11.

Guidelines on Boiler PJBF Pre-Installation Activities

Below are the Pre-installation activities which can be taken up before installation.

A) Foundation checking:

Following steps are to be followed while checking the civil foundations.

a. Extend the plant centreline / main equipment centreline (both X & Y-axis) and
bench mark (i.e. datum-line) between footings.

b. Transfer this centreline (X & Y axis) on respective footings.

c. Check the foundation bolt pockets of individual footing w.r.t. these centreline.
Repeat this procedure for all footings.
Once marking of centreline on all footings is completed, the axial and diagonal
measurements are to be checked and maintained within the tolerances mentioned
in table.

Sl. Description Allowable Deviation

No.
1 Axial measurement in X & Y + / - 5mm
axis
2 Diagonal measurement 1mm/mts or 8mm (whichever is min.)
(Overall) – In plan view
3 Diagonal measurement 1mm/mts or 8mm (whichever is min.)
(Individual footing) – In plan
view
4 Elevation + / - 10mm either side. The variation to
be adjusted either in packing pates or
by foundation chipping

Measure the axial & diagonal measurement and record it as per the format.
If the foundations bolt pocket fouls to any of the centreline, the pocket needs to be
chipped in line with the centreline measurements, to have the foundation bolt at
correct location, as per centreline requirement.

23
d. After checking & ensuring the centreline of footings, foundation bolt grouting is to
be done, as briefed below –

• Insert the foundation bolt in pockets.

• Place the template on footing, with levelled packing of approx. 50mm and bolt
the foundation bolts with template.
• To check the sufficient clearance between foundation bolt w.r.t. respective
pocket side walls, rotate the foundation bolt.
If foundation bolt is rotates freely, it indicates that there is sufficient clearance
between pocket side wall and foundation bolt.
If foundation bolt touches the pocket wall, the respective side of pocket need
to be chipped out, to have sufficient clearance between foundation bolt and
pocket wall, as briefed above.

e. After ensuring the freeness of foundation bolt in all pockets, the foundation bolts
alignment to be done. For this purpose, following steps to be followed –

i) Check & ensure that the top level of template is same as that of support
structure base plate top level, indicated in General Arrangement drawing.
Procedure for making template
After checking the foundation & its pocket’s alignment, the templates are
required to cast the foundation bolts in their respective pockets. These
templates can be fabricated using sheet / plate with min. 2.5mm thick.
Take MS sheet / plate and make the following markings.
Mark the centreline along axis XX and YY.
Mark the centre distances of the holes as per hole dimensions of support
structure base plates. Punch these centres and drill holes. The hole diameter
shall be similar to the hole size in support structure base plate.

ii) Based on above (i), calculate out the thickness of the packing plates required
to maintain the support structure base plate level and place them on the
foundation. The number of packing plates should be kept minimum by
providing the higher thickness packer to avoid multiple packing plates. These
packing plates should be stitch welded with each other, after RABH bearing
alignment and before grouting.
While placing the packing plates, ensure that minimum 50mm grouting
clearance is available between foundation top and template / support structure
base plate. If sufficient clearance is not available, foundation top face should
be chipped out to have this clearance.

iii) In this process, ensure that thread length equivalent to minimum 2.5 times of
foundation bolt diameter is kept above template (i.e. top of support structure
base plate).

24
 iv) Align the templates i.e. centre markings on templates, [with foundation bolts
(in both X & Y–axis)] with the markings on bag filter footings, made earlier
during foundation checking.
Then lock the template with foundation in such a way that the foundation bolt
alignment will not be disturbed during pocket grouting.
v) After ensuring the foundation bolt alignment and template locking, pour the
grouting cement in pocket. Always use NSG type grouting cement. While
pouring the grouting cement, keeps the foundation bolt rotating to allow
releasing the trapped air.

WHILE GROUTING THE POCKET, ONLY HALF OF THE POCKET SHOULD

BE GROUTED. This is to have little flexibility to adjust the deviations in
support structure base plate hole centres (if any), during erection of support
structure.
vi) Remove the template after grouting cement’s curing.
vii) Curing for all footings should be allowed for 5 days

Repeat such procedure for all other foundations.

f. After completing the foundation bolt grouting, check & ensure the alignment of all
foundation bolts w.r.t. axis, elevation (as referred above), diagonals (individual
footing & over all).

In case insert plates provided in place of foundation, please check the followings.

1. Sprit level of Insert plates. It should be +/- 2 mm.

2. Check elevation of all insert plate with the help of dumpy level. It should be within
10 mm. In case elevation is more than 10mm for some plates, weld MS plate
over insert plate.
3. Check centre line of insert plates. It should be +/- 5 mm.

