Plant Client Code Doc ID Code Project No.

BFI Brunei
Fertilizer Complex
Fertilizer Industries
BFI PDE-EQS-02-DZ-0071 KXEO-00045

Operation and maintenance instruction

Pages attached 14

COVER SHEET

00 For approval 13.08.18 Hoffmann

Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code

Bar code
- Translation of the original -
OPERATION MANUAL
Air Intake Systems
DELBAG® Pulse Filter System 8x10
 Content Page

1 General .......................................................................................... 3
1.1 Introduction ............................................................................................................ 3
1.2 Notes on Safety ....................................................................................................... 3
1.3 Copyright ................................................................................................................ 5
2 Product information ........................................................................ 5
2.1 Delivery and accessories ........................................................................................... 5
3 Design and function of the pulse filter ............................................ 5
3.1 Design ..................................................................................................................... 5
3.1.1 Pulse filter ...........................................................................................................................5
4 Transport and storage.................................................................... 6
4.1 Packing and dismantling degree .............................................................................. 6
4.2 Arrival of delivery ..................................................................................................... 6
4.3 Handling ................................................................................................................. 6
4.4 Storage ................................................................................................................... 6
5 Assembly / Installation ................................................................... 6
5.1 Installation of filter unit ........................................................................................... 6
5.2 Installing the pulse filter cartridges ........................................................................... 6
5.3 Checks before commissioning.................................................................................. 8
5.4 Monitoring of the filter system................................................................................. 8
5.5 Adjustments, settings .............................................................................................. 9
5.6 Final inspection ........................................................................................................ 9
6 Measuring Points of the Pulse Filter Control System .................... 9
7 Operating Manual .......................................................................... 9
7.1 Operator control ...................................................................................................... 9
7.2 Start-up ................................................................................................................. 10
7.3 Operation .............................................................................................................. 10
7.3.1 Operating instructions.......................................................................................................10
7.3.2 Replacement of the filter cartridges ..................................................................................10
7.3.3 Disposal of filter material ..................................................................................................10
8 Maintenance ................................................................................ 11
8.1.1 Maintenance without cleaning ..........................................................................................12
8.1.2 Maintenance with cleaning ...............................................................................................12
8.1.3 Inspection .........................................................................................................................12
8.1.4 Disposal of filter material ..................................................................................................12
9 Trouble shooting .......................................................................... 12
9.1 Trouble shooting Filter control ............................................................................... 12
9.2 Trouble shooting process engineering .................................................................... 12
10 Spare parts list .......................................................................... 13
10.1 Filter elements ....................................................................................................... 13

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 1 General

1.1 Introduction
The Instructions for Use at hand provides information about the product, assembly and commissioning,
operation, maintenance and ordering of spare parts.
The illustrations shown in this Technical Documentation relate to standard elements and for that rea-
son may deviate from the actual design to a varying degree.
The technical documentation is intended for plant owners, operators and maintenance personnel. Eve-
ryone assigned to work on DELBAG® Air Filtration products should be familiar with the entire scope
of this Technical Documentation.

Make sure to carefully observe all safety instructions and notes contained in this
Technical Documentation:
• General notes on safety are given in this chapter.
• Special instructions are given at the beginning of each individual chapter.
• Safety instructions relating to individual operations are given before the relevant operational step
is described.

1.2 Notes on Safety

The products developed, made and supplied by DELBAG® Air Filtration reflect state-of-the-art tech-
nology. Nevertheless, it cannot be ruled out that dangerous situations may arise. To avoid injury and
damage and to use the plant in the best possible way, the operating manual contains special notes.
These notes are marked by different symbols.

This symbol signifies danger to life and limb.

This symbol warns against damage to the product and to other property.

This symbol draws attention to further information and recommendations.

Dangers and damages can especially occur

• if insufficiently trained personnel controls or handles the product,
• if the product is inexpertly installed, operated or serviced,
• if the product is used for other than the intended purposes.

