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Rev. : C
Page : 1/33
OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Maintenance tip
Replace compressed air filter annually to avoid restriction on compressed air line and dirt carry over.
Maintenance tip
Replace or maintain properly the draining mechanism annually to avoid liquid carry over.
Control point
Cleaning start/stop settings value on the control pressure switch.
ON-time/Off-time on each sequencer card.
Pulsing cycle is initiated by Start/Stop signal from control pressure switch and clock timer.
Each valve should be pulsing during a full cleaning cycle.
Operation tip
For harsh and dusty environment the system can be switched to MANUAL mode for continuous pulsing
Maintenance tips:
Before installing new filters, clean mating surface on the tube sheet
Before installing new filters, thoroughly clean each filter retention bolt with a metal brush.
If hardware is damaged or corroded always replace with new hardware.
Ensure all element supports are in good shape and good condition.
Install new filter element with new gasket washer and filter retention nut.
Before tightening the filter element, check its perpendicular alignment with the tube sheet .
Tightened the filter retention nut at the torque specified in the O&M Manual. Do not exceed 20Nm!
After tightening, one should not be able to rotate by hand the filter element around its axis.
All filter elements should be from same type, installed at the same time.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Donaldsons unique Spider-Web technology with nanofibers provides ultimate surface filtration for optimal cleaning and unmatched filtration effi-
ciency throughout the life of the filter elements.
Accept no substitutes! Use only genuine Donaldson replacement filter elements in your Donaldson Air Filter System.
Additional information on the Spider-Web technology is available with your nearest Donaldson Sales Representative.
The above Golden Rules are given for information only. For more details, please refer to the Operations and Maintenance Manuals for proce-
dures, settings and other maintenance recommendations. Alternatively, contact your nearest Donaldson Sales Representative for additional
information.
North&SouthAmerica Europe Middle East Africa Asia Pacific
filterinfo@donaldson.com GTS-europe@em ea.donaldson.com gtssales.apac@donaldson.com
+1 (800) 431-0555 +32 (16) 38 39 40 +65 6311 7373
www.donaldson.com www.emea.donaldson.com www.asia.donaldson.com
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
TABLE OF CONTENTS
1 ABOUT THIS MANUAL 6
1.1 Purpose ............................................................................................. 6
1.2 Target audience ................................................................................. 6
1.3 How to use this manual ...................................................................... 6
2 DESCRIPTION 7
2.1 Air filter description ............................................................................ 7
2.1.1 Functioning ............................................................................ 9
2.2 Performance and design characteristics .......................................... 11
2.2.1 Filtration ............................................................................... 11
2.2.2 Airflow .................................................................................. 12
2.2.3 Pulse cleaning ...................................................................... 12
2.3 Description of the cleaning system ................................................... 14
2.3.1 Physical ............................................................................... 14
2.3.2 Electrical .............................................................................. 15
2.3.3 Pneumatic ............................................................................ 19
2.3.4 Evaporative cooler system ................................................... 19
2.3.5 Temperature and relative humidity sensor............................ 24
2.3.6 Lighting ................................................................................ 24
2.3.7 Alarm instruments ................................................................ 24
2.3.8 Mechanical pressure switch ................................................. 25
2.3.9 Relative humidity & temperature transmitter ......................... 26
2.3.10 Dust evacuation fans............................................................ 26
2.4 Technical data ................................................................................. 26
2.5 Instruments ...................................................................................... 28
2.6 Life of the filter elements .................................................................. 28
3 ANALYSIS OF FAILURE IN SERVICE 30
3.1 Trouble shooting chart ..................................................................... 30
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
LIST OF FIGURES
Figure 1: Air filter assembly ................................................................................. 7
Figure 2: Function of air filter ............................................................................... 9
Figure 3: Pulse cleaning of filter elements ......................................................... 13
Figure 4: Psychometric chart ............................................................................. 22
Figure 5: Cooling media..................................................................................... 23
Figure 6: Relative humidity sensor ..................................................................... 24
Figure 7: Pressure transmitter ........................................................................... 25
Figure 8: Mechanical pressure switch ................................................................ 25
Figure 9: Relative humidity & temperature transmitter ....................................... 26
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
LIST OF TABLES
Table 1 Orientation aids ....................................................................................... 6
Table 2: Efficiency of elements........................................................................... 12
Table 3 Component parts of control box............................................................. 16
Table 4 Indicator lights/displays ......................................................................... 18
Table 5: Air filter spec ........................................................................................ 27
Table 6: Compressed air requirements .............................................................. 27
Table 7: Electrical requirements ......................................................................... 28
Table 8: Instruments .......................................................................................... 28
Table 9: Troubleshooting.................................................................................... 33
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
1.1 Purpose
The purpose of these instructions is to describe this self-cleaning air
filter system.