B) Verification of the PJBF material received at site:

All Bag filter materials are dispatched in CKD condition. All these materials are
dispatched in different stages. Hence the verification is essential, prior to its
assembly and erection.
For this, all the materials must be checked w.r.t. the packing slips / loading reports
and bill of material.
Any deviation found must be informed to Thermax Ltd. Enviro Division within 7
(Seven) days from the receipt of material. In case Thermax engineer not available
at site while unloading the material, customer should verify the quantity of loose
items and wooden boxes. In case of any mismatch on quantity, the same should
be written over LR slip. In case the same is not done due to negligence, M/s
Thermax should not be responsible for short supply.

25
 C) Ground Assembly of PJBF Parts:

After verification of material, ground assembly of following Bag filter parts can be
done and kept ready for erection –
• Assembly of hopper panels.
• Assembly of modules.
• Assembly of Inlet cum bypass damper(ICBD)

General Instructions:

Prior to start the ground assembly work for PJBF , below points should be
considered well in advance.
1. Check the available material w.r.t. BOM & ensure that all items are available
at site as per BOM. In case of any shortages, inform to the concerned project
manager in Pune.
2. Arrange for the levelled ground / surface for assembly of different parts.
3. All ground assembly works are to be carried out on a levelled surface. This is
required to maintain the quality of the material being assembled.
4. Ensure the availability all needed resources like categorised manpower,
material-handling equipment like hydra / crane (of sufficient capacity), other
tools & tackles, prior to respective part’s assembly.
5. All seal weld joints must be checked for its leakages with help of kerosene
test. The brief procedure of kerosene test is explained below –

Kerosene Test:
• Apply lime paste on surface of the weld joint. Allow it to dry.
• After drying the lime paste, spray kerosene from bottom side of weld joint
• Any missed out welding / blow hole etc. will be indicated by a wet patch on
the lime paste.
• Based on the weld defects, trace out the defects and repair it by grinding and
welding. After repair, do the testing again at repaired locations. It is advisable
to carry out leak test as soon as the welding is completed and before the
scaffolding / staging are removed from a particular area.
• The welding portion which are checked and found ok during assembly stage
need not to test again after erection.
Similar procedure of kerosene should be followed for site weld joints.

Following are the brief procedure about the assembly of above parts

Hoppers panels assembly

a. All hopper parts (except bottom portion) are supplied in CKD condition, for
easy transportation of hopper parts.
b. For reference, refer hopper assembly drawing.

26
 c. While doing the ground assembly, sufficient ground clearance (approx.
800mm) shall be provided between levelled surface and hoppers bottom
edge, for access (for man & cables) & also for proper ventilation inside
hopper, during assembly. Assembly bed can be prepared with ISMB 300
and 6 mm thick plate.
d. Place and assemble the hopper panels as per referred drawing.
e. While assembling the hopper, ensure that all inside pipe supports are
provided at correct locations, shown in referred drawing.
f. Prior to start the seal welding, check and ensure that hopper opening
dimensions are correct, as per drawing and are within acceptable
tolerances. (For axial dimensions the variations should be within +/- 5mm
and diagonal dimensions should be +/- 8mm).
g. After seal welding, all seal weld joints are to be checked for any visual
welding defects (e.g. blow holes /left out welding spots) and to be rectified.
h. After weld defect rectification, all weld joints are to be tested for its
leakages by kerosene test method.

The above procedure shall be followed for assembly of other hoppers.

All the assembled hopper parts are to be stacked properly on a levelled
surface, with wooden packing. This is required to avoid the defects to
assembled components while they are stacked. Provide additional temporary
stiffeners if required for strengthening.

Ground assembly of hoppers

Assembly of Modules.

a. Normally casings are supplied in assembled condition. However if the

Bag filter size is big then, casing panels’ parts are supplied in CKD
condition, for easy transportation.
b. For reference, refer Module assembly drawing (which is sent separately).
Place the small casing panel’s parts side by side and join and aligned

27
 them nut bolts. Match distance and diagonals as per drawing. Do
necessary welding at split joints. Now one full panel is ready. Likewise
make all 4 panels in a particular chamber.
c. Make the box / module with other remaining 3 panels. Necessary
temporary pipes are to be provided for rigidity.
d. Make alternate modules by the above process.
e. Prior to start the vertical seal welding, check and ensure that module
opening dimensions are correct, as per drawing and are within acceptable
tolerances. (For axial dimensions the variations should be within +/- 5mm
and diagonal dimensions should be +/- 8mm).
f. After seal welding, all seal weld joints are to be checked for any visual
welding defects (e.g. blow holes /left out welding spots) and to be rectified.
g. After weld defect rectification, all weld joints are to be tested for its
leakages by kerosene test method.