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 Safety notes for plant owners
• Make the present Instructions for Use available to your staff.
• Make sure that your staff has read and understood the Instructions for Use.
• Make sure that the staff observes all the information given in the Instructions for Use.
• Make sure that only trained, fully instructed and authorized personnel works with the product.
• Make sure that the plant is handled and used properly and in accordance with its designated
use.
• If the operating parameters differ from the data indicated in the Instructions for Use, please con-
tact the DELBAG® Air Filtration before operating the plant.
• Make sure that a main inspection is carried out on the overall plant at regular intervals.
• Instruct personnel to wear protective clothing when performing work that requires this.
• Clarify the duties and responsibilities of all the staff members to guarantee that work with and on
the equipment can be safely performed.
• Supplement the Technical Documentation by valid statutory accident prevention regulations and
other applicable guidelines and rules.

Safety notes for operators and maintenance personnel

• Refrain from doing anything that may affect occupational safety.
• Operate the product only when it is in a perfect condition.
• Wear protective clothing and your gas mask if this becomes necessary due to special opera-
tional circumstances, such as the presence of dangerous or toxic dust, high temperatures or
similar circumstances.
• Inform your superior or the plant owner in case of technical changes or unusual events during
operation.
• Work on electrical systems or equipment must be exclusively carried out by competent expert
personnel.
• Cut off the power and compressed air supply before installing or replacing filters and before car-
rying out servicing, maintenance and repair work. Take precautionary measures to prevent the
plant from being inadvertently switched on, particularly when carrying out checks or working in-
side the plant.
• In case of high temperatures, let the system cool down before installing or replacing filters and
before carrying out servicing and maintenance work.
• Once you have completed the necessary work, make sure tools and non-system parts are re-
moved from the plant. Protective shielding must be properly re-installed.
The plant should be commissioned by trained personnel only.

The warranty of DencoHappel GmbH shall become null and void in the event of
• changes made to operational parameters,
• not observing instructions set forth in the Instructions for Use,
• not responding to error messages of the control system and differential pressure monitoring de-
vice,
• incorrectly storing, handling, controlling, or operating the equipment,
• not duly fulfilling maintenance and not professional care requirements,
• carrying out unauthorized modifications of the control unit and the plant itself,
• using wear and spare parts that are not supplied or not approved by DELBAG® Air Filtration.

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 1.3 Copyright
The copyright on this technical documentation and the accompanying drawings and documents re-
mains the property of Fläktgroup Deutschand GmbH.
Any contravention will be prosecuted.

2 Product information

2.1 Delivery and accessories

The design of the filter and scope of delivery complies with the contractual agreement.

3 Design and function of the pulse filter

3.1 Design

3.1.1 Pulse filter

The filter unit is a self cleaning air intake filter unit.
Atmospheric air is lead into the filter unit. This can be done directly or through a weather hood to
prevent rain an extreme fog from entering the filter housing. The weather hood can optionally be
equipped with droplet separators, weather louvers or protection grids if necessary.

The pulse cleaning system requires compressed air that needs to be supplied by the operator/plants
compressed air system. The cleaning system releases air pulses, which are injected from the clean
air side of the cartridge (against the process air flow) by solenoid valves.

Function and Operation of a Pulse Filter System (surface filtration)

When operating a pulse air filter, the surrounding air flows through the filter media of the filter car-
tridges before entering the clean air plenum. During this process solid air contaminants settle on the
surface of the cartridge.
A differential pressure measuring device constantly monitors the differential pressure across the car-
tridge. Consequently, with continuing operation, an accumulated filter cake is building up on the
cartridge surface. When a “high” differential pressure difference across the filter media is reached,
considerable amounts of accumulated dust are successively cleaned by short surges of compressed
air. This cleaning is operated in a preset sequence of cartridges at a time. The cleaning sequence is
operated until a pre-set “low” value is reached. Once this value is reached the cleaning sequence is
stopped again, allowing the filter cartridge to keep a minimum dust cake and to accumulate a greater
dust cake again when operation continues.
The new cleaning cycle is started when a “high” differential pressure is reached again.

The cleaning / pulsing process is also stopped directly after power switch off.
A restart of the control continues the cleaning / pulsing with the next single solenoid valve.

