier has failed.



-Check movement of sealing plate. -Check hydraulic pressures. -Adjust/replace sensors.



-Slurry pump is failed. -Slurry feed time is too short. -Slurry density is too low. -Weight sensor or amplifier has failed. -Return line oil filter is clogged. -Oil temp is too low or viscocity improper -Cable is disconnected. -Pressure switch S410 has failed. -Oil filter is clogged. -Oil temp is too low or viscocity improper -Cable is disconnected. -Pressure switch S412 has failed.



-Skip over air drying stage to avoid filtration. -Plates bending. -Repair or replace weight sensor/amplifier.



S410 RETURN LINE OIL FILTER PRESSURE SWICH (G)



Pressure switch S410 signals a high differential pressure in the RETURN LINE oil filter.



S412 OIL FILTER PRESSURE SWITCH (G)



The differential pressure switch S412 signals a high differential pressure.



-Check if diaphragms are leaking or broken. -Change sensor S531. -Check if diaphragms are leaking or broken. -Change sensor S532. -Remove extra mass from filter. -Repair or replace weight sensor/amplifier.



-Run the hydraulic unit to warm up the oil. -If alarm is active when the oil is warm, replace the oil filter. -Reconnect the cable. -Replace S410.



-Run the hydraulic unit to warm up the oil. If alarm is active when the oil is warm, replace the oil filter. -Reconnect the cable. -Replace S412.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



Name (Group) B491 CLOTH WASH WATER PRESSURE TRANSMITTER (E) B501L OIL LEVEL LOW (G)



S601 OIL TEMPERATURE HIGH HIGH, 0 T>70 C (G)



B601L OIL TEMPERATURE LOW (G)



B601H OIL TEMPERATURE HIGH (G)



29.2.2012



Cause B491 transmitter is not detecting pressure while cloth is washed.



Reason -Hand valve is closed. -Filter is blocked. -Sensor B491 has failed.



Oil level transmitter B501 in hydraulic oil reservoir is indicating low oil level. Thermostat S601 in hydraulic oil reservoir is indicating high high oil temperature (above 70°C).



-Leak in the hydraulic system. -Level transmitter B501 has failed.



Oil temperature transmitter B601 in hydraulic oil reservoir is indicating low oil temperature (below 10°C). Oil temperature transmitter B601 in hydraulic oil reservoir is indicating high oil temperature (above 65°C).



-Oil cooler is off. -Oil heater has failed on. -Transmitter B601 has failed. -Thermostat S601 has failed or not adjusted properly. -Oil heater is off. -Filter has been shut down when ambient temperature is low. -Transmitter B601 has failed. -Oil cooler is off -Oil heater has failed on. -Transmitter B601 has failed.



B601HH OIL TEMPERATURE HIGH HIGH (G)



Oil temperature transmitter B601 in hydraulic oil reservoir is indicating high oil temperature (above 70°C).



-Oil cooler is off -Oil heater has failed on. -Transmitter B601 has failed.



B403A ACCUMULATOR PRESSURE (G)



Recharging the pressure accumulator takes too long time.



-Leak in the pipelines or hoses. -Unsuitable oil type. -Accum. precharge (nitrogen) pressure is too low. -Pressure release valve is leaking. -B403 has failed.



Measures -Check if hand valves are closed and open them. -Check and clean wash water filter. -Change transmitter B491. -Check the oil level and add oil if necessary. -Check the system for oil leaks. Never run the hydraulic pump if the tank is empty -Replace B501. -Check the oil cooler OC is on -Check the oil heater R04 is off -Check oil temperature from the thermometer TM. Allow cooler to cool down the oil for 30 min. Replace S601, check adjustment of S601. -Check the oil heater is on. -Check oil temperature from the thermometer TM. -Allow heater to warm up the oil for 30 minutes. -Replace B601. -Check the oil cooler OC is on -Check the oil heater R04 is off -Check oil temperature from the thermometer TM -Allow cooler to cool down the oil for 30 minutes. -Replace B601. -Check that the oil cooler OC is on. Check that the oil heater R04 is off. -Check oil temperature from the thermometer TM. Allow cooler to cool down the oil for 30 minutes. -Replace B601. -Check the pipes and hoses. -Check the oil type. -Check accumulator precharge (nitrogen).



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



Name (Group) B403R ACCUMULATOR RECHARGE (G)



Cause The recharging of the pressure occurs too often.



M01 HYDRAULIC PUMP MOTOR (C) M02 PRESSING WATER PUMP MOTOR (C) (OPTIONAL) M05 OIL COOLER MOTOR (C) (OPTIONAL) M06 CLOTH WASH PUMP MOTOR (C) (OPTIONAL) M08 CAKE CONVEYOR (C) M09 SLURRY PUMP MOTOR (C) M15 CAKE WASH PUMP MOTOR (C) (OPTIONAL) M16 HIGH PRESSURE CLOTH WASH PUMP MOTOR (C) (OPTIONAL) M24 CAKE POPPING MOTOR (C) (OPTIONAL) R04 OIL HEATER (C)



No feedback signal after K1M** output turns on, or the feedback signal still on after K1M** output turns off. Alarm delay 2 sec.



CCOL1 CONTROL CIRCUIT OVERLOAD IN X1 (H)



29.2.2012



Reason -Leak in the pipelines or hoses. -Unsuitable oil type. -Accum. precharge (nitrogen) pressure is too low. -Pressure release valve is leaking. -B403 has failed. -Safety switches open. -Fuse tripped.



Measures -Check the pipes and hoses. -Check the oil type. -Check accumulator precharge (nitrogen).



No feedback signal after K1M** output turns on, or the feedback signal still on after K1M** output turns off. Alarm delay 5 sec.



-Safety switches open. -Fuse tripped.



-Reset switches. -Replace fuses. -Test the motor in question with TEST mode.



No feedback signal after K1R04 output turns on, or the feedback signal still on after K1R04 output turns off. Alarm delay 2 sec. Automatic fuse has tripped. Alarm delay 1 sec.



Fuse tripped.



-Replace fuses. -Test the heater by TEST MODE.



-Overload. -Short circuit. -Lose wire connection.



-Reset the tripped device. -Measure the current of the device and find out the reason for the overload.



-Reset switches. -Replace fuses. -Test the motor in question with TEST mode. NOTE: plate pack must be closed if pressing water pump is tested.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



29.2.2012



Name (Group) CCOL2 CONTROL CIRCUIT OVERLOAD IN X2 (H) ***F MOTOR OVERLOAD (C)



Cause Automatic fuse has tripped. Alarm delay 1 sec.



Reason -Overload. -Short circuit. -Lose wire connection.



Measures -Reset the tripped device. -Measure the current of the device and find out the reason for the overload.



Thermal overload relay or motor protector has tripped.



-Overload. -Short circuit. -Lose wire connection.



VALVE SENSORS S1** is open sensor. S2** is closed sensor.



Abnormal state of sensor in valve V**.



B415M FEED MANIFOLD PRESSURE HIGH (E)



Feed manifold pressure transmitter B415 is indicating too high pressure (above max. operating pressure set point in auxiliary parameters, typically 16.0 bar). Feed manifold pressure transmitter B415 is indicating low slurry feed pressure while slurry pump is running and slurry inlet valve V02 is open.



-Instrument air / hydraulic oil pressure low. -Break in pneumatics/ hydraulics. -Sensor not adjusted properly or has failed. -Break in electrical wiring. -Blown fuse in terminal box. -Slurry feed, wash water or drying air system produces excessive pressure. -Transmitter B415 has failed.



-Reset the tripped device. -Measure the current of the device and find out the reason for the overload. -Clean the motor. -Actuate the valve in question in TEST mode. -Follow the indicator LED's in the valve circuit for easy troubleshooting. -Check instrument air/lines. -Adjust/replace sensors. -Check electrical system.



B415F SLURRY FEED PRESSURE LOW (E)



B415H HOSE WASH PRESSURE (E) LOW B415C CAKE WASH PRESSURE LOW (E)



Feed manifold pressure transmitter B415 is indicating low wash water pressure during HOSE WASH or CAKE WASH stage.



-Slurry feed pump inoperative or cavitating. -Slurry tank is empty. -Manual valve closed. -Pressure set point “MINIMUM FEED PRESSURE” incorrectly set. -Transmitter B415 has failed. -Wash water pump inoperative or cavitating. -Wash water tank is empty. -Manual valve closed. -Pressure set point in Data 2 for HOSE WASH or CAKE WASH stage incorrectly set. -Transmitter B415 has failed



-Check feed manifold pressure from the pressure gauge. -Correct the reason for over pressure. -Replace B415.



-Start the slurry feed pump. -Maintain correct slurry level. -Open the manual valve. -Enter correct value into “MINIMUM FEED PRESSURE” set point. -Adjust/replace pressure transmitter B415.



-Start the wash water pump. -Maintain correct wash liquid level. -Open the manual valve. -Enter correct value into Data 2 set point. -Adjust/replace pressure transmitter B415.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



Name (Group) B415A DRYING AIR PRESSURE LOW (E)



Cause Feed manifold pressure transmitter B415 is indicating low drying air pressure immediately after opening the valve V06 during DRYING stage.



B415N FEED MANIFOLD PRESSURE NOT RELEASED (E)



Feed manifold pressure transmitter B415 is indicating too high pressure after opening the drain valve V07. Pressing manifold pressure transmitter B419 is indicating too high pressure (above max. operating pressure set point in auxiliary parameters, typically 16.0 BAR). Pressing manifold pressure transmitter B419 is indicating low pressing manifold pressure after closing the valve V04 and opening the valve V03.



B419M PRESSING MANIFOLD PRESSURE HIGH (E)



B419P PRESSING MANIFOLD PRESSURE NOT REACHED (E)



B419N PRESSING MANIFOLD PRESSURE NOT RELEASED (E)



Pressing manifold pressure transmitter B419 is indicating too high pressure after opening the pressing air outlet valve V04.



29.2.2012



Reason -Compressor not running. -Manual valve closed. -Low air pressure/volume. -Pressure set point in Data 2 for DRYING stage incorrectly set. -Transmitter B415 has failed. -Drain pipe is clogged. -Slurry strainer is clogged. -V07 valve failed. -Transmitter B415 has failed -Pressing system produces excessive pressure. -Transmitter B419 has failed



Measures -Start up the compressor. -Open the manual valve. -Check operation of compressor. -Enter correct value into Data 2 set point. -Adjust/replace pressure transmitter B415.



-Valve V03 not opening. -Manual valve closed. -Valve V04 not closed -Pressing air system pressure too low. -Pressure set point in "MINPRPRE" incorrectly set. -Transmitter B419 has failed. -Too short air drying time. -Outlet pipe is clogged. -V04 valve failed. -V03 valve failed. -Transmitter B419 has failed.



Ensure valves V03 and V04 are operating normally.



-Ensure that pressure in feed manifold is released. -Clean the pipeline. -Check operation of valve V07. -Adjust/replace pressure transmitter B415. -Check pressing manifold pressure from the pressure gauge. -Correct the reason for overpressure. -Replace B419.



-Ensure that pressure in manifold is released. -Adjust DRYING time to allow the pressing air to escape. -Clean the pipeline.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



Name (Group) B415D FEED MANIFOLD PRESSURE TRANSMITTER DRIFT (E) B419D PRESSING MANIFOLD PRESSURE TRANSMITTER DRIFT (E) B473S SEALING PRESSURE (G)



B472Y PLATE PACK YIELDING (G)



SLLO SLURRY LEVEL LOW (E)



MINT MINIMUM CAKE THICKNESS (E) (OPTIONAL)



MAXT MAXIMUM CAKE THICKNESS (E) (OPTIONAL)



QPC HYDRAULIC AMPLIFIER CARD (G)



Cause Signal from transmitter that pressure does not fall below 0.5 bar when it should.



Sealing pressure transmitter B473 is indicating low oil pressure during plate pack closing stage. Abnormal signal from the sensor B472 when plate pack is pressurized (during pressing stage). The signal from SLURRY TANK LOW LEVEL switch is missing and causes the filter to stop at the end of cycle. Cake thickness after pressing is less than set minimum cake thickness in parameters. Cake thickness after pressing is higher than set maximum cake thickness in parameters. The Hydraulic´s flow/pressure control card is located in terminal box X5 top of the hydraulic unit.



29.2.2012



Reason -Feed manifold drain valve V07 inoperative. -Drain pipeline blocked. -Pressing water return valve V04 inoperative. -Transmitter not adjusted properly or has failed. -Proportional pressure control has failed. -Transmitter B473 has failed.



Measures -Measure mA-signal (4-20mA) when pipeline pressure is zero. -Check feed manifold drain pipeline. -Adjust/replace pressure transmitter.



-Hydraulic valves are leaking (yield). -Sensor not adjusted properly or has failed.



-Check movement of sealing plate. -Check hydraulic valves. -Adjust/replace sensors.



-Slurry tank is empty. -Level switch is faulty adjusted or failed.



-Check the slurry level and level switch. -Check the signal coming to the control panel.



-Slurry pump is failed. -Slurry feed time is too short. -Slurry density is too low. -Cake thickness sensor has failed. -Slurry feed time is too long. -Cake thickness sensor has failed.



-Skip over air drying stage to avoid filtration. -Plates bending. -Repair or replace cake thickness sensor.



-Error in hydraulic's flow/pressure control. -Hydraulic´s flow/pressure control card has failed.



Check error message from card.