The above procedure shall be followed for assembly of other modules.

All the assembled modules parts are to be stacked properly on a levelled surface, with
wooden packing. This is required to avoid the defects to assembled components while
they are stacked.
If required provide additional temporary supports for further strengthening while shifting.

Assembled Casing at ground

Assembly of ICBD

ICBD has following parts and the same are getting despatched in CKD form.

1. Damper plenum or casing

2. Damper flap
28
 3. Mild Steel shaft
4. Poppet damper’s supporting frame
5. Pneumatic cylinder
6. Glands.
7. Locking nuts & bolts --- longer one for coupling flap and MS shaft.

Assembly activities for ICBD are as follows:---

1. Place the damper plenum over assembly bed and lock it with temporary supports
after checking the verticality.
2. Place the damper flap inside and over the ring.
3. Place the supporting frame over damper plenum.
4. Slide MS shaft through the supporting frame. Flat collar welded with MS shaft
should be located in-between angle frame.
5. Place the top part of supporting frame and bolt the same after checking the spirit
level.
6. Lock the MS shaft with flap with longer bolt. Bolt should be hand tightened and
tack weld the same so that nut should not came out.
7. Manually lift the MS shaft 3-4 times to ensure smooth movement of shaft. This
automatically aligns the MS shaft with supporting frame. Tack welds the
supporting frame.

Now this assembly is ready for installation. Install the pneumatic cylinder after placing
the assembly in it’s proper place. With pneumatic air check the smooth movement of MS
shaft. Once that is ensured, full weld the supporting frame with damper plenum.

Ground assembled ICBD

29
 12 : Boiler Bag filter installation sequence and standard Bar Chart.

Sequence of Installation of components for Boiler PJBF are given below :

1. Supporting Structure installation and alignment. Protocol making. In case PJBF is

to be installed over Insert plates in RCC structure, levelling and centre distances
between plates are to be checked as per drg.
2. Hopper frame installation and alignment. Protocol making.
3. Hopper installation and alignment.
4. Hopper to hopper frame seal welding.
5. Modules erection and alignment. Assembly of modules can be done at ground if
the size is big and then full module can be erected by crane.
6. Inter Modules seal welding.
7. Seal welding of hopper frame to casing bottom.
8. Staircase and platform installation and full welding wherever required.
9. Installation of inlet duct plenum. This activity is required if duct plate sent in CKD.
10. Outlet top duct placement and alignment (for bigger bag filter).
11. Complete seal and stitch welding of all above duct plates as per front availability.
12. Installation of ICBD with pneumatic cylinder.
13. Installation of Air header and alignment.
14. Fixing of Pulse valve and rubber hoses. Hoses should be perfectly straight down.
15. Pneumatic line installation with pressure regulator in main line and lubricator in
ICBD’s pneumatic line.
16. Duct Disposal system installation.
17. Necessary Bag filter’s inlet and outlet ducting.
18. Installation of field mounted instruments.
19. Complete thermal insulation.
20. Bag fixing. This is to be done before commissioning and in presence of
Thermax’s engineer only.
21. Necessary electrical and instruments cablings and termination.
22. Pre-commissioning activity.

Normally a standard Boiler bag filter took 15 to max.20 days time for total installation and
commissioning
There should be 2 different gangs.

• Manpower for Assembly work at ground level. It should have a fitter gang with
necessary backup man power.
• Manpower for installation activity. It should have 2 fitter gangs with necessary
manpower back up in each gang. It also should have 2 good rigger gangs also.

30
 13. Guidelines on PJBF mechanical Installation -- Component wise and
field quality assurance plan (FQAP)

A) Supporting Structure :

Before starting of the erection activities, check the supporting structure well in advance
so that any correction required can be taken at ground.

First check the datum line. Mark the datum line always from the top plate. This is to
ensure that when the supporting structure is levelled the entire column top is in the same
elevation. Mark the datum line by centre punch on all four sides. Check the column for
straightness by line thread. Bow allowed is + / - 5 mm. If the bow is more than this,
columns are to be straightened by jib screw. Check the base plates holes for hole
diameter, pitch and diagonals. If the base plate holes are out of diagonals, the only way
to erect the column is by gas cutting the holes. If the holes are gas cut a washer of at
least 16 mm thickness with drilled holes should be full welded to the base plates.

Erect the column. In the some case the columns can be assembled in ground also.
While assembling in ground the following precautions are to be taken.

Assemble the columns on levelled surface / platform. Column should be assembled in

pairs. Check the following :

I) The distance between column to column.