At the end of the cartridges lifetime, the cartridge cannot be cleaned below the preset differential pres-
sure. The result is constant pulse cleaning. At this time it is recommended to change the cartridges.
At any time cartridges shall be changed before reaching 1000Pa to prevent mechanical failure.

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 4 Transport and storage

4.1 Packing and dismantling degree

DELBAG® Air Filtration packs the equipment in accordance with the chosen route and mode of
transport. The pulse filter unit is delivered in a dismantled condition.

4.2 Arrival of delivery

Please check the delivery immediately after arrival for:
• for completeness (use the check lists attached),
• for damage caused in transit.
Please inform DELBAG® Air Filtration immediately about any complaint in written form (incl. photos).

4.3 Handling

Attention!
Make sure the plant or its parts are only transported with lifting tools which are in
perfect condition and have a sufficient lifting capacity.

During transport, please also observe the instructions regarding the use of fork lifts,
cranes etc.
Please attach the plant to the intended suspension points only.
Attach ropes and hooks in such a way that the varnish and protruding parts cannot be damaged.

4.4 Storage
Until the plant is assembled, store the plant or the plant parts in a dry and safe place.
Position the parts on an even, vibration-free surface and cover them carefully.
Store the filter inserts in shelves in a dry and temperate environment.
Leave the parts in their original packing until they are needed.

5 Assembly / Installation

5.1 Installation of filter unit

To find the instructions for mechanical and electrical installation please refer to the separate
document: MO-P562095-01 “Installation and commissioning instructions”

5.2 Installing the pulse filter cartridges

• Remove the new pulse filter cartridge from the card box.
• The required fixing material, the washer, seal washer and nut, has been packed separately.
• For conical cartridges the following fixing material is delivered with the first cartridge set:
1 pc. rubber / steel washer per cartridge pair for tight sealing and centering
1 set screw, nuts, washers per cartridge pair to fix it with 20Nm

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 Before installation:
• Check of the seal ring/gasket
• Check of the filter inserts using a light. In case of damage, the beam of light shines through the
filter material
• Put the cartridge over the cartridge holder and fix it with washer, seal washer and nut on the car-
tridge bottom. By fixing the lock nut the cartridge is pressed against the cartridge bottom and
sealed airtight.
• Check the proper condition of the bolt, nut and threats.

Attention:
Make sure the cartridges are correctly positioned over the opening in the filter wall!
The cartridge must embrace the opening of the cartridge bottom completely.
The washer and the seal washer have to cover the bolt hole of the cartridge end cap
Cartridges with damaged seal ring/gasket have to be replaced as a whole.
We always recommend keeping 10 % or more of the total quantity in stock.
The permanently elastic seal on the cartridge cap guarantees reliable air density between cartridge
bottom and cartridge.
In this context see detail cartridge:

Cartridges may contract in case of installation during “warmer” temperatures and later decreasing
temperatures (e.g. installation at +1 °C, operation at –15° or lower)
The cartridge seal may be less elastic during installation at “colder” temperatures and later increasing
temperatures (e.g. installation at -1 °C, operation at +15° or higher)

-> In any case make sure that the lock nuts are re-tightened after temperature-variations!

After installation:
• Check if the cartridge is properly centered on the cartridge holder
• Check for any gaps and free spaces which would allow air to pass the filter stage
• Check the right and tight position of the rubber/ steel washer
• It is recommended to keep one set of spare cartridges in stock