You must carefully read and understand this document in order to:
avoid danger,
execute the tasks correctly and
increase the reliability and service life of the equipment.
Element Location
Table of contents Beginning of book
List of figures and tables Beginning of book
Running header and footer Throughout the book
Table 1 Orientation aids
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
2 DESCRIPTION
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
See figure 1 for main component parts of the air filter. The GDX sys-
tem is a single stage self-cleaning air filter utilising conical and cy-
lindrical Donaldson filter cartridges, sequentially cleaned by a re-
verse flow pulse of compressed air.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
2.1.1 Functioning
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
These hoods and plenum protect the cartridges against foreign ob-
ject damage, excessive ingestion of rain, UV rays and serves at the
same time to ensure a downward airflow through the cartridges.
Blowpipes are installed in the clean air plenum, one blowpipe for
two element sets.
When pulsed, they come off in larger masses than when they were
deposited.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
2.2.1 Filtration
The single stage filtration of the filter is provided by conical and cy-
lindrical filter elements, produced by Donaldson and using proprie-
tary materials exclusive to Donaldson.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
2.2.2 Airflow
Both the airflow pattern and the specified flow rates have been cal-
culated to improve filtration and pulse cleaning of the filters.
During pulse cleaning, normal flow through two element sets is in-
terrupted for about 0.1 second.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Each pulse of air from the nozzle into the blowpipe above each ele-
ment set provides both a shock wave inside the filter cartridge and a
momentary reverse flow. Together this provides the cleaning energy
necessary.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
The start and stop parameters for pulse cleaning are shown in section 2.4
2.3.1 Physical
Donaldson utilises standard modules to make up the many configu-
rations of product offered for large gas turbine applications. The
module used in constructing this GDX-type filter is 4 element pairs
wide.
This filter module section consists of combined filter module and fan
hopper
The air filter control box is described in section 2.3.2. of this chapter.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
The droplet separator panels are a wave form type drift eliminator
which separates the water droplets from the ambient airflow before
it enters the barrier filter section. This system also includes a propri-
etary D-Fog system to further reduce moisture.
2.3.2 Electrical
See the following documents for information concerning electrical components
and the electrical system:
P&ID document 105T2838
Control box wiring diagram 3EA-AE5567963
Junction box wiring diagram 3EA-AE5567964
The GDX System requires only low electrical power supply to oper-
ate the cleaning mechanism.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
The following indicator lights and displays are on the front of the
control box:
Indicator Function
-H01 light up (white) when the power
switch (-S01) has been turned
ON and when 400 V AC - 50 Hz
is available at the air filter control
box input lines
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Indicator Function
-H02 light up (white) when the power
switch (-S01) has been turned
ON and when 230 V AC - 50 Hz
is available at the air filter control
box input lines
-H03 light up (white) when the power
switch (-S01) has been turned
ON and when 110 V AC - 50 Hz
is available at the air filter control
box input lines
-H04 lights up (green) when pulse-
cleaning is in operation
-H05 lights up (red) when alarm panel
is open
-H21 lights up (green) when
evaporative cooler is on
-H22 lights up (green) when the water
pump 1 is on
-H23 lights up when the water pump 2
is on
-H24 lights up (green) when the
system is under local control
-H25 lights up (red) when the water
level in the sump is too low
-H26 lights up (red) when the water
flow is abnormal
-H27 lights up (red) when conductivity
is too high
COND1 displays conductivity from
conductivity sensor 1
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Indicator Function
COND2 displays conductivity from
conductivity sensor 2
Table 4 Indicator lights/displays
This air intake filter has six modules. During one cleaning cycle the
filter elements of these modules of the complete air intake system
are cleaned.