Ii) Diagonal within + / - 5 mm.
Iii) Dimensions and diagonal of base plate holes. No twist of the base plate should
be allowed. If the base plates are found with twist, nullify them by gas cutting and
re-welding.

Erect the assembled column on the foundation pedestal. For alignment purpose and
keeping the elevation as required some packing plates will have to be given between
civil foundation and the base plate of the supporting structure. The place where the
packing plates will sit on the civil foundation should be chipped and made plain.

After the columns are assembled with cross bracings and horizontal bracing full weld
them. Care must be taken to ensure that no welding distortion takes place.

After levelling the columns plumb it. The admissible tolerances is 1 mm per meter, not
exceeding 10 mm whatever be the height of the column.

Protocol of the alignment should be signed jointly by Thermax engineer and customer.
When columns are straight but out of plumbs, we can bring it to plumb by giving proper
packing. Ensure that all columns tops are in the same level. After alignment, give
clearance for grouting.

31
 B) Hopper frame Installation:

• Normally Hopper frame supplied fitted with hopper. However for big bag filter
where hopper supplied in CKD, frame installation can be carried out over
supporting structure. Check water level at different place. This should be within +/-
3 mm. Weld the frame with supporting structure.
• Hopper frame box between two adjacent modules are to be full welded from top.

C) Hopper Installation:

Small hoppers can be placed directly over supporting structure. However for bigger
hoppers sequence of installation procedure is as follows:-

• Install pre-assembled hoppers at four corners one by one and then install hoppers
at LHS and RHS side in sequence. This will ensure uniform loading over hopper
frame.
• Align hopper top part with hopper frame and carry out necessary tack welding with
hopper frame
• While installing the hopper, ensure that the diagonals at the top and bottom and
the diagonals between the top corner and the bottom corner match. While doing
the seal welding, leave 300 mm from the top without welding. This is for any
adjustment at the time of fit up of the hopper to the hopper frame. This welding
can be completed after full fit up of the hopper to the hopper frame.
• Carry out kerosene test at all site welded joints to ensure leak proof ness of
welding.
• Ensure that discharge opening of all the hoppers on one side is in the same line
and elevation. It is always advisable to erect the hopper with the access door
fixed.

.
D) Installation of Modules :

Performance of a bag filter fully depends on the proper installation and seal welding of
the modules. After hopper installation, module erection can be taken up. Normally entire
Module can be lifted with crane to place over hopper frame. Seal weld the hopper to
casing joint. Bolting arrangement on casing panel provided for assembly and alignment
purpose.

E) Erection, alignment and welding of staircase & working platforms with

Access doors.

After completion of module alignment and welding, staircase and platform installation
can be started. Stair case installation in this stage is very important to have a proper
access..

32
F) Installation of ICBD

After casing installation, ICBD can be lifted and placed at bag filter inlet. It is normally
held in position by bolting. Necessary gasket arrangement is to be provided at flanged
joint.

G) Dust Disposal system installation:

Dust disposal system mainly consists of :

1. RAV
2. Screw conveyor / Drag Chain Conveyor.

1. ROTARY AIR LOCK VALVE :

Normally we supply 350 NB RAV which has a capacity of 30 m3/ hr discharge rate which
means around 25 TPH discharge rate for ash. While erecting the RAV, care must be
taken to ensure that no foreign material, scrap is trapped inside. Keep the RAV inlet
closed temporarily till all the activities inside the hopper are completed. Check motor
blade up & body.

Before running the RAV check for the oil in gearbox.

33
2. SCREW CONVEYOR / DRAG CHAIN:

Normally, screw conveyors are connected to the RAVs through an expansion joint and a
discharge chute. Check for the expansion provision on screw conveyor supports.

3. MOTORISED DOUBLE FLAP DUMP VALVE :

At times this is used in place of RAV. The two flaps, one above the other are operated by
cam mechanism. First the top flap opens admitting the hopper dust in valve body
between two flaps. Then the top flap closes and after a few seconds the bottom flap
opens discharging the material. Cam is driven by a geared motor, mounted on the valve
itself, thus avoiding special foundation for the motor.

Flap shaft and body sealing is by the compression glands. Counterweight attached at the
other end of flap shaft ensures positive seating of flap in the body minimizing the
leakage. The flap shafts are mounted on the anti-friction bearing pillow blocks. Overall
construction of the valve is very rugged to sustain rough operating conditions in the field.