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 5.3 Checks before commissioning
The plant must be commissioned only by expert personnel or by specially trained plant
mechanics.
The required checks prior to the first start-up of the filter housing are part of the assembly
and listed under "Checklist after completion of assembly".
Nevertheless, it is essential to check following things before commissioning:
Ladders, railings, gratings, platform (if available)
• carefully check if all works are finished and the safety for the maintenance and operation staff is
given
All bolted connections which were fixed during the assembly on site
• check for tightness
Filter housing
• optical check for air-tightness
• check for cleanliness and loose parts and particles
Filter elements/ filter cartridges
• check for damages
• check if all elements and cartridges are free of dirt
• check if elements/ cartridges are properly fixed and airtight
Pulse-system
• check for air leakages
• check if a compressed air supply acc. to the specifications is provided
Electric devices
• check the wiring according to the wiring scheme and local regulations
• check the proper function of all devices
Differential pressure measurement
• check all joints for tightness
• check the function of the transmitter - during the start-up, compare the indicated differential pres-
sure to the usual initial pressure drop of the filter elements/ cartridges
The unit is not operational before the assembly according to the assembly drawing and
assembly manual und all wirings according to the electrical wiring plan are finished and
checked. All systems must be operational and in proper conditions.

5.4 Monitoring of the filter system

The filter control unit serves to control and monitor the pulse filter cleaning operation.
When a preset final differential pressure (p max.: 750 Pa) has been exceeded the control sequence
is initiated. Based on pre-adjusted control times for cleaning duration and intervals all solenoid valves
are actuated in a set sequence. When the last solenoid valve in the sequence has been actuated the
cycle is repeated until the preset differential pressure ( p min.: 450 Pa) has been reached.

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 5.5 Adjustments, settings
All devices installed in the filter housing have been adjusted and their settings have been checked by
the manufacturer.

Initial pressure drop Approx. 300 Pa

Differential pressure at start of pulse 750 Pa (adjustable)
Differential pressure at end of pulse 450 Pa (adjustable)
Rec. differential pressure for replacement Approx. 750 Pa
Rec. final differential pressure Approx. 1000 Pa
Impulse Time 0,1 sec
Pulse Frequency 60 seconds

5.6 Final inspection

For final inspection check all which are listed under -> chapter 5.3 Checks before commissioning must
be performed.

6 Measuring Points of the Pulse Filter Control System

The Filter Control Box is preferable installed outside of the filter housing and measures the currently
occurring pressure difference across the filter cartridges.
Measuring point A (dust air) monitors the condition before the cartridge filter stage.
Measuring point B (clean air) monitors the condition after the cartridge filter stage.
The Filter Control System measures the differential pressure of the filter cartridges (between measur-
ing point A and B) and activates the cleaning / pulsing of the filter cartridges.
The starting point to activate cleaning / pulsing is set at 750 Pa (adjustable) and will be continued until
a differential pressure of 450 Pa (adjustable) is reached.
The alarm point for the filtering unit (pressure loss too high) is 1000 Pa.

Attention:
The control unit must only be opened by trained expert personnel.
In case safety rules are disregarded DANGER TO LIFE is imminent.

7 Operating Manual

7.1 Operator control

Check that maintenance and repairs have been completed every time you turn on the plant.
Make sure that no persons are inside the plant.
Observe the safety rules given in the different chapters of this technical documentation.

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 7.2 Start-up
Make sure that the plant is in proper condition.
• Have tools or other objects been removed from the plant?
• Are the filter inserts installed properly? Are all doors closed?
• Turn on the main switch of the control unit.

7.3 Operation
Check the pressure drop in the filters at regular intervals.
Carry out checks regularly in accordance with the inspection schedule.

7.3.1 Operating instructions

After the power supply line is connected, the filter unit is ready for continuous operation. All electric
devices and controls are working.
The rise of the pressure drops can be monitored and controlled by means of the Filter Control Box.
These checks prevent a sudden pressure rise and therefore they should be performed at least once a
day. We recommend that all values should be registered.

At the end of the cartridges lifetime, the cartridge cannot be cleaned below the preset differential pres-
sure. The result is constant pulse cleaning. At this time it is recommended to change the cartridges.
At any time cartridges shall be changed before reaching 1000Pa to prevent mechanical failure.

7.3.2 Replacement of the filter cartridges

The dust-coated cartridge is loosened by unscrewing the nut. The cartridge is pulled out of its holder.

Follow section 5.1 for installation of the new filter cartridge.

7.3.3 Disposal of filter material

Pulse Filter cartridges are disposable materials and cannot be re-used. They have to be disposed of
in accordance with their field of application and local regulations.