-Check oil pressure. -Adjust or replace proportional pressure control. -Replace B473



-Skip over air drying stage to avoid filtration. -Plates bending. -Repair or replace cake thickness sensor.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



Name (Group) X* COMMUNICATION



ERROR NODE * (H) BUS FIELD BUS FAILURE (H) (It depends on the control system type) S8XXRT DOORS RIGHT SIDE NOT ACKNOWLEDGE D (D)



BxxxW TRANSMITTER WIRE BREAK KA100 FAULT IN EMERGENCY STOP RELAY (D)



29.2.2012



Cause Node X* is not available.



Reason -Bus cable is loose. -I/O card is loose or faulted.



Measures -Check the bus cable. -Check I/O cards.



Field bus disconnected or failed.



Bus cable is loose.



Check the bus cable.



Protective doors in right side open or not acknowledged with blue push button in left side of the filter after closing. Analog signal of transmitter below 4 mA



Protective doors closed but not acknowledged.



Acknowledge “doors closed” with blue push button S742.



Wire break. Transmitter failed. Analog card failed.



Check wires. Check/replace transmitter. Check/replace analog card.



Fault in programmable emergency stop relay. Check fault from relay indication leds.



Fault in base unit. Customer MCC feedback loop disconnected.



Find out the reason for fault. Acknowledge the alarm and restart the filter.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



29.2.2012



5.12.



Operation stages in automatic operation



5.12.1.



SBR01 Pressure release For security reasons, pressure release is always the first stage when starting an Outotec PRESSURE FILTER. During this stage, the remaining pressure in the filter chambers is released for safe plate pack opening. This stage is divided into two periods of time: in the first and main period the inlet valves are closed. During the second period, the manifold drain valves V07 and V17 are opened.



5.12.2.



SBR02 Plate pack opening On completion of the PRESSURE RELEASE the plate pack is unsealed by driving the sealing cylinders downwards. The quick action cylinders are then driven to release the pins from the column holes. The locking pins are unlocked (pins move into the upper pressure plate). After the locking pins have been unlocked, the plate pack is opened by driving the quick action cylinders upwards until the plate pack is fully open. The cloth strain starts at the same time as the PLATE PACK OPENING.



5.12.3.



SBR03 Cake discharge When the plate pack is fully open, the cloth drive motor HM09 is started and the cloth wash inlet valve V09 is opened. The cake formed on the cloth is then discharged into the cake chutes at both ends of the filter. After the first plate length of discharge, the speed of the cloth is increased, reducing thus the cloth washing time.



5.12.4.



SBR04 Restart operation Operation delay. The system executes a restart check and proceeds to the next stage.



5.12.5.



SBR05 Plate Pack closing On completion of the restart operations delay, the filter begins to close the plate pack. First the quick action cylinders are moved downwards after which the locking pins are locked. Finally, the plate pack is sealed by driving the sealing cylinders upwards until the required sealing pressure is reached.



5.12.6.



SBR06 Pre-Filtration When the filter plates are closed and sealed, the slurry is fed to the distribution pipe through V02 and V12 and further to each chamber through the feed collectors. The filtrate passes through the cloth into the filtrate pan and exits the filter chamber via filtrate collectors into the filtrate side pipe and out through the valve V08. Cake begins to form on the cloth. When the filtration time runs out, the filtration stage starts.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



5.12.7.



29.2.2012



SBR07 Filtration (Slurry feed) When the filter plates are closed and sealed, the slurry is fed through the distribution pipe to each chamber through the feed collectors. The filtrate passes through the cloth into the filtrate pan and exits the filter chamber via filtrate collectors into the filtrate side pipe and out through the valve V01. Cake begins to form on the cloth.



5.12.8.



SBR08 Pipe washing After the filtration stage, the distribution pipe is cleaned by opening the manifold drain valves V07 and V17 and feeding water through the pipe from cake wash inlet valve V05.



5.12.9.



SBR09 Hose washing After the pipe washing stage, the slurry feed hoses are cleaned by opening the cake wash inlet valve V05 which forces water through the slurry feed hoses and into the filter chambers. The drain valves V07 and V17 are closed.



5.12.10. SBR10 Pressing 1 In the pressing stage, the pressing air enters through the pressing air pipe and the hoses into the space above the rubber diaphragms. All the remaining liquid from the filter chamber above the formed cake is forced through the cake and it exits the filter. Finally the cake is pressed for elimination of any liquid mechanically disposable still present in the cake. Proceed now to CAKE WASHING.



5.12.11. SBR11 Cake washing (optional) The washing liquid is fed to the filter chamber through the wash liquid inlet valve V05. The washing liquid washes the cake and passes through the cloth into the filtrate collectors.



5.12.12. SBR12 Pressing 2 (optional) After the washing stage the washing liquid remaining in the filter chamber is pressed out by introducing the pressing air into the diaphragms, like in the Pressing 1 stage.



5.12.13. SBR13 Drainage of distribution Pipe After the last pressing stage and before the cake air drying the distribution pipe is drained of water/slurry by opening valves V07, V17 and vent valve V27.



5.12.14. SBR14 Cake air drying Drying of the cake is accomplished with compressed air. The air enters the distribution pipe through V06 and V16 valves. The air flowing through the cake reduces its moisture content to the optimum value simultaneously emptying the filter chamber from the pressing air.



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B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



29.2.2012



Table of Contents 6.



Maintenance instructions................................................................................................................. 3 6.1. General Notes on Maintenance Work .................................................................................... 4 6.2. Preparation for maintenance.................................................................................................. 7 6.2.1. Slackening the filter cloth .............................................................................................. 7 6.2.2. Space arrangement between the filter plates for maintenance ...................................... 8 6.2.3. Space arrangement in the upper part of the plate pack (filter plates no. 8…25)........... 10 6.2.4. Space arrangement in the lower part of the plate pack (filter plates 2…7) ................... 11 6.2.5. Removing the upper part of the cake chute ................................................................. 14 6.2.6. Safety supports ........................................................................................................... 15 6.3. Scheduled Maintenance ...................................................................................................... 18 6.3.1. Daily maintenance ....................................................................................................... 19 6.3.2. Weekly maintenance ................................................................................................... 20 6.3.3. Monthly maintenance .................................................................................................. 20 6.3.4. Semiannual maintenance ............................................................................................ 20 6.3.5. Replacement of wearing parts ..................................................................................... 20 6.4. Unscheduled maintenance .................................................................................................. 21 6.4.1. Filter cloth ................................................................................................................... 21 6.5. Filter plate............................................................................................................................ 25 6.5.1. Replacement of the filter plate ..................................................................................... 27 6.5.2. Replacement of the seal .............................................................................................. 32 6.5.3. Installation and replacement of grids ........................................................................... 36 6.5.4. Symptoms of leaking diaphragm ................................................................................. 36 6.5.5. Risks of the leaking diaphragm ................................................................................... 37 6.5.6. Locationing of the leaking diaphragm .......................................................................... 37 6.5.7. Replacing the diaphragm ............................................................................................ 37 6.5.8. Replacing the filtrate vat .............................................................................................. 40 6.6. Slide pieces ......................................................................................................................... 41 6.7. Scrapers .............................................................................................................................. 42 6.7.1. Adjusting the scrapers ................................................................................................. 42 6.7.2. Replacing the scrapers................................................................................................ 42 6.8. Hoses .................................................................................................................................. 43 6.8.1. Replacement of hoses................................................................................................. 43 6.8.2. L-coupling band circle installation ................................................................................ 44 6.9. Cloth conveyor and tensioning device ................................................................................. 45 6.9.1. Cloth driving ................................................................................................................ 45 6.9.2. Automatic cloth tracking .............................................................................................. 45 6.9.3. Cloth tensioning device ............................................................................................... 47 6.10. Rollers ............................................................................................................................ 48 6.10.1. Replacing the roller bearing of the plate ...................................................................... 48 6.10.2. Replacing the plate roller ............................................................................................. 49 6.10.3. Drive rollers ................................................................................................................. 52 6.10.4. Centering roller............................................................................................................ 52 6.10.5. Replacing the guide roller ............................................................................................ 52 6.10.6. Replacing the auxiliary drive roller ............................................................................... 53 6.11. Cloth wash spray nozzles ............................................................................................... 54 6.12. Quick action cylinder ....................................................................................................... 54 6.13. Suspension plates .......................................................................................................... 61 6.14. Lubricant recommendations ............................................................................................ 67 6.15. Spare parts ..................................................................................................................... 68 6.15.1. Storing instructions for rubber parts............................................................................. 68



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How to order spare parts ............................................................................................. 69 Spare Parts recommendation ...................................................................................... 69



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6.



29.2.2012



MAINTENANCE INSTRUCTIONS Appropriate protective equipment, such as a safety helmet, goggles, protective overalls, protective footwear, safety gloves, ear protection, a respirator etc. must be used whenever needed.



When carrying out maintenance or repair work, make sure the machine cannot accidentally be turned on by performing the appropriate lockout-tagout procedures.



DANGER Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Stop the machine completely before maintenance, repairs or disassembly.



Electrocution hazard. Electrocution will cause serious injury or death. Cut the power supply to the machine before maintenance, repairs or disassembly



Hydraulic fluid injection hazard. High-pressure hydraulic fluid spray can penetrate the skin and will cause death or serious injury.



WARNING High-pressure air injection hazard. High pressure air spray can cause death or serious injury. Make sure that the pneumatic system is not pressurized before maintenance, repairs or disassembly.



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6.1.



29.2.2012



General Notes on Maintenance Work Safety Before starting any work: -



Inform the operating personnel on the maintenance work.



-



Make sure you know the structure of the filter.



-



Get familiar with all different operation stages of the filter.



-



Learn how to use the control panel push buttons.



-



Never use faulty service tools during maintenance.



-



Follow all safety regulations.



-



Carry out check-ups regularly.



-



Wear proper protective clothing and equipment.



-



Check that there are no persons or foreign objects in between the moving parts.



-



Close the manual valves in the process piping.



-



If maintaining hydraulics, lower all loads, unload accumulators, switch off pumps and secure them from being switched back on.



-



Open the main switch and the fuses and lock the main switch in its OPEN position for the time the maintenance or repair work is being done.



-



Keep the EMERGENCY-STOP button pushed down always when the activation of the functions of the filter is not necessary. This is how you prevent manual and remote starts of the filter.



The filter operates automatically, thus never start any maintenance or repair work when the filter is energized. When working on top of the filter, drive the plate pack to its open position and lock the top pressing plate to the columns with locking pins. NOTE!



Before starting any maintenance or repair work, always open the main switch and the fuses and lock the main switch in its OPEN position for the time the maintenance or repair work is being done. Close all the manually actuated process valves.



NOTE!



Do not keep maintenance tools fixed in the filter



In possible emergency situations, there are several Emergency-Stop switches. They are situated on the control panel, side of the cloth conveyor unit casing, in hydraulic unit and in hand held unit. The Emergency-Stop switches stop the filter immediately. Before a new start, make sure that the switches have been released.



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NOTE!



29.2.2012



Inspect the condition of the distribution pipelines and hoses for wear and tear, as well as their joints.



The filter uses hydraulic pressures so that in case of possible failure the pressure is released immediately. The filter is always open on its filtrate side. Check that the hose guards are in place, as they are meant to receive the force of the pressure blow in case of possible hose damage. When changing the cloth, beware of the pinch points formed by the rollers. Carefully follow the instructions for changing the cloth given in the Operation and Maintenance Manual. In case the filter is located in a place where there is a danger of explosion, make sure that the cloth does not move before it is wetted all around with conductive liquid, e.g. water. NOTE!



If the cloth is moved while dry, there must be no hazardous gases, dust or any other explosively sensitive materials in the same space with the filter.



In case there are explosion sensitive materials in the same space with the filter and the cloth, the filter has to be moved for carrying out maintenance work. Similar approach to ensure the work safety is recommended as what is the mill practice, when carrying out maintenance work (e.g. welding at the same area). The reason for these safety precautions is a possibility of electrical charging of the cloth. The cloth can be charged with static electricity under some process conditions. If particles attached to the cloth are electrically non-conductive, a static charge can be generated. This would create a spark associated with rapid electrostatic discharge (ESD). The reliable operation and the long life of the PF filter largely depends on the proper knowledge and following of the operation and maintenance instructions. These instructions are general; do not refer to measures required in special conditions. The customer's own maintenance instructions for the machinery and equipment, as well as the nature of the process and operating conditions largely determine the maintenance measures to be taken.



Only qualified persons who are familiar with the functions of the pressure filter may carry out the filter maintenance.



The persons responsible for the operation and maintenance of the automatics must be familiar with the safety regulations for electrical equipment, as well as with the operation of the PF filter's electrical equipment.



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It is absolutely forbidden to use the filter and its automatic devices if any fault has appeared.



The regular change of wearing parts, as well as ascertaining their premature failure and immediate repair constitute a condition for the validity of the warranty. Pressure filter maintenance includes: -



daily inspection and



-



preventative maintenance



Before maintaining the hydraulics, make sure that you are familiar with the structure and the function of the hydraulic system. Before detaching any components of the hydraulic system, make sure that there is no pressure in the line, which is under work. Before maintaining the pneumatics, close the shut-off valve in the pneumatic box. Closing the valve releases pressure from the actuators of process valves. Close all pressurized pipelines before shutting off the instrument air.



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6.2.



Preparation for maintenance



6.2.1.