There are five manifold junction boxes per filter module. The power
leads to these points will be activated at all times.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
2.3.3 Pneumatic
Compressed air at 7 bar (effective) is supplied to the filter manifold
by a supplied compressor. A filter/regulator with automatic drain is
installed on the compressed air piping at a low point of the filter.
Shut-off valves are included to isolate the manifolds for repairs
and/or inspections. The compressed air pressure can be checked at
any time via a pressure transmitter + pressure gauge located on the
pressure regulator assembly.
The compressed air temperature at the pneumatic valves should not exceed
80C, to prevent damage to the valve diaphragms.
DANGER
Hazardous gases
Gas will cause death or injury
Do not use hazardous gas in compressed air supply
Water is pumped from a sump and is sent to the top of every level of
the cooler module. Flow regulators are provided to ensure a correct
water delivery on every module.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Demister panels are also installed inside the cooler after the media
section. They are used to eliminate any risk of water drop carry-
over.
The control of the cooler is integrated in the control box of the filter-
house; it is designed to start the pumps at the right moment and to
control the correct working of the cooler in accordance with the wa-
ter available in the system.
The operation of the cooler should be avoided at temperatures below 10C. This
condition together with the cooling effect of the air stream velocity could induce
freezing of the water on the media.
During days with high relative humidity the cooler effect decreases.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
The extent to which the cooled air approaches the wet-bulb temper-
ature defines the cooler efficiency. This efficiency is often referred
to as saturation efficiency because as the air accepts more evapo-
rated water it approaches saturation and the wet-bulb temperature.
During normal operation, warm air enters the evaporative cooler and
passes through the water saturated evaporative cooler media.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
2.3.6 Lighting
For filter maintenance, lighting is installed inside the filter house at each platform
level.
A differential pressure transmitter (-96TF-1), with pick-up point in the ductwork af-
ter the evap cooler is foreseen for turbine alarm purposes. It sends a signal (4-20
mA) to the customer main control room.
Filter high pressure drop alarm: a pressure switch (-63CA-1) gives an alarm
when the compressed air pressure drops below a certain preset value.
These instruments should be checked for their activation point on a regular basis.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
A relative humidity and temperature transmitter has been installed under the con-
trol box. This transmitter transduces the site conditions (temperature and relative
humidity, detected by the sensor) into two analogue signals (4-20 mA). The first
analogue signal (corresponding to the dew point) is available at terminals 1, 2
and 3 of the terminal block X05 inside the control box. The second analogue sig-
nal (corresponding to the relative humidity) is available at terminals 4, 5 and 6 of
the same terminal block X05 inside the control box.
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Electrical Requirements
Controls
Voltage 230 VAC 50Hz
Power 0,5 Kw
Lighting
Voltage 230 VAC 50Hz
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Electrical fan
Voltage 400 VAC 50Hz
Quantity 6
Degree of IP55
protection
Area Safe area
classification
Table 7: Electrical requirements
2.5 Instruments
The maximum filter element operating life is 2 calendar years after installation in
the filter house.
Therefore, for the most profitable use of our filter element, the storage period
should be limited to 3 years, e.g. 3 years storage + 2 years operation = 5 years
(max. life).
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Rev. : C
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
Table 9: Troubleshooting