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 8 Maintenance
This chapter contains information about care, maintenance and repairs.

- Before entering the individual levels, the corresponding louvres (special component) must be
shut. Only one level at a time can be separated from the air flow. Then the level can be entered
and maintenance work performed.
- If work is performed on the louver motors, the motors must be disconnected from the power
supply using the maintenance button (louver main switch).

- Before entering the plant, the pulse process must also be interrupted. For this purpose, the
maintenance button (control main switch) must be operated. After the completion of the
maintenance, the plant can be released again using this button.

You can help make the plant work reliably and properly if you maintain it at regular
intervals.

In addition the plant must be subjected to a main inspection on a regular basis. This
inspection also includes components, which are not checked during maintenance.
The main inspection should be carried out by the DELBAG ® Air Filtration customer
service. Required repairs are determined with regard to the results of the main
Maintenance schedule

Component Checks Interval / Status

Filter Control, transmit- Check pressure drops Daily, during operation
ter, differential pressure
gauges
Weather louver, droplet Check if dirt or leaves/paper have set- Weekly, during operation
separator, protection tled on the surface
grid
Pulse filter Check that the pulse filter car- Weekly, during opera-
tridges sit properly and tightly tion
Compressed-air sys- Check for leaks Monthly, during oper-
tem Drain condensate ation
Solenoid valves Check function Monthly, during oper-
ation
Filter Control Check function Monthly, during oper-
ation
Filter sections and at- Check if all bolts are tight. Monthly, during oper-
tached parts Check if flange connections are ation
tight
Complete plant Maintenance without cleaning Monthly,
during standstill
Complete plant Maintenance with cleaning Every 3 months,
during standstill
Complete plant Inspection Every year, during
standstill

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 8.1.1 Maintenance without cleaning
Thorough inspection of all plant components and equipment for function and condition. As a rule, this
maintenance should be carried out monthly.

8.1.2 Maintenance with cleaning

Thorough inspection of all plant components and equipment for function and condition including the
execution of all necessary cleaning work.
As a rule, this maintenance should be carried out every 3 months.

8.1.3 Inspection
A function and performance check of all plant components and equipment, including assessment of
the general condition of the plant, should be carried out every 6 months.

8.1.4 Disposal of filter material

Pulse Filter cartridges are disposable materials and cannot be re-used. They have to be disposed of
in accordance with their field of application and local regulations.

9 Trouble shooting

9.1 Trouble shooting Filter control

9.2 Trouble shooting process engineering

Symptom Cause Remedy
Air flow disturbed Filter cartridges clogged Replace filter inserts
Air leak in the unit Tighten
Dust in the clean-air Filter cartridges do not sit tightly Check gasket/sealing
area surface, tighten
clamping nut
Filter cartridges defective Replace
No cleaning of the filter No compressed-air Check the compressed
air supply
Check gaskets
Solenoid valve does not Solenoid valve does not receive Check cables and
respond control voltage control unit
Magnet coil defective Replace coil or valve
Valve contaminated Replace valve
Filter pressure drop too Final pressure drop is reached Replace filter inserts
high
Improper setting of interval or Set correct interval time
pulse times
Operating pressure of the com- Set pressure regulator to
pressed air too low for cleaning higher pressure
Control unit does not work Check unit setting, re-
properly place if necessary
Solenoid valve defective Replace valve

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 10 Spare parts list

Use original spare parts only.

This will ensure trouble-free operation of the unit.
Please order spare parts in written form, if possible. Always specify order number and type number.
You will find those specifications on the type plate of the plant.
We recommend having the following spare parts in stock:
Selection of wear parts with the corresponding identification number.

10.1 Filter elements

Type Ident Number

Pulse filter cartridge MultiPuls 960/30/50/D13-38 DLT0903915

Name Datum
Erstellt M. Wittenborg 01.09.2016
Geprüft M. Grochowski 06.12.2016
Revision: A M. Hoffmann 11.09.2018

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 Operation and Maintenance Manual · Pulse Filter
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