Slackening the filter cloth



29.2.2012



1. Drive the plate pack in its open position by test drive and lock the plate pack. 2. Drive the tension roller(1) of the filter cloth(2) in to the uppermost position. Lock the roller by closing the oil circulation in the cloth tensioning device motor by the restrictor valve. The valve locates in the lower part of the cloth drive device. See pictures below.



A



B



2 1 2



1



A =Tension roller in its lower position, B = Tension roller in its upper position



Restrictor valve in the lower part of the cloth drive device



3. Pull the loose filter cloth near the tension roller to a place where it is needed. 4. After maintenance work release the cloth tension device motor oil circulation by opening the restrictor valve on the lower part of the cloth drive device.



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Space arrangement between the filter plates for maintenance Tasks where filter plate needs to be removed or space between filter plates is needed for maintenance: -



Replacement of diaphragm



-



Replacement of seal



-



Replacement of vat



-



Replacement of filter plate



WARNING Crushing hazard. Falling filter plates can cause death or serious injury. Do not *) work between filter plates. Remove the filter plate requiring maintenance from the plate pack according to manufacturer’s instructions. *) Working here means all other measures except those needed for extracting the filter plate from the plate pack.



A



A



A-A Crushing hazard zone between the filter plates. Do not work in that area!



Read the safety instructions



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Always use 12 pieces of suspension plates (2 pieces in every support pin) when the filter plate is lifted and suspended by the suspension plates. Lock the suspension plates with retaining rings.



1



3



1



3



3



1 3 A 1 2 A



1 1. 2. 3.



3



1



3



3



1



A-A



Suspension plate (12 pieces/filter plate) Retaining ring Support pin in the filter plate ( 6 pieces)



Always lock the plate pack to its uppermost position before starting to work between the plate pack.



Plate pack locked in the uppermost position (upper pressure plate locking pins in the uppermost holes of the columns).



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Space arrangement in the upper part of the plate pack (filter plates no. 8…25) A sufficient maintenance space is obtained by cutting the plate pack as follows 1. Drive the plate pack to its close position. 2. Cut the plate pack by removing the suspension plates from the filter plate, below the place where space is needed. Refer to figure below 3. Install the suspension links and fix the retaining rings. 4. Drive the plate pack into its open position and lock it. Observe the pressing air and feed hoses, when the plate pack is being driven up. Make sure that the hoses are not too tight. Remove, if necessary.



B B



A- A 1



B- B



8



A A



The plate pack is cut and driven into its open position. The filter plate no.8 is below formed space. 1. 8.



Note!



Retaining ring of the suspension plate Plate number 8



A – A = Order of the suspension plates. Always use 12 pieces of suspension plates in one filter plate



5. Remove the filter plate requiring maintenance from the plate pack according to paragraph service the filter plate outside the plate pack. 6. After maintenance/repair work, join the plate pack back in reverse order. 7. Remember to check the suspension plate operation by driving the plate pack to its open and close position.



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Space arrangement in the lower part of the plate pack (filter plates 2…7) A sufficient maintenance space in the lower part of the plate pack (filter plates 2...7) is obtained by cutting the plate pack and using the suspension bars (8 pcs) delivered with the filter. 1. Drive the plate pack to its close position. 2. Cut the plate pack by removing the suspension plates from the filter plate, which is below the place where space is needed. Refer to figure below 3. Connect the filter plates (6 pcs) located right above the filter plate, from where the suspension plates were removed, by installing a pair of suspension bars in place of the suspension plates on every corner of the filter plates. Install also suspension links to the lower end of the suspension bars.



B B



A



1



A



3 5



4



2



1



1



A-A



7



3



B- B



The plate pack is cut, suspension bars and links installed and plate pack driven to its open position. The filter plate no.7 is below formed space. 1. 2. 3.



Note!



Suspension bar The lowest filter plate fixed to suspension bar Retaining ring



4. 5. 7.



A – A = the order of suspension plates and bars



Suspension link Washers M30 Plate number 7



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4. Check the correct location of the suspension bars (1) and links (2). Refer to figure below 5. Fix the filter plates joined by suspension bars on the filter plate above using suspension plates (use 12 pcs of suspension plates according to paragraph 6.2). 6. Fix the retaining rings (4) and washers (3) in their places. 7. Drive the plate pack to its open position and lock it. Note!



Observe the pressing air and feed hoses, when the plate pack is being driven up. Make sure that the hoses are not too tight. Remove, if necessary.



8. Remove the filter plate requiring maintenance from the plate pack according to paragraph service the filter plate outside the plate pack. 9. After maintenance/repair work, join the plate pack in reverse order. 10. Remember to check the suspension plate operation by driving the plate pack to its open and close position. Install the suspension bars and links. Use washers and retaining rings to secure them.



A



B



1



3



4



4 3



1



2



3



2 1



1 Position of the suspension bars and links 1. 2.



Suspension bar Suspension link



3. 4.



Washer M30 Retaining ring



1



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Install the suspension bars on the filter plates, which are located right above the filter plate under maintenance. Refer to figure below. Note!



Do not fix any load into the filter plates (6 pieces), which have been connected by means of suspension bars (except the filter plate to be removed from the plate pack).



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Removing the upper part of the cake chute 1. Verify the load of the crane, lifting loops and hooks (mass of the upper part app. 460 kg)



730 3



2. Install the lifting devices into the lifting lugs of the upper part of the cake chute.



4. Lift the cake chute by means of a crane. 5. Install the upper part in reverse order. Note!



2900



3. Open the screws on the side and on the end of the upper part of the cake chute.



Remember to verify that the screws are tightened properly to avoid accidental falling of the upper part of the cake chute.



1



2



1200



6.2.5.



29.2.2012



1. 2. 3.



Upper part of the cake chute; mass app. 460 kg Lower part of the cake chute Lifting lug



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Safety supports Safety supports are accessories for the maintenance of the PF 60-144 pressure filter. Cut the plate pack as instructed in the filter‟s service instructions for the necessary service space in between the plate pack. Safety supports are intended for ensuring the suspension of the filter plates above the service space during service work. It is not allowed to use the safety supports for any other purposes. The instruction for cutting the plate pack and suspending the filter plates above the service space are available in the filter‟s service instructions. This instruction is for using the safety supports only. The safety supports are installed (4 pieces) to the columns that connect the upper and lower frames. There are two supports for each column on both sides of the plate pack.



1



1.



Guide of the safety supports (on both side of the plate pack)



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Safety When using safety supports -



Make sure that each lug is on the same height



-



There must be four lugs–one on each column



Use only original Outotec safety supports and fastening pins



-



Inspect visually the condition of the fastening pins and safety supports before use



-



Always lock the fastening pins of lugs with cotter



-



Lugs of the safety supports are only to be used at plate pack maintenance operations: do not activate hydraulics!



-



Maximum load of the safety supports is 40 tn (10 tn/lug)



WARNING Crushing hazard. Falling filter plates can cause death or serious injury. Safety supports are an extra suspension of the plate pack during maintenance: Do not use safety supports as only support for holding up the filter plates!



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Installation Refer to figure below and proceed as follows 1. When the plate pack is cut, driven to its upper position and locked as explained in the service instructions, the lugs of the safety supports (2) can be installed in their positions. 2. Set the lugs under the filter plate, which is located above the service space, as far up as possible (there are 3 different heights in the lug for locking pin). Make sure that all safety supports are on the same height. 3. Lock the lug by using the pin no 3 and the cotter no 4. There must not be gap between the filter plate and lugs. Tighten the screws no 5 against the filtrate plate. Maximum tightening length by using screws is 30 mm.



1



4 5 3



400



2



225



154



Main parts of the safety supports No. 1 2 3 4 5



Description Guides, plate pack Lug Pin Cotter, ring Screw



Dimensions 120x120x10 PL12 ø30



Material AISI 316 RAEX 500 MC OPTIM 42CrMo4



Weight 13 kg



Pcs. 4 4 4 4 4



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6.3.



29.2.2012



Scheduled Maintenance MAINTENANCE PERIOD x FILTERING CYCLE OR LIFETIME A = DAILY 1 = CHECK/FILLING B = WEEKLY 2 = CHANGE C = MONTHLY D = SEMI-ANNUALLY 15 000 x E = YEARLY 30 000 x OBJECT A B C D E OPERATION



OPERATOR PANEL DIAPHRAGM EMERGENCY STOP SWITCHES FILTER CLOTH



1 1 1 1



SEAM OF FILTER CLOTH FILTER PLATES SUSPENSION PLATES GREASE NIPPLES HOSES HYDRAULIC UNIT HYDRAULIC PIPING AND HOSES



1 1 1 1 1



2



1 1



HYDRAULIC CYLINDERS HYDRAULIC MOTORS HYDRAULIC MOTOR COUPLINGS HYDRAULIC OIL HYDRAULIC PRESSURES LIMIT SWITCHES ACTION OF ROLLERS PARALLELISM OF ROLLERS ROLLER BEARINGS AND SEALS



CLEAN IF NECESSARY 2



1 1 1



2 1 1



CLOTH CONDITION / CENTRING CHECK CONDITION OF SEAM WIRE CHECK GRIDS + PLATES STRAIGHTNESS CHECK/CHANGE LUBRICATION HOSE FIXING CHECK THE LEAKS CHECK CONNECTIONS AND CHANGE HOSES IN EVERY 3 YEARS CHECK IF MOUNTED PROPERLY CHECK WARMING UP AND SOUND CHECK FLEXIBLE ELEMENT AND CHANGE IF NECESSARY CHANGE OR FINE FILTRATION DURING OPERATION FIXING, OPERATION



1 1 1



CHECK WARMING UP, SOUND AND LUBRICATION



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MAINTENANCE PERIOD x FILTERING CYCLE OR LIFETIME A = DAILY 1 = CHECK/FILLING B = WEEKLY 2 = CHANGE C = MONTHLY D = SEMI-ANNUALLY 15 000 x E = YEARLY 30 000 x OBJECT A B C D E OPERATION



PLATE SEAL PRESSURE REDUCING VALVE PRESSURE SWITCHES SCRAPERS SEALING PRESSURE SLIDE PIECES TENSIONING DEVICE VALVE ACTUATORS VALVES WASH NOZZLES + FILTER LUBRICATORS Note!



6.3.1.



1



2 1



ADJUST 1



1 1



ADJUST



1



2 1 1



ADJUST AND CHANGE IF NECESSARY CHECK + ADJUST TIGHTNESS OF CHAINS INSPECTION



1 1



CLEAN OR REPLACE 1



2



As far as standard components are concerned, follow the manufacturer's instructions.



Daily maintenance The daily inspection and maintenance measures, when the filter is started and stopped: -



Remove cake and foreign particles from between the filter plates and on the filter cloth.



-



When the filter is operated in cold conditions and the temperature of the hydraulic oil has sunk below the recommended temperature for the oil in question, operate the filter first without slurry. Check the operation of the oil heater.



-



Observe the sealing pressure of the sealing cylinders. A decrease in sealing pressure may cause leakages in the plate pack.



-



The filter cloth must be free of holes and folds. Check cloth tracking.



-



During the first filtration cycle, check that all filter plates have a cake of even thickness (i.e. the feed pipe connections are open).



-



When the filter is stopped, complete the filtration by filling the filter with water. This enables you to clean the feed holes and grid space. Dry slurry stuck in the feed holes causes pressure differences, which may bend the filter plates. If corrosive slurries have been filtered, wash the filter outside, too.



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29.2.2012



Weekly maintenance 1. Visual inspection of the scrapers 2. Checking the emergency stop function 3. Condition and fixing of the limit switches 4. Checking the pressure of the hydraulics. Check hydraulic pressures during ON cycle, when the filter is in operation (see the pressure values in the hydraulic diagram). 5. Observing the condition of slide pieces 6. Filling of grease nipples



6.3.3.



Monthly maintenance 1. Inspection of filter plates, seals and diaphragms 2. Checking that the filter plates are straight and that the plates in the plate pack are in line 3. Checking the hydraulic pipeline hoses 4. Checking the hydraulic cylinders and fixings 5. Checking the operation of locking pins 6. Checking the chains and sprockets 7. Checking the seam thread of the filter cloth



6.3.4.



Semiannual maintenance -



6.3.5.



Analysis of a hydraulic oil and if necessary changing or fine filtration with a separate filtration unit. The first oil analysis 1 month after start up. Oil recommendations have been presented in the hydraulic unit instructions of this manual.



Replacement of wearing parts NOTE! -



If the conditions are corrosive and the operating temperature is above 60 °C, special instructions must be required from the manufacturer.



Pinch valve sleeves, filter cloth, pressing diaphragms, plate pack seals, slide pieces and scrapers must be changed immediately when noticed in order to prevent greater break up.



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6.4.



Unscheduled maintenance



6.4.1.



Filter cloth



29.2.2012



Cloth drive system To remove the cakes and to wash the cloth, the cloth is moved by means of drive rollers (2 & 8) between filtering cycles. A spring-loaded pressing roller (3) presses the cloth against the drive roller in order to improve the maintenance of tension. The cloth functions both as a filtering element and as a conveyor belt transporting the cake out of the filter. Besides having a good filtering ability, the cloth must withstand tension. Only special type of fabrics can be used. The most commonly used material is a multifilament fabric which is lengthwise (warp) stronger than crosswise (weft). Pay special attention to possible holes in the cloth. Patch the holes immediately; solid matters entering through the holes wear the filtrate channels heavily especially during drying when the air flow speed is high.



1. 2. 3. 4. 5. 6. 7.



Vat roller Main drive roller Pressing roller Centering roller Impulse roller Tensioning roller Guide roller



8. 9. 10. 11. 12. 13. 14.



Auxiliary drive roller Cloth scraper Roller scraper Cloth wash nozzles Cake Spread roller Encoder



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Replacement of the cloth 1. Place the cloth on a rack outside the conveyor unit where the new cloth is on the top and the cloth to be changed is rolled up around a tube underneath. 2. Open the conveyor unit hatches. Follow the cloth seam and drive it by means of test drive next to the pressing roller. 3. Loosen the cloth by driving the tensioning roller upwards and close the restrictor valve beside the tensioning motor. 4. Open the cloth joint and fix a new cloth to the cloth to be replaced. 5. Drive the cloth to its place by means of test drive and join it as instructed in the paragraph "Installation of the cloth". 6. Open the restrictor valve and tighten the cloth. Check the tracking by means of test drive. Installation of the cloth The installation of cloth takes place in the plate pack "open" position. The top pressing plate must be fixed to the columns with locking pins. Drive the tensioning roller (6) to its uppermost position by means of test drive. Close the restrictor valve beside the tensioning motor (for locking the tensioning roller). Place the cloth pack on a rack outside the conveyor unit, where it can be easily rotated. Open the conveyor unit hatches and bring the cloth end over the centering roller (4) on the spread roller (13), from where it is passed through the tensioning roller (6) up on the impulse roller (5). Bring the cloth end to the guide rollers (7) (of the filter plates), where the cloth is passed between the scraper (9) and the roller (10). Pass the cloth through the guide roller (7) and vat rollers (1) and further between the wash nozzle pipes (11) onto the main drive roller (2). Loosen the pressing roller springs and pass the cloth between the pressing roller (3) and main drive roller (2). Pull sufficiently enough, loosen and join the cloth ends. Bend one end of the joining thread double for about 10 mm. Pass the thread through the seam so that the bent end of the thread gets inside the seam. Clip off the excess length so that the other end of the thread remains about 5 - 10 mm over the width of the seam. Bend also the other end into the seam. Open the restrictor valve. Tighten the cloth and check the tracking by means of the test drive. The cloth length is correct when there is a motion allowance of at least 700 mm for closing the plate pack above the tensioning roller in the plate pack "open" position. The recommended maximum allowance is approx. 2000 mm. Excess motion allowance decreases the tensioning allowance required for the cloth stretching.



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Patching the cloth



NOTICE Inappropriate cloth may cause damage to the machinery. Patch all holes immediately.



The cloth can be patched by sewing. A zig-zag sewing machine for industrial purposes is suitable for use, e.g. Singer 200 is provided with a 9 mm zig-zag. NOTE!



It is easiest to patch the cloth, when the holes are still small.



Patch the cloth as follows: 1. Follow the area to be patched and drive the cloth by means of test drive above the cloth drive unit. 2. Slacken the filter cloth according to paragraph Slackening the filter cloth 3. Pull the cloth out of the tensioning roller so that the area to be patched would be easy to handle. 4. Wash the cloth approx. 10 cm x 10 cm around the hole with a high-pressure washer. 5. Dry the washed area with pressurized air. 6. Sew a patch over the hole according to figure below. Pay special attention to the front edge of the patch, because this seam is strained most by the scrapers.



1. 2. 3. X



Zig zag stitching over the edges Stitch lenght 1 mm width 6-8 mm At least 3 pcs 6-8 mm zig zag stitching Direction of Cloth drive



7. First sew the hole edges tightly on the patch and then make a couple of sews crosswise over the patch, then sew outer edges.



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Joining the cloth The cloth is delivered in the ordered length and provided with a clipper seam joint that can be opened. If necessary, a part of the cloth can be renewed by making a sewn joint or if the joint has been damaged, separate clipper seams are available. Pay attention to the cloth length. The correct length has been defined in the paragraph "Installation of the cloth". The sewn joints are made according to instruction drawing below. A zig-zag sewing machine for industrial purposes is suitable for use, e.g. Singer 200 is provided with a 9 mm zig-zag.



Only one clipper seam joint in the cloth is allowed.



1. 2.



Cloth Seam



3. 4.



Reinforced with glue Metal hook



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Cloth tracking Let the cloth circulate several times and make sure that it does not drift to either side systematically. If the cloth does not stay centered, the cloth seam is inclined or one of the rollers does not rotate.



Make sure that the cloth stays in the center area after maintenance work.



6.5.



Filter plate



DANGER Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Always when maintaining the plate pack, make sure that the filter is stopped, the manual valves of the pipes are closed, the EMERGENCY-STOP switch of the Hand Held unit is pressed down and the electricity is switched off from the main switch.



WARNING Crushing hazard. Falling filter plates can cause death or serious injury. Secure the open position of the plate pack by locking it to the columns with locking pins of the upper pressing plate.



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Plate pack in open position NOTE: This drawing is only an example of the plate pack in open position and the number of filter plates may be different in your filter. 17



16



15



13 14



11



12



9



10 7 8 5



6



3



4



2



1



1. 2. 3. 4. 5. 6. 7. 8. 9.



Note!



Filter plate no. 1 (lowest)* Filter plate no.2 (right) Filter plate no.3 (left) Filter plate no.4 (right) Filter plate no.5 (left) Filter plate no.6 (right) Filter plate no.7 (left) Filter plate no.8 (right) Filter plate no.9 (left)



10. 11. 12. 13. 14. 15. 16. 17.



Filter plate no.10 (right) Filter plate no.11 (left) Filter plate no.12 (right) Top Filter plate Upper pressing plate Suspension plate Top suspension plate (6 pcs) Column



Numbering of the Filter plates is referred to the instructions of Space arrangement between the Filter plates



*Filter plates are numbered from bottom to top. Cleaning of the plate pack The plate pack must be washed with water daily. It is important to wash the rollers and scrapers as well. This ensures that cloth tracking functions properly and that the plate pack stays tight.



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Replacement of the filter plate 1. Verify the load of crane (mass of the filter plate app. 1700 kg). 2. Necessary maintenance tools (included in Outotec maintenance tools):



3 1 2



1. 2. 3.



Suspension bar (8 pcs.) Lifting bar (2 pcs.) Lifting chains with lifting rings, hooks and chain tackle



Note!



The top plate cannot be replaced with the tools mentioned above. However, damaging the uppermost plate is very unlikely, because the frame part of the top plate leans on the top pressing plate.



3. Remove the upper part of the cake chute according to paragraph Removing the upper part of the cake chute. 4. Drive the plate pack to its open position by means of test drive and lock it. 5. Drive the cloth clipper seam (3) to the guide roller (2) of the filter plate (1) to be removed.



2 3



2



1



1 1. 2.



Filter plate (to be removed) Guide roller (Above the filter plate to be removed)



3.



Clipper seam



6. Slacken the cloth according to paragraph Slackening the filter cloth. Pull the slackened filter cloth to the clipper seam. 7. Detach the clipper seam of the filter cloth by removing the seam thread.



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8. Loosen the scraper of the filter plate to be removed. 9. Pull off the filter cloth from the top of the filter plate to be removed. 10. Arrange working space between filter plates by cutting the plate pack above the plate to be replaced according to page 8. 11. Remove collectors, hoses and possible auxiliary cloth drive motor from the filter plate to be removed. 12. Disconnect guide bars from the lower end and from the middle fixing points. Loosen the fixing of the upper end of the guide bars and remove guide bars further off the plate pack.



WARNING Crushing hazard. Falling filter plates can cause death or serious injury. Check the limit stops of the lifting bar’s end positions before lifting the filter plate



13. Fasten the plate lifting bars (2) (delivered with the filter) into the suspension links of the filter plate (3) above the filter plate (1) to be removed.



3 2



1. 2.



Filter plate (to be removed) Lifting bar (weight 85 kg)



1



3. 4.



4



Filter plate (next above) Filter cloth



14. Lower the plate pack and fasten the plate to be replaced from its suspension pins to the lifting bars.



1



1.



The filter plate to be replaced



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15. Lift the plate pack upwards and push carefully the plate up to the limit stops of the lifting bar.



WARNING Crushing hazard. Falling filter plates can cause death or serious injury. Make sure that there is nothing in front of the filter plate and between the plate pack before driving the plate pack upwards. The filter plate can glide up to the limit stop by itself.



1



1.



The limit stop of the lifting bar



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16. Attach the lifting chains into the suspension pins at the end of the plate. Lift the plate so that you can release the suspension parts from the plate.



NOTICE Incorrect hoisting may also cause damage to the machinery. When lifting, keep in mind the weight of the filter plate.



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17. Pull the plate out of the plate pack up to the limit stops by means of a crane (Figure A). 18. Attach the lifting chains with a lifting tackle to the suspension pins at the other end of the plate. Refer to figure B. 19. Tighten the lifting chains with the chain tackle (1) so that the plate is balanced. Refer to figure C. Note!



Make sure that the chain tackle is always on the plate pack side. Refer to figure B.



20. Release the suspension parts from the plate. Refer to figure D. A



B 1



C



D 1



1.



Chain tackle



21. Mount a new plate in reverse order.



1



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Replacement of the seal Necessary equipment for seal replacement: Screwdriver Tongs Chisel Hammer



Removing the old seal 1. After having detected the damaged seal, mark the filter plate. 2. Slacken the filter cloth according to paragraph Slackening the filter cloth. 3. Remove the filter plate requiring maintenance from the plate pack according to former paragraph. 4. Place the filter plate upside down on wooden beams. Do not damage the vat„s upper surface. Otherwise the sealing may not be optimal. 5. Remove the old seal from filter plate: Push a screwdriver between the frame and the seal. Squeeze the seal with the screwdriver and at the same time bend the other end up.



1. 2. 3. 4. 5.



Seal Frame Bottom plate Vat Diaphragm



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Installing a new seal 1. Install the other edge of a new seal into the groove. Bend the seal downwards and press the other edge into the groove by using a blunt chisel. Use hammer if necessary.



2. Install a new seal according to numbered order, as indicated in the picture below 2



3



1



4



2 3 4



3 2



3 2



1. 2.



End part of seal Corner part of seal



3. 4.



1



Outermost part of seal Midmost part of seal



3. Press the end part of the seal (1) into its groove. 4. Install the corner parts of the seal (2). Install the both ends in the same way.



2 2



1



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5. Press the corner parts (2) against the end part (1) by means of chisel in order to make app. ~2 mm compression between the seals. Refer to picture below. Use a hammer if necessary.



6. Install the outermost parts of the seals (3). Press the outermost seals against the corner parts (2) in order to make app. ~2 mm compression between the seals. 7. Install finally the midmost parts (4) to both sides. At first fix the ends of the seal into the groove. Then use a chisel and hammer in order to get the central part of the seal into its groove. Refer to figures below



A Note!



B Do not shorten the seals



8. Install the maintained filter plate back to the plate pack according to paragraph Replacement of the filter plate.



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Adjustment of the filter plates Proceed as follows 1. Close the plate pack. 2. Lift up the first plate by driving the plate pack upwards. 3. Unscrew the slide pieces‟ fixing nuts and eccentric sleeves. 4. Install the slide piece support and eccentric sleeve so that the maximum adjustment allowance remains for the slide piece wearing. 5. Adjust the plates„ lengthwise position by means of the slide pieces. The linear measure must be same at both sides  1 mm. Hold the adjusting lever of the eccentric sleeve with key (wrench) and tighten the nut. 6. Lift up the second plate by driving the plate pack upwards and adjust the plate by means of slide pieces. 7. When all plates are adjusted, remove the gap between the lateral guides and slide parts by unscrewing the guide‟s fixing screws and pushing the guide against the slide parts. Tighten the fixing screws. 8. Drive the plate pack upwards and check the gap between the lowest filter plate and pressing plate. Gap should be 15 mm. You can adjust the gap with the nuts on the suspension bars. It is easiest to adjust the gap while the plate pack is on its lower position.



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Installation and replacement of grids The grid set (two sets in each filtrate vat) in the filter chamber consists of four different items; Ten middle pieces, three end pieces and two different corner pieces attached to each other with clamping pins in the grid. The middle and end pieces are interchangeable (The corner pieces are interchangeable to the opposite side of the filter chamber corners). 1. Slacken the filter cloth according to paragraph Slackening the filter cloth. 2. Remove the filter plate requiring maintenance from the plate pack according to paragraph Replacement of the filter plate. Place the filter plate on a flat plane for maintenance. 3. Remove the broken grid plate and replace it with a new one. Remember to check that the grid fixings are in place. Note!



There are clamping pins between certain grid plates. Do not forget to take this into account when replacing the broken ones.



4. Install the maintained filter plate back to the plate pack according to paragraph Replacement of the filter plate.



6.5.4.



Symptoms of leaking diaphragm Observe the condition of the diaphragms continuously. In case the consumption of pressing air has increased and it flows into the chamber even at the end of pressing stage, change the damaged diaphragm immediately. There is a sensor (S531) in the pressing manifold for detecting moisture (slurry or water)



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Risks of the leaking diaphragm Observe the diaphragms. They must remain undamaged. A damaged diaphragm results in a wet cake, and the solids are escaping into the pressing water wearing down the press water piping and pump.



6.5.6.



Locationing of the leaking diaphragm



Wear safety goggles when searching for a leaking diaphragm. Do not open the feed pipe when the plate pack is closed.



A defective diaphragm is localized as follows: when the plate pack is open, one filtrate hose at a time is removed from the filter plate. Then the plate pack is closed and sealed. After this, diaphragm pressing is started. It is possible to locate the defective diaphragm by checking, if water comes out from the filtrate outlet of the filter plate. The defective diaphragm is located above this filter plate. 6.5.7.



Replacing the diaphragm Filter plate has to be removed from the plate pack in order to change a diaphragm. 1. After locating the leaking diaphragm, mark the filter plate. 2. Slacken the filter cloth according to paragraph Slackening the filter cloth. 3. Set 4 pcs of support plates on the plywood sheet(s) to facilitate the installation of a new filter diaphragm (e.g. polyurethane or polystyrene plate 40x1000x1500, (4 pcs). 4. Remove the filter plate requiring maintenance from the plate pack according to paragraph Replacement of the filter plate. Place the plate on plywood sheet(s) (4) standing on supports (5). 5. Unscrew the frame fixing screws (2) using the drive impact wrench (30 mm socket) delivered with the filter.



1. 2. 3.



Broken filter diaphragm Hexagonal screw M20 Frame



8.



Filter plate no. 8



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4



5



4.



Plywood sheet(s)



5.



Support (made of wooden beams for example)



6. Lift the upper part of the filter plate upwards so, that the bottom part can be maintained.



1. 2.



Frame Support plate



3. 4.



Diaphragm groove Plywood sheet



7. Install a new filter diaphragm (3) by pressing the filter diaphragm„s edge into the frame„s groove.



1. 2. 3. 4.



Frame Support plate New filter diaphragm Plywood sheet



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8. Lift the upper part of the filter plate back on top of the bottom part and reinstall the frame screws (Tightening torque 350Nm). Apply Rocol J160 or similar to screws in order to prevent the threads from seizing. 9. Reinstall the maintained filter plate into the plate pack according to paragraph Replacement of the filter plate.



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Replacing the filtrate vat 1. Remove the upper part of the cake chute according to paragraph Removing the upper part of the cake chute. 2. Slacken the filter cloth according to paragraph Slackening the filter cloth. 3. Remove the filter plate requiring maintenance from the plate pack according to paragraph Replacement of the filter plate. Lay the filter plate down on wooden beams for maintenance. 4. Loosen the filtrate collectors. 5. Loosen the fixing elements of the filtrate vat: 5 pcs on both sides and 1 pcs at each end.



D C D C



A



A



11



9 1



11



6 1. 2. 3. 4. 5. 6.



7



2



12



2



4



4



3



5



A-A



4



8



12



D-D



C- C



Filtrate vat Bottom plate Frame Grid Diaphragm Seal



7. 8. 9. 10. 11. 12.



10



7



Filtrate collector Slide piece longitudinal guidance Slide piece lateral guidance Collector seal Fixing element (1 pcs at each end) Fixing element (5 pcs on both sides)



6. Remove the filtrate vat from the filter plate. 7. Install a new filtrate vat in reverse order. Check alignment of the collectors before tightening the fixing elements.



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6.6.



29.2.2012



Slide pieces



Replacement and adjustment of slide pieces Wearing of the slide pieces causes the plate to move in its longitudinal axis direction, and the alignment of the filtrate collectors changes. As a consequence of this the collector lines begin to leak damaging the collector seals. Observe the slide pieces for possible wear, and adjust when necessary. When there is no adjustment tolerance left, replace the slide pieces as follows: -



At first unscrew the fixing nut. Then remove the eccentric sleeve and slide piece support. Finally remove the slide piece.



-



Check the filter plate alignment and insert a new slide piece. Install the slide piece support and eccentric sleeve so that the maximum adjustment tolerance remains for the slide piece wearing. Hold the adjusting lever of the eccentric sleeve with a key (wrench) and tighten the nut. VIEWA



SLIDEPIECE



VIEWA



Note!



SLIDEPIECE ECCENTRICSLEEVE NUT



GUIDEBAR



Also refer to former chapter Adjustment of the filter plates



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6.7.



6.7.1.



29.2.2012



Scrapers



Adjusting the scrapers Adjust the roller scraper (1) with rubber cushions (3) so that the scraper gently touches the roller. Tighten the locking nut (4). If the adjustment tolerance is not sufficient, loosen the locking screws (5) of the adjusting lever (2) and the locking nut of rubber cushions‟ (4). Close the rubber cushions to their extreme position. Press the scraper (1) lightly against the roller, and tighten the lever locking screws (5). The plate pack must be open when adjusting the cloth scrapers. The cloth scraper is prestressed so, that it is slightly bends upwards in the middle. Adjust the cloth scraper with the screws (7) so, that the scraper edge touches the cloth on its whole length with even pressure. Tighten the locking nuts (6).



6.7.2.



Replacing the scrapers Roller scrapers: Loosen the locking screws (5) at the end of the scraper (1). Remove the adjusting lever (2). Turn the scraper so that the knife of the scraper is outside of the roller fixing lug. Move the scraper laterally and release it from the roller fixing lugs. Insert a new scraper and adjust it. Cloth scrapers: Loosen the locking nuts (6) and the screws (7). Remove the screws (9) and the scraper (8). Insert a new scraper in reverse order and adjust it.



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6.8.



Hoses



6.8.1.



Replacement of hoses



29.2.2012



Wear safety goggles when changing a hose. Also make sure that the emergency stop switch is pressed down and the plate pack is in open position.



Pay attention to the following when changing the feed and pressing air hoses: -



The correct type and length (see the figure)



-



Mount the hoses when the pack is open. Bend the hoses upwards and tighten the hose L-coupling bands



-



No sharp bends in the hoses



-



High pressure hoses must be used (Pressure rating atleast 25 bar)



-



Use the original spare parts (hoses).



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L-coupling band circle installation Note!



Do not overtighten the L-coupling bands.



-



Max torque for M8 nut is 10 Nm



-



Leave about 2 mm gap between the bands



Notice that the connectors are similar both in feed and pressing air hoses. Connect the hoses as shown in the figure below



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6.9.



29.2.2012



Cloth conveyor and tensioning device The equipment should be inspected twice a year.



6.9.1.



Cloth driving The filter is equipped with a seam detector. The driving system "positions" the seam automatically. An encoder (2) attached to the roller measures the length of the cloth travel. The cloth is stopped by means of the seam detector switch (S332) and encoder (B331) (2). The discharge length (plates) must be defined so, that the filter is discharged completely. It is recommendable for the cloth to travel forward at least three plate lengths. The seam may stop on any roller, as well as in the conveyor unit's area. Check that the clipper seam finds its right position on the guide roller, i.e. outside the sealing surface.



2



1 1. 2.



Tracking roller Encoder



It is forbidden to stop the cloth clipper seam in between the sealing surfaces of the plate pack.



6.9.2.



Automatic cloth tracking Normally the filter cloth moves in the plate pack without crossing the guide roller edges. However, in case the cloth tends to be directed towards either of the edges, the automatic cloth tracking brings the cloth back into the center position. The cloth tracking takes place by moving the left end of the tracking roller in the cloth conveyor unit up or down. The roller moves according to the signals of the cloth edge position transmitter B503 (angle transmitter) and cloth tracking cylinder position transmitter B504 according to the automatic control operation. Tracking roller is moved up/down by means of hydraulic cylinder HC4. This cylinder has built in position feedback (potentiometer). Automatic tracking control can be turned on/off from OIU configuration screen (“Automatic cloth tracking”). When the automatic cloth tracking is off, the tracking cylinder can be run from Hand Held unit.



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The position of the cloth right edge is actively followed by means of wheel fixed sensor B503 (placed below the tracking roller). The effective range is +20°…-20° (+ 30…–30 mm). The adjustment range has been divided into 1000 parts; Left edge 1000, middle 500 and the right 0. If the cloth tracking device can‟t keep the cloth in the center position, and the alarm switch is activated for a long time (5 sec delay), the limit switch (S838A or S839A) gives an alarm. The cloth edge sensors S838A (left) and S839A (right) are located on both sides of the cloth tracking device. If the cloth drifts too much to the left, the switch S838A is activated. If the cloth drifts too much to the right, the switch S839A is activated.



3



5



4



a



6



2 b 60



20°



1



20°



a = 0,1 second (the cloth edge is read every 0,1 second bymeans of sensor B503). b = Tracking in steps (every tracking step takes 0,25s) 1. 2. 3.



Tracking roller Cloth edge position transmitter B503 Perambulator B331 (see seam positioning)



4. 5. 6.



Limit switch S838A Limit switch S839A Hydraulic cylinder HC4 with position transmitter B504



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6.9.3.



29.2.2012



Cloth tensioning device The change in the cloth length that takes place during the opening of the plate pack and cloth travel is compensated by means of tensioning device. A torque brought by means of hydraulic motor tightens a pair of chains fixed to the tensioning roller. Observe the pressure used by the tensioning device motor and compare it to the pressure used during the start-up. Raising the pressure increases the torque and lowering the pressure decreases it. Tracking a slackened cloth is not possible. Inspection and maintenance measures to be taken: -



Condition and tightening of chains



-



Sprockets



-



Position of the tensioning roller (must be horizontal)



-



Hydraulic motor coupling



-



Clam wheels



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6.10.



Rollers



6.10.1.



Replacing the roller bearing of the plate The plate‟s roller bearing will be replaced with its housing. Proceed as follows: 1. Slacken the cloth on the roller, where the damaged bearing is located. 2. Remove the locking screws (1), 4 pcs and a plug (2). Remove the roller end plate locking screw (3) (only on the other end of roller). 3. Fix a bolt (size M16 x 100) with a bushing into the plug drilling. 4. Pull the housing out by tightening the screw. 5. Install a new housing by using a soft hammer or use installation tool bolt (4). 6. Fix bolt into the roller end and then install bearing housing by rotating the nut clockwise on the bolt. Both removing and installation tools are included to Outotec maintenance tools.



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Auxiliary drive roller, motor side (fig. 1):



1. Remove the motor and make sure that the weight of the motor does not burden the hydraulic hoses. 2. Loosen the locking screw of the roller shaft coupling half and remove the coupling half. 3. Remove the coupling„s locking screws (4 pcs). 4. Fix the M12 threaded rods (1) (2 pcs) into the holes of the housing. 5. Use e.g. U-beam (2) and pull the housing out by tightening the nuts (3). Install a new housing (Fig. 2) by means of pipe (1) and a soft hammer or, as in the drawing, by means of a pipe (diameter min 75 / max 130) (1), M12 threaded rod (3) and M12 nut (4).



6.10.2.



Replacing the plate roller



DANGER Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Make sure that there are no persons or foreign objects in between the moving parts Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Always keep the EMERGENCYSTOP button pushed down (for preventing the manual and remote starts), when the activation functions of the filter are not necessary.



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Make sure that the working conditions are safe. Inform the operating personel when maintaining the unit, and close the manual valves in the process piping.



Wear proper protective clothing.



Note!



The filter plate roller weighs about 150 kg, so a crane is required for the work.



Note!



Because the uppermost rollers of the plate pack are located quite high, extreme caution is needed when replacing them. Use a lifting platform to guarantee safe working conditions.



The roller is located at the end of the filter plate in a "loop" formed by the filter cloth. There are two possible ways to get the roller out.



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The first one is to drive the cloth so that the clipper seam stops at the roller to be changed. The seam is opened and the roller can be changed. Another and more recommendable possibility is to gather so much loose cloth at the roller, which is to be changed by using the "extra" cloth in the tensioning device. The cloth can be drawn over the end of the roller to either side of the filter plate. Proceed as follows: 1. Stop the filter, and drive the plate pack completely open by means of handheld unit. Drive the locking pins into their holes. Refer to Operation instructions section if needed. 2. Slacken the cloth. Refer to paragraph Slackening the cloth if needed. 3. Remove scrapers. - Roller scraper: Loosen the locking screws (5) of the lever (2) at the end of the scraper (1). Unfasten the adjusting lever (2). Turn the scraper (1) so that the knife of the scraper is outside of the roller fixing lug. Move the scraper laterally and release it from the fixing lugs. - Cloth scraper: Loosen the locking nuts (6) and screws (7). Remove the cotters (10) and remove the scraper.



4. The slack cloth is drawn up to the roller, which is to be changed and moved on the side of the plate. Move the cloth on either side on top of the plate pack, so that the overhead crane hook can be lowered down to the level of the roller to be changed.



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Drive rollers The moving of the cloth is hydraulically controlled. The auxiliary drive rollers are located in the plate pack. The rotation speed of the drive rollers is synchronized with hydraulics. Inspection and maintenance measures to be taken:



6.10.4.



-



Hydraulic motor pressures



-



Hydraulic motor couplings



-



Roller bearings



-



Lubrication of main drive roller bearings



Centering roller The extreme positions of the roller are adjusted by means of limit switches. Inspection and maintenance measures to be taken:



6.10.5.



-



Fixing and function of the limit switches



-



Checking and lubrication of the adjusting screw



-



Fixing of the worm gear



-



Worm gear oil quality and quantity



Replacing the guide roller 1. Use lifting belts for lifting. 2. Hang the roller, loosen the side guide rails, unfasten the roller brackets by removing the bolts (12) and the pins (11). Lift the roller off (with brackets). Refer to former figure 3. Provide a firm enough plane for the cake chute at the end of the tensioning device on which the rollers can be placed. 4. Remove the cake chute off from its free end. A separate lifting platform is not necessary, as the crane can freely move in the crosswise direction of the filter. 5. Install a new roller in opposite order.



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Replacing the auxiliary drive roller 1. Proceed with the cloth and the scraper as instructed with a normal roller. 2. At first remove the hydraulic motor from the auxiliary drive roller. The hydraulic hoses may stay fixed to the motor, but it must be supported in a way that the motor does not hang on the hoses. 3. Fix the lifting belts to the both ends of the roller and lift the roller lightly up. After this, the fixing screws of the roller lug are removed and then the roller can be removed. 4. Install a new roller in opposite order.



Replacing the auxiliary drive roller without removing the hydraulic motor In case the hydraulic motor is kept fixed to the auxiliary drive roller, observe the following points: 1. Make sure that the hydraulic unit has been stopped and that there is no pressure in the pipeline. De-pressurization can be done by choosing HM09 on the hand-held unit and pressing S725 and S723 in turns a few times. 2. Before removing the hydraulic hoses from the auxiliary drive roller, make sure that the hoses and the motor's openings are marked. 3. The hoses can now be removed. Plug the couplings on both the hoses and the motor. 4. Lifting and replacing the roller is performed according to previous chapter. After replacing the roller, the filter cloth must be layed back in the middle of the rollers. The loose cloth must be drawn back to the tensioning device by choosing HM08 of the manual controlling device and by pressing S723. In case the cloth loop is in the lower part of the filter, it may be necessary to draw the cloth upwards by hands a few plate lengths before the tensioning device is able to tighten the cloth.



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6.11.



29.2.2012



Cloth wash spray nozzles Flat spray nozzles (Delavan AZM 5.5) are used as the cloth wash nozzles. The direction of the spray can be adjusted by turning the nozzle with a screwdriver. Adjust the sprays so, that they cover the whole width of the cloth, but do not cross each other. The intersecting angle is adjusted by turning the spray pipe. At first loosen the L-couplings and tensioning flanges on the side of the filter. Then turn the pipe. The new position is locked by tightening the L-couplings and tensioning flanges.



A



Filter cloth



30°



) 5° (7 (75 °)



Direction A Mark indicates direction of spray



6.12.



Quick action cylinder



Necessary equipment for cylinder replacement: 3 pcs. wooden beams (150x100, L=2000) torque wrench with presettable torque (700Nm) Cylinder lifting tool 2 pcs (included in Outotec delivery maintenance tools) hex head driver: size 19mm Pneumatic wrench (included in Outotec delivery maintenance tools) Support 1 pcs (included in Outotec maintenance tools) 2 pcs lifting belts: preferable different length



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Replacing the quick action cylinder Proceed as follows 1. Drive the plate pack to its close position. 2. Drive the upper pressing plate carefully upwards until the wooden beams will be fitted under it. 3. Install 3 pieces of wooden beams under the upper pressing plate and drive the plate down on the wooden beams. 4. Remove fixing plate (7), shaft nut (4), nut (5) and ring (6) on the top end of the cylinder body. Refer to figure B on the next page 5. Drive the cylinder manually to lower end position. 6. Remove the hydraulic pipe„s T-connectors from the end of the piston rod.



Wear safety goggles when disconnecting fittings in the hydraulic system.



Note!



Make sure that the pressure in the hydraulic pipeline is below 5 bar before opening the connections. The hydraulic oil pressure can be checked from the measuring connections at the upper end of the piston rod by using a measuring tube with pressure meter. Refer to figure below



T-connectors 7. Remove the fixing flange (2) from the lower end of the cylinder and the fixing screw of cover (3). Refer to figure A on the next page. 8. Remove the fixing flange (8) at the top end of the cylinder. Refer to figure C on the next page.



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2:1 8



C



4 5 6 7



4 5 6



7



2



A



1 2:1 3



1. 2. 3. 4.



Hex socket screw (M24, 7 pcs.) Fixing flange Hex socket screw of cover (M8x185, 2 pcs) Shaft nut



5. 6. 7. 8.



Nut Ring Fixing plate Fixing flange



B



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9. Attach the cylinder lifting tools (included in Outotec maintenance tools) into the end of the piston rod (M16 threads). Refer to attached figure 10. Attach two (2) lifting belts (shorter and longer) to the lifting tools.



Note!



Lifting tools must be tightened with a torque of 10 Nm.



NOTICE Incorrect hoisting may also cause damage to the machinery. Verify the load of the crane. The weight of the hydraulic cylinder is approx. 700 kg. Use rotating lifting points for hoisting. Make sure that the platform, on which the cylinder is lowered can support the weight.



11. Lift the cylinder rod upwards carefully until the piston rod end is above the fixing hole of the lower frame. Lift the cylinder cover with screwdriver in order to see the piston rod.



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12. Pull the end of the cylinder piston rod from between the brackets with lifting belt.



13. Lower the cylinder carefully down until the upper end of the piston rod is below the upper frame. Refer to figures B and C on the next page. 14. Install the support (included in Outotec maintenance tools) and attach the shorter lifting belt to it.



15. Lower the cylinder down, so that it hangs from the shorter lifting belt. Refer to figure C on the next page. 16. Move the longer lifting belt outside of the top frame. Lift the cylinder until you can remove the shorter lifting belt from the cylinder. Refer to figure D on the next page. 17. Lift the cylinder away. Refer to figure E on the next page.



IOM MANUAL PF1032 B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



A



C



29.2.2012



B



D



E



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18. Install the cylinder in reverse order. See the positions of hydraulic couplings from picture below. Black arrow shows the side of the cloth conveyor unit



1



2



2



1



2



1



1



2



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29.2.2012



Suspension plates



Inspection and replacement of suspension plates



WARNING Crushing hazard. Falling filter plates can cause death or serious injury. Omitting inspection and replacing the suspension plates may lead to personal injury or damaged property, which Outotec cannot be held responsible for. Follow manufacturer’s instructions. Check all suspension plates annually for possible cracks and replace the damaged ones. The designed maximum service life for a suspension plate is 5 years. (Variations to both directions are possible depending on several factors; number of working cycles, cake weight, number of filter plates, environmental factors etc…) Checking/replacing the suspension plates: 1. Close the plate pack (fig. A). 2. Remove the locking nuts (2) and sleeves (3) of the topmost suspension plates (fig. B).



2



4



3



1 4



1. 2.



Top suspension plate Adjusting nut



3. 4.



Sleeve Lug of the upper pressing plate



3. Drive the upper pressing plate into its open position. Lock the plate with locking pins. Refer to figure C 4. Remove all suspension plates from the plate pack.



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5. Clean all suspension plates in a meticulous manner. 6. Check suspension plates visually and replace the damaged ones. Pay attention to possible cracks in the suspension plates on inspection. Slight battering and polishing of the pinholes are acceptable. Areas A and B (see picture below), where the biggest stresses affect, are most likely to break first. 7. After inspection, mark the inspected suspension plate by nail punch. When there are five (5) marks made by nail punch, replace the suspension plate. Note!



Check also the condition of each suspension pin and its joint to the filter plate. Cracks in the welding area and excessive bending of the pin needs to be fixed before reassembly. Slight battering and polishing of the pins are acceptable.



A = possible failure area at the circular hole B = possible failure area at the end of the elongate hole



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8. Assemble the suspension plates in their positions from top to bottom. Remember to install all retaining rings. Refer to figure below



A



B



C



1 1



1 2/3 2



2 4/5



3



3 6/7



4



4 8/9



5



5 10/11



Assembly order of the suspension plates: A B C



Assemble the lowest suspension plates (1, 2, 3..). Assemble the top suspension plate (1) and the midmost suspension plates (2, 3, 4…) Assemble the topmost suspension plates and retaining rings.



The correct order of suspension plates



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9. Drive the upper pressing plate down until there is a gap about 30mm long between the upper end of the topmost suspension plate (1) and bottom surface of the lug (2). Refer to figure A 10. Install the sleeves (3) one at a time to their positions, so that the studbolts in the topmost suspension plates are in the sleeves. Refer to figure B



3



2 2 1 1



1. 2. 3. X



Topmost suspension plate Lug of the upper pressing plate Sleeve of the topmost suspension plate ≈ 30mm = gap between the upper end of the topmost suspesion plate and bottom surface of the lug.



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11. Drive the upper pressing plate on the plate pack and install adjusting nuts of the topmost suspension plates. Refer to figure A. See pre-set dimension for the adjusting nuts from the figure B below. 12. Set the same pre-set dimension for all top suspension plates. 13. Drive the plate pack into its open position. Refer to figure C.



2



100



1 1 3



1. 2.



4



Top suspension plate Adjusting nut



2



3 4



3. 4.



Sleeve of the topmost suspension plate Lug of the upper pressing plate



14. When the plate pack is in its open position, there must be about 70 mm gap between the lowest filter plate and the filter plate above. 15. If adjustment of the filter plates is needed, drive the plate pack into its closed position and adjust the adjusting nuts.



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16. Check the gap by driving the plate pack into its open position.



70



1



2 ~70mm gap between lowest filter plate and the filter plate above 1. 2.



Filter plate above Lowest filter plate



17. When the suspension of the plate pack is adjusted, close the plate pack and lock the adjusting nuts. Refer to figure below



A



B



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29.2.2012



Lubricant recommendations These lubrication instructions are for general use, and should not be used as a reference in special conditions. Lubricate the following items with a grease gun or brush regularly: -



Conveyor screws of the cloth centering roller



-



Chain of the cloth tensioning device



-



Drive shaft



-



Roller grease nipples Centralized lubrication point (points 22-25)



22 23



24 25



26 27 14 15



12 13



9 16 17



10 11 28 29 18 19 7 8



5 6



Centralized lubrication point (points 1-6)



1 2



LUBRICATION CHART ITEM 1-4 NIPPLES IN ROLLER BEARINGS 5-6 NIPPLES IN TENSIONING SHAFT 7-8 NIPPLES IN DRIVE SHAFT



LUBE NLG-2 NLG-2 NLG-2



9



TENSIONING DEVICE CHAINS



NLG-2



10-11 12-21 22-25 26-29



NIPPLES IN PLATE ROLLERS NIPPLES IN ROLLERS LOCKING PINS AUTOMATIC LUBRICATORS



NLG-2 NLG-2 NLG-2 NLG-2



20 21



3 4



AMOUNT 45 g 25 g 10 g LUBE WITH BRUSH 10 g 10 g 25 g 125 g



INTERVAL 1 MONTH 1 MONTH 1 MONTH 1 MONTH 1 WEEK 1 MONTH 1 MONTH 1 YEAR



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6.15.



Spare parts



6.15.1.



Storing instructions for rubber parts



29.2.2012



The properties of vulcanized rubber parts change during storing. Careful storing minimizes the damages. Pay attention to the following: -



Temperature; The storing temperature should not exceed +25°C, preferably below +15°C.



-



Humidity; Avoid high moisture contents in the surrounding air. Prevent water from condensing on products.



-



Light; Avoid ultraviolet light. Protect the products against straight sunlight.



-



Oxygen and ozone; Remove all equipment developing ozone from the room where products are stored. Minimize the store room ventilation.



-



Deformation; Store rubber and polyurethane parts (diaphragms, plate seals, rollers, scrapers) straight (not rolled), this would enable them free from tension.



-



Solutions and vapours from solvents; Keep the rubber parts off the chemical effect of solutions and solvent vapours.



-



Stock circulation; Try to keep the storing time of the rubber parts as short as possible. Always use the material which has been longest in stock first.



In addition, take into consideration the following when storing the rubber parts: -



coming into contact with certain metals



-



compatibility of different rubber qualities



-



storing methods used.



For further information refer to standard ISO 2230 and the standard proposal SFS 3553 or contact the manufacturer of the rubber parts. As for the rest, we refer you to the guidelines of the DIN 7716 standard "Caoutchouc and rubber products -requirements for storage, cleaning and maintenance" and, in particular, to par. 3 and 4 of the DIN 7716 standard if the storage will last longer than 6 months. If these prescriptions and requirements are complied with, the usability of the membranes will not undergo any substantial change within a 2 years' storage time. In case of a longer storage time, the membranes must be additionally protected against damages by strong tarpaulins.



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How to order spare parts When ordering spare parts always state the type and serial number of the filter in question and specify the spare parts as shown in following example below:



6.15.3.



Filter type



Serial No



Part code



Part name



Description (material, type )



PF 144 A1 60



No. 540



P26854



Rubber diaphragm



NR601RH



Spare Parts recommendation Spare parts Filter plate spare base plate (right) Filter plate spare base plate (left) Filter plate frame Filtrate vat Filtrate pipe Guide roller Suspension link



QTY 1 1 2 2 4 2 24



Wearing parts Grid Scraper Rubber diaphragm Sealing set for filter plate Rubber hoses Pressing air hoses Slide pieces (longitudinal guidance) Slide pieces (lateral guidance) Filtrate collector Filtrate collector seal



22 26 24 24 88 22 92 44 4 88



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Table of Contents 7.



Special instructions ......................................................................................................................... 2 7.1. Transport Instructions ............................................................................................................ 2 7.1.1. Filter protection for sea shipments................................................................................. 2 7.1.2. Handling and storing of the filter plates ......................................................................... 2 7.2. Checking delivery .................................................................................................................. 3 7.3. Storage .................................................................................................................................. 3 7.3.1. Storage of machine ....................................................................................................... 3 7.4. Preparation of the hydraulic unit for storage .......................................................................... 4 7.5. Restart after long term storage .............................................................................................. 4 7.6. Disposal of the filter components ........................................................................................... 4



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7.



SPECIAL INSTRUCTIONS



7.1.



Transport Instructions



29.2.2012



DANGER Only qualified personnel are allowed to attach loads and do transporting duties.



7.1.1.



Filter protection for sea shipments Individually identified parts in each Outotec (Filters) Oy filter are specially protected during transportation.



Protected parts -



Piston rods of hydraulic cylinders



-



Hydraulic blocks/valves/connectors



-



All machined, uncovered (not painted) surfaces



How to remove protection A tin of thinner is delivered with each filter for removing protection. The person who starts up the filter removes the protection from the piston rods of hydraulic cylinders, locking pins and column holes. 7.1.2.



Handling and storing of the filter plates The filter plates are delivered lying flat on pallets if they are not installed onto the machine.   



Handle with care and avoid putting them down roughly. Only use means of transport with soft surfaces to lift and transport the filter plates. Store filter plates flat on a smooth base and never in an upright position. Protect filter plates from frost, direct sunlight or heat and make sure they do not come into contact with oil or solvents.



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29.2.2012



Checking delivery Before starting installation, use the packing list to check that all the items for the filter and all the accessories have been supplied completely and are free of damage. Immediately contact Outotec (Filters) Oy if there are any missing or damaged parts. We refer to our terms of sale and delivery. The assembly and connection material for the interfaces of the dismounted components is included in the delivery. All the other accessories are appropriately packed and included with the delivery.



Dispose of packing and insulating material properly and in an environmentally compatible manner. Observe national regulations.



7.3.



Storage These instructions are to give a basis to prepare your fast opening filter press for storage. NOTE!



7.3.1.



Site specific details can vary and must be taken into consideration by the client. These instructions do not overrule local operating instructions or regulations.



Storage of machine



When preparing the machine for storage, all liquid must be removed from the machine parts to prevent freezing, corrosion and other damage. Use appropriate means to protect all bright or uncoated parts. NOTE!



Outotec Filters (Oy) gives no warranty whatsoever for any damage from corrosion resulting from inappropriate storage.



Minimum temperature:



-15°C



Maximum temperature:



+65°C



The storeroom must be dry, shady and kept at a constant temperature. Solvents, oils or paints can not be stored in the same room. Protect filter plates from frost, direct sunlight or heat. Make sure they do not come into contact with oil or solvents. 



Depressurize all pipelines







Grease plate shifter chain



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7.4.



7.5.



7.6.



29.2.2012







Plate pack closing cylinder to be in half open position







Position Pinch valves to be in open position to avoid formation of pinch valve hose







Swivel plates to be open. This will reduce static load on motors.







Main switch to be in off position and locked in that position







Check purity of the filter and surrounding equipments. If needed, wash all equipments well to prevent corrosion. Note IP rating of equipment when cleaning the filter and use only proper methods for cleaning.







Wax all non protected surfaces like piston rods and the side bar slide strips







Cover the filter with tarpaulin



Preparation of the hydraulic unit for storage -



Hydraulic power pack must be disconnected from the electric power supply



-



Check that hydraulic power pack is unpressurized



-



Fill up the oil reservoir almost full (two centimeters from the top level). Purpose is to reduce air volume in the reservoir and avoid condensation.



-



Remove air breather and plug the connection in the reservoir.



Restart after long term storage -



Inspect all wearing parts and change all worn out components before restarting the filter



-



Clean all waxed surfaces and remove motor hoods (inhibitor plastic).



-



Drain additional amount of hydraulic oil to gain the proper oil level. Make sure that oil is in proper condition and if needed change the oil.



-



Reinstall air breather into the oil reservoir.



-



Follow instructions given in Instruction manual section “Mechanical commissioning”.



Disposal of the filter components



Dispose of the filter parts according to local regulation.



NOTE!



Separate the plastic and metal parts of the filter and recycle them appropriately.



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Table of Contents 8.



Optional devices ............................................................................................................................. 2 8.1. Load cell module ................................................................................................................... 2 8.1.1. Equipment description ................................................................................................... 2 8.1.2. Hardware installation ..................................................................................................... 4 8.1.3. Operation instructions ................................................................................................... 5 8.1.4. Alarms ........................................................................................................................... 6 8.1.5. Calibration ..................................................................................................................... 7



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8.



OPTIONAL DEVICES



8.1.



Load cell module



8.1.1.



Equipment description



29.2.2012



Load cell transducers are constructed of stainless steel. This figure illustrates a typical load cell configuration. The transducers are made to operate in industrial, wash down environments, require no periodic maintenance, and are immune to electrical noise due to high level output voltage. Load cell transducers wire to signal processors, which convert the transducer’s voltage outputs to weight measurement.



1. 2. 3. 4.



Load cell transducer Terminal box (in filter) Control cabin Field bus cabling



5. 6.



Field bus cabling to other terminal boxes I/O modules (resistor bridge input terminals for weighing control)



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Load cells transducers will be installed between the filter and customers foundation with mounting kits. Some of filter may have separate weighing beam between the filter and the load cell mounting kit in order to stabilize load to load cells.



Load cell transducer with mounting kit



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8.1.2.



29.2.2012



Hardware installation To achieve the most accurate weight measurement from the load cell transducers, consider the following factors before installation: -



The surfaces where the base plates bolt down must be flat and horizontal with less than one degree of slope in any direction. Besides, the surface must be clean and smooth.



-



The foundation on which a filter rests must be of concrete or steel so that it does not allow excessive movement when the weight in the filter changes.



-



Shock loads can damage load cells. If the load cell mounting kit can be struck by forklifts, trucks, etc., install protective barriers or stops to prevent vehicles from hitting the mounting kit.



Process control system with beams



Process control system without beams



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Important installation notes



8.1.3.



-



During filter installation do not put all filter load on one transducer.



-



Position load cell transducers so that the transducer cable cannot be snagged or chafed, and can be easily routed to the terminal box.



-



In case you need to weld near to the load cell, be sure the ground path is not trough the load cell. The ground cable should be close to the welding, in between the welding and the load cell, i.e. the welding current can not be in any conditions run trough the load cell. Also be careful with the heat. The load cell must be always cool enough to touch. Further, it is recommendable to disconnect the wires from the sensor, to avoid a ground loop via the electronics.



-



Supporting structures of the pipelines connected to the filter should also carry the load of the filter’s pipelines. After the erection work, the filter’s pipelines are released from the filter to stay on the supports of the pipelines connected to filter. Also, other vertical supports fixed to the filter, which may affect the process control system, have to be replaced by new supporting structures and disconnected from the filter.



Operation instructions The process control system can be separately activated to control FILTRATION, PRESSING and AIR DRYING stages. If the system is not activated, stages are controlled by preset time. To activate the system to control the filtration stage, set parameter “MAX FILLING WEIGHT (kg)” in parameter screen No. 3. If parameter is Zero, control is not on. Similar parameters are optional for pressing and air drying stages, which are normally not used. When the process control is activated, filtration (filling the chambers) is controlled by time, weight or maximum pumping pressure. Whatever reaches the set value first, stops filling. The weight setpoint is set into parameter “MAX FILLING WEIGHT (kg)”. When the process control is activated, pressing is controlled by time and changing speed of the filter weight. Whatever reaches the set value first, stops pressing. The weight changing speed setpoint is set into parameter “WEIGHT CHANGE IN FILTRATION (KG/S)”. Note that this is optional and normally not used. When the process control is activated, air drying is controlled by time and changing speed of the filter weight. Whatever reaches the set value first, will stop air drying. The weight changing speed setpoint is set into parameter “DRYING STOP WEIGHT CHANGE (kg/s)”. Note that this is optional and normally not used. To get access to capacity information select REPORT screen and press HISTORY report button in the operator interface panel.



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Screen information: 1. 2. 3. 4. 5. 6. 7.



Production per hour. Cumulative cake weights of the last hour. Production per shift. Cumulative cake weights of the current 8 hour period. Production per day. Cumulative cake weights of the current day. Production per week. Cumulative cake weights of the current week. Production per month. Cumulative cake weights of the current month. Production per year. Cumulative cake weights of the current year. Total cake production from the start-up of the filter.



Note! 8.1.4.



UNIT kg t t t t t t



Production per shift is reset according to the shift start time parameters (PARAMETER screen No. 3).



Alarms



Minimum weight alarm Cause: Cake weight after pressing is less than minimum cake weight set in parameters. Reason: Slurry pump is failed. Slurry feed time is too short. Slurry density is too low. Weight sensor or amplifier has failed. Measures: Skip over air drying stage to avoid filtration plates pending. Repair or replace weight sensor/amplifier.



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Tare alarm Cause: Measured weight is greater than max tare weight after plate pack closing stage. Reason: Extra mass has been gathered to filter. Weight sensor or amplifier has failed. Measure: Remove over load from filter. Repair or replace weight sensor/amplifier. Note! 8.1.5.



If the parameter “MAX TARE WEIGHT(kg)” is set to zero, the alarm is not in use



Calibration Normally there is no need for mechanical calibration. The only parameter required to be entered for calibration is the load cell nominal size (which can be read from electrical or load cell documentation). Select “B91*” from process screen and from there “Param”.



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29.2.2012



Enter load cell nominal size.



In info screen all load cell (each load cell separately) related data (signal, reference voltage, weight) can be monitored:



This screen is only for information to monitor weighing system operation



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Table of Contents 9.



Appendices ..................................................................................................................................... 2 9.1. Filter datasheet ...................................................................................................................... 2 9.2. Error Report for the Documentation ....................................................................................... 3 9.3. Error Report for the Filter ....................................................................................................... 4 9.4. Start-up Report ...................................................................................................................... 5 9.5. Order form for Manuals.......................................................................................................... 6 9.6. Mechanical drawings ............................................................................................................. 7 9.7. Electrical drawings................................................................................................................. 8 9.8. Diagrams ............................................................................................................................... 9 9.9. Modification parts ................................................................................................................ 10



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9.



APPENDICES



9.1.



Filter datasheet



29.2.2012



9-2 (11)



TECHNICAL SPECIFICATION TECHNICAL SPECIFICATION For Outotec Larox® PF 60-series Filters 20.05.2011



www.outotec.com



TECHNICAL DESCRIPTION DOC23600 REV B / teeelo 2nd August, 2011 1 (10)



CERTIFIED PKn



CUSTOMER



Minera Escondida



APPLICATION



Cu Concentrate LAROX PF M SERIES AUTOMATIC PRESSURE FILTER



DRAWINGS



Type



Larox PF 144/144 M60 1 60



Filtration area



144 m2



According DIR:



DOC23599



MARKING LAROX PF 144/144 M60 1 60 Filter type



PF



Filtration area /expandability Filter series



144/144



Construction material



1



Chamber height



60



PROGRAM Short program 1. 2. 3. 4.



Filtration Pressing Drying Cake discharge



C:\Aton\ATONPDM\Server\pdf\tmp\590013.doc



M60



TECHNICAL DESCRIPTION DOC23600 REV B / teeelo 2nd August, 2011 2 (10)



CERTIFIED PKn



CONSTRUCTION MATERIALS 1 = all metal parts in contact with slurry, material AISI 304L or equal



PRESSURES



Infeed pressure Diaphragm pressing pressure Air drying pressure Feed pipe/hose washing pressure Cloth washing pressure Instrument air pressure



0,2...1,0 MPa 0,5...1,6 MPa 0,4...1,2 MPa min. 0,15...0,2 MPa over infeed pressure 1,0…1,4 MPa 0,6…1,0 MPa



CONSTRUCTION DESCRIPTION Item numbers according to dimensional drawing. Item



1



2



Description



Lower part - U-beam frame - liquid collecting vat - foundation plate - cloth wash unit -housing -cloth wash piping - sealing cylinders



Material information



Mild steel AISI 304 Mild steel AISI 304 AISI 304 Splash-proofed



Lower pressing plate - cake chute



Mild steel AISI 304



3



Columns



Mild steel



4



Upper pressing plate - locking pins - hydraulic cylinders



Mild steel



Top frame



Mild steel



5



C:\Aton\ATONPDM\Server\pdf\tmp\590013.doc



Further information



Nozzles: DELAVAN Qty 8 pcs



Filter cake is discharged on both sides of the filter



Qty 4 pcs Qty 2 pcs



TECHNICAL DESCRIPTION DOC23600 REV B / teeelo 2nd August, 2011 3 (10)



CERTIFIED PKn



6



Cloth drive unit - side plates and doors AISI 304 - power transmission through hydraulic motors and flexible coupling



7



Cloth tensioning device - power transmission through chains, hydraulic motor and flexible coupling - frame for cloth tensioning device AISI 304



8



Filter plate (size 1 500 x 4 010 mm) - body plate - frame - diaphragm - grid - vat - filter plate guides - cloth and roller scrapers



9



Rollers - cloth drive rollers - cloth centering roller



- guide rollers - auxiliary drive rollers



10



Qty 24 pcs AISI 304L AISI 304L Natural rubber PP PE POM Polyurethane edge



Max. temp. 60 °C



AISI 316 frame, same amount as plates



Mild steel/AISI316 Rubber lined Mild steel/AISI316 Rubber lined - automatically controlled with hydraulic cylinder Mild steel/AISI 316 Polyurethane lining Mild steel/AISI 316 Qty 6 pcs Rubber lining



Process pipelines - Flanges According to ANSI B 16.5 (150 lbs) - slurry feed pipes - slurry hoses



AISI 304L EPDM



- pressing air distribution pipe with air remover - pressing air distribution hose - filtrate collection hoses



AISI 304 EPDM Natural rubber



11



Filter plate guide bars



AISI 304



12,13,14



Quick action cylinders, fixing parts and shields



Splash-proofed



C:\Aton\ATONPDM\Server\pdf\tmp\590013.doc



Qty 2 pcs 4 pcs per filter plate Spirally reinforced



1 pce per filter plate Qty 4 pcs



Qty 4 pcs



TECHNICAL DESCRIPTION DOC23600 REV B / teeelo 2nd August, 2011 4 (10)



CERTIFIED PKn



15



17



Hydraulic connections between hydraulic unit and filter



3 pcs



Process valves Larox pinch valves * housing * sleeve * PVE 50 H 16 * PVE 100 H 16 * PVE 125 H 16 * PVE 150 H 16



Ball valves Butterfly valve 18



Hydraulic hoses



GRS SBRT Qty 2 pcs Qty 1 pce Qty 3 pcs Qty 2 pcs



DN 65/50 DN 100 (control valve, drying air)



Qty 3 pcs Qty 1 pce



Side shields - frame mild steel - plates transparent polycarbonate - stairs and maintenance platforms are optional



19



Hydraulic piping



AISI 304



Fittings JIC-Fe/Zn+CR



20



Maintenance tools



21



Filter cloth The delivery includes one filter cloth. The installed cloth is for factory test and start-up purposes only. Type: material polypropylene Cloth width 1,7 m, length 136,0 m. Seam type SH1.



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TECHNICAL DESCRIPTION DOC23600 REV B / teeelo 2nd August, 2011 5 (10)



CERTIFIED PKn



AUTOMATION AND ELECTRIFICATION For the control of all functions of the filter as well as quoted accessories and process control functions. The control panel is to be regarded as interface between automatic pressure filter and the operator. The panel can be used for - Displaying the status of position sensors - Displaying the status of valves and motors - Displaying the flow diagram including process valves, showing the status and process pressures - Supplying of recipes and parameters Selection of modes - Test mode - Manual mode - Automatic mode - End mode Language for screen text



English and desired one



Electrification and instrumentation is designed acc. to European standards. Material of construction - Control panel - Terminal boxes - Terminal box, in hydraulic unit



Coated mild steel, IP65 AISI304, IP66 Coated mild steel, IP65



PLC system



Modicon ( Quantum )



Operator interface unit (OIU) Voltage supply to the system



Proface AGP3500 10,4” 120 VAC 50 Hz 1-phase



The control panel requires voltage supply from which following field voltages are internally generated: - Instrumentation 24 VDC - Control solenoids 24 VDC ELECTRIC MOTORS AND CABLING Motor starters, cabling external to the filter and its associate parts is excluded from the Outotec delivery. The limits for supply of electrical components and cabling shall be as shown in cabling diagram. Auxiliary I/O controls for Outotec supplied process motors and auxiliary devices are included in Outotec automation control system.



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TECHNICAL DESCRIPTION DOC23600 REV B / teeelo 2nd August, 2011 6 (10)



CERTIFIED PKn



Motor voltage 460 VAC 50 Hz 3-phase - Hydraulic unit 110 kW,1500 rpm (50 Hz) IP55 - Hydraulic oil cooler 2,2 kW, 1500 rpm (50 Hz) IP55 Integrated structure, not changeable motor. - Hydraulic oil heater (optional) 3 kW



HYDRAULIC UNIT Type Oil tank volume Operating pressure Max. flow Q l/min



LAROX 600 0,6 m3 0 - 280 bar 420 l/min



Equipped with removable case. It is important to take care of adequate cooling air recirculation around the hydraulic unit. The delivery includes hydraulic hoses between filter and hydraulic unit. The length of the hoses is approximately 5 m. The changes have to be agreed separately before the delivery. Hydraulic unit will be delivered without oil. First filling at site by the customer. Electrically controlled axial piston pump - max. continuous pressure 350 bar - output flow Q in l/min P1 355 l/min Constant pressure axial piston pump - max. continuous pressure 210 bar - output flow Q 50 l/min P3 65 l/min Electric motor for P1 and P3 Pressure accumulator volume 10 litres. - charging with constant pressure pump Pressure filter for pressure control line of pump P1 rating 5 µm Return oil filter rating 5 µm Level and temperature transmitter Heater Air cooler (alternatively water cooler)



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TECHNICAL DESCRIPTION DOC23600 REV B / teeelo 2nd August, 2011 7 (10)



CERTIFIED PKn



WELDING PROCESS The following welding procedures are used at Outotec: electrode (111), MAG (135), TIG (141) (ISO 857-1). The weldings are carried out according to welding class C at the minimum (SFS-EN ISO 5817). A welding co-ordinator is responsible for welding (IWE 00132 FIN) and he has full authority over any necessary action. Welders competence is based on (SFS-EN 287-1). Welding instructions have been accepted according to SFS-EN ISO 15614-1, SFS-EN ISO 15610, SFS-EN ISO 15611. Weldings are checked visually and the parts in plate pack which are in contact with slurry are tested for tightness (pressure water 16 bar / pressure air 6 bar). In addition, parent material traceability for the above parts is secured. A final inspection is carried out with a complete product according to ISO 9001:2000.



PAINTING



Mild steel parts are epoxy painted, stainless steel and plastic parts are not painted. Parts with heavy corrosion and abrasion environment conditions: SFS-EN ISO 12944-5/S7.03/C5-M/M (EP 300/2-FeSa 2½) - surface treatment epoxy painting, 2 coats of epoxy, 2 x 150 microns, total paint thickness 300 microns Other parts with normal corrosion and abrasion environment conditions: SFS-EN ISO 12944-5/S7.02/C5-M/L (EP 200/3-FeSa 2½) - surface treatment epoxy painting, 2 coats of primer * primer paint 1 x 60 & 1 x 80 microns, 140 microns * 1 coat of epoxy paint 60 microns * total paint thickness 200 microns Colors:



Window Grey Basalt Grey



RAL 7040 RAL 7012



More details in the painting instruction of the filter.



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TECHNICAL DESCRIPTION DOC23600 REV B / teeelo 2nd August, 2011 8 (10)



CERTIFIED PKn



FEED PIPE AND HOSE FLUSH WATER CONSUMPTION



PF 144/144



1,5 m3/cycle



Recommendation for pump sizing: Volume Head



40...80 l/s 15...20 m over feed pressure



When possible, filtrate is recommended to be used as the feed pipe and hose flush liquid. CLOTH WASH WATER CONSUMPTION Water pressure (bar) 10 14



Flow rate (l/min) 240 295



Flow is required only during cloth advancement which is from 0,5 to 1,5 minutes per cycle. INSTRUMENT AIR



Air pressure: 6 - 10 bar (overpressure) Air temperature: 5 °C - 80 °C Compressed air quality according to ISO 8573-1 class 4.4.4. - Dirt: max. particle size 15 μm, max. concentration 8 mg/m3 - Water: max. pressure dew point +3 °C - Oil: max. concentration 5 mg/m3 Air consumption: - average consumption while operation 140 l/cycle - maximum instantaneous flow 800 l/min



PRESSING AIR



Air temperature: 10 °C - 80 °C Compressed air quality according to ISO 8573-1 class 2.7.2. - Dirt: max. particle size 1 μm, max. concentration 1 mg/m3 - Water: no requirements - Oil: max. concentration 0,1 mg/m3 - air pressures and consumptions according to filter’s sizing report



DRYING AIR



Air temperature: 10 °C - 80 °C Compressed air quality according to ISO 8573-1 class 4.7.4. - Dirt: max. particle size 15 μm, max. concentration 8 mg/m3 - Water: no requirements - Oil: max. concentration 5 mg/m3 - air pressures and consumptions according to filter’s sizing report



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TECHNICAL DESCRIPTION DOC23600 REV B / teeelo 2nd August, 2011 9 (10)



CERTIFIED PKn



OPTIONAL DEVICES Load cell module according to the separate description.



FILTER CONSTRUCTION The filtration elements (i.e. plates) of the PF filter are placed horizontally between two pressure plates. During filtration the plate pack is pressed together, and the pack is opened for cake discharge. The plate pack is opened and closed by means of hydraulic cylinders. The endless filter cloth zigzags between the filter plates, which results in the filtered cake being formed on either side of the cloth. The filter cloth is thus automatically back flushed and any particles adhering to it or lodged in the filter cloth from the previous filtration cycle are washed out when filtering on the reverse side of the cloth. The cloth transports the cakes off the filter and, at the same time, the cloth is cleaned on both sides by high pressure water sprays. The cloth moving device is driven by the hydraulic motor which actuates the cloth drive roller. When the filter plates are opening and closing, the tension of the filter cloth is maintained at a constant level by a simple cloth tensioning device. The cloth tensioning device does not operate when the plate pack is closed. Slurry is fed into sealed filter chambers through the distribution piping. Wash water and drying air are fed in through the same pipe. The feed pipe is emptied through a drain valve on completion of the feed pumping cycle. The operation of the filter is controlled automatically by the operation unit containing the programmable logics and indicator lamps for all operations. The automatically controlled actuators for the pinch valves are hydraulic operated and for the ball valves pneumatic.



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TECHNICAL DESCRIPTION DOC23600 REV B / teeelo 2nd August, 2011 10 (10)



CERTIFIED PKn



OPERATION



1. Filtration When the filter plate pack has been closed, slurry is pumped into the filter and fed simultaneously into each filter chamber through the distribution pipes. Filtrate flows through the cloth into the filtrate collection area, then out through the discharge pipe. The filtered material is collected on the cloth surface and forms the filter cake. 2. Pressing I Pressing air flows in behind the rubber diaphragm. The diaphragm presses the cake against the cloth surface, thus pressing the filtrate from the cake through the cloth. 3. Washing (optional) Wash liquid is pumped into the filter chambers in the same way as slurry. As the liquid fills the filtration chamber, the diaphragm is lifted up and air is forced out from the upper side of the diaphragm. The wash liquid flows into the discharge pipes after passing through the filter cake and the cloth. 4. Pressing II (optional) The wash liquid remaining in the chamber after the washing stage is pressed out of the cake as in stage two above. 5. Drying The final drying of the cake is accomplished with compressed air. The air which enters through the distribution pipe fills the filter chamber, raises the diaphragm and forces the pressing air above the diaphragm out of the filter. The air flow through the cake reduces its moisture content to the optimum and, at the same time, empties the filtrate chamber. 6. Cake discharge When the air drying has been completed, the plate pack is opened and the cloth moving mechanism started. The filter cake on the cloth is discharged from both sides of the filter.



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IOM MANUAL PF1032



9-3 (11)



B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



9.2.



29.2.2012



Error Report for the Documentation We have provided this form to help us track any errors that may exist in our manuals. Should you find an error in this manual, please describe it in the space below and fax this form to us, telefax No. +358 20 529 4277. We appreciate your input. Current Information PF No. ____________Page number(s): ______________Figure number(s): ___________



Information as currently printed:



Proposed Change Information as it should be printed:



Any additional information:



Address (optional): Name Title Company Address Telephone Telefax Date Received Date resolved Manner Resolved



IOM MANUAL PF1032



9-4 (11)



B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



9.3.



29.2.2012



Error Report for the Filter



WARRANTY CLAIM



CLAIM



Customer’s name/Contact Address



RETURNED GOODS



DATE:



Affiliate or distributor Outotec (Filters) Oy P.O.Box 29 FIN-53101 Lappeenranta, Finland



Country Phone



E-mail



Phone



+358 20 529 4236



E-mail:



[email protected]



Fax



Fax



+358 20 529 4439



Internet:



www.Outotec.com



Filter type



Model



Principal part involved



Part No.



Filter No.



Date of failure Operating cycles or time



For Outotec’s use only Type of operation Business unit Description of the case, place, circumstances, etc.



Goods to be returned Component delivered to customer with filter other delivery date: Qty. Code Description



Signature



For Outotec´s use only Actions To be repaired



Warranty status Warranty period



Yes Date



By



No



Rejected Date of credit



Credit invoice



Claim returned for completion To be scrapped



To be delivered to supplier for inspection



Claim accepted Date



By



IOM MANUAL PF1032 B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



9.4.



Start-up Report Can be added only after start-up.



29.2.2012



9-5 (11)



IOM MANUAL PF1032



9-6 (11)



B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



9.5.



29.2.2012



Order form for Manuals Additional copies of these documents can be ordered from the manufacturer. Please note that further copies are not free of charge. All rights expressly reserved. Reproduction or communication to third parties, no matter in which form, is not permitted without our written consent. When ordering additional copies, always state serial number of the filter in question and specify the needed documents as shown below: Serial no



Document



Pcs



Description (delivery type)



1032



IOM manual



1



1 x paper file 1 x CD



1032



eCatalogue



1



1 x CD, 1 x paper file



1032



OEM documents



2



2 x paper file



IOM MANUAL PF1032 B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



9.6.



Mechanical drawings



29.2.2012



9-7 (11)



IOM MANUAL PF1032 B100232FI Minera Escondida DOC23605 Rev. B Outotec (Filters) Oy / Documentation / sl



9.7.



Electrical drawings



29.2.2012



9-8 (11)



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