H) Installation of Pulse jet type cleaning arrangement

There are four main components involved for cleaning arrangement:

• Sequential controller box.
• Pulse-Sol.valve with pipe & hose assembly
• Air header

34
 • Manifold pipe assembly

Installation procedure:--
1. While installation of air header, first fix the pulse valve assembly at two
ends of air header. This will help to align the pulse pipe with manifold bend
pipe. Lock the header with U clamps with Z bracket and weld the same.
2. Installation of other pulse valves. Rubber hose should be perfectly in
straight position.

Blow pipe arrangement over tube sheet Header positioning w.r.t. external blow pipe

Pulse valve with rubber hose Pulse valve

3. Installation of sequence controller box above air header with the help of
angle support. Assembly should be located at the centre of air header.
35
I) Pneumatic Piping :

Pneumatic piping installation can be taken up after completion of the mechanical

erection. Care must be taken to ensure that all joints are properly sealed by welding. Do
not use Teflon tape.
Welding should be done only after full assembly of the piping. After completion of
assembly of the pipes test it for any leakage at 5 kg/cm2 pressure. Before connecting
the instruments / equipments to the pipe, flush the whole pipe line for at least half an
hour at 5 kg/cm2 pressure. This is to remove all dirt / rust from the pipes which if enters
the instruments / equipments can do irreparable damages to the same. For all joints
other than welded joint like coupling, valves use hole tight. Do not use teflon tape.

Necessary Filter Air Regulator and Lubricator unit is to be installed for lubricating the
pneumatic cylinder.
Air pressure is to be maintained at 5 kg/cm2 for Non woven bags and 3.5 kg/cm2 air
pressure for woven glass bags. More pressure at 6 to 7 kg/cm2 can cause air seal
damages in long run.

J) Insulation :

Once Air leak test is over, insulation fixing work can be started. Full casing, hoppers,
ICBD and inlet duct has to be insulated.
Below is the sequence of procedure for insulation work

36
 • Insulation lug should be fixed prior to bag fixing. Make sure that there is no hole
on casing wall while welding lugs. Keep provision for insulation air gap of min. 50
mm.
• Apply insulation wool as per specification given in drawing.
• Do necessary cladding.
• Refer separate drawing for details.

K) Bag fixing :

The bags are of two types.

i) Collar type bags:--This consists of filter bag, cage and venturi. The filter bag is
supported on a cage, which is clamped to the top of the tube sheet and extends down
into the compartments, supporting the full length of the bag. The cage has flange at the
top and base cup at the bottom. Each bag is clamped by different hold down washers.
The venturi specially designed for the quantity of air flowing through it, is inserted in the
cage. The collar of the bag, which is clamped between the cage and tube sheet, serves
as a seal between the clean and dirty gas side of the bag filter. Bag removal with the
cage is from the top, through the tubesheet.

ii ) Snap Ring type bags:--These type of bags have ring made of spring steel at the top.
They get hooked to tube sheet by means of spring action. The cage is resting with bag.
The venturi is installed into cage. The typical sketch is shown as below.

37
Bag fixing is the last and final activity. This is the most critical activity also. Bags are the
most delicate part and hence all care must be taken to ensure that bags are handled
very carefully and any chance of damages, puncture to the bag should be avoided. No
smoking should be allowed inside the module at the time of bag fixing as fire, spark etc
can damage bag. Even a pin hole on the bag, should be avoided. A pin hole on bag in
course of time can get enlarged and subsequently the bag will be damaged. Module
cleaning off scrap, debris should be completed before fixing the bag. No cutting, welding
and grinding activity should be allowed inside a module after the bags are fixed / taken
inside. Bags are despatched to site in card board boxes. Bag fixing arrangement
consists of the following components:

1) Cages
2) Ventury
3) Bag holding washer with nut ------ for collar type bags

Procedure for Snap ring type bag fixing :

• First clean the tube sheet top. Check for any sharp edges over tube sheet hole. If
any rough edges found, clear it with round file.
• Insert the bag through the tube sheet hole. Grab the bag as shown below.
38
 • Now align the groove portion of snap ring with tube sheet as shown below

• Push bulge in snap band outward- bag should snap into place. The entire groove
portion should get fitted into tube sheet. Try to rotate the bags. If bags are not
rotating, clamping is assumed done perfectly.

BAG FIXING SHOULD BE CARRIED OUT IN PRESENCE OF THERMAX ENGINEER

ONLY. IF NOT, THERMAX WILL NOT BE RESPONSIBLE FOR REPLACEMENT OF
DAMAGED BAGS WHICH MAY OCCUR DUE TO MIS HANDLING.

39
 INSTALLATION AND OPERATING CARE FOR FILTER BAGS

1. Filter bags are a delicate material and one should take extra care while handling
these bags. Multiple handing or mechanical rubbing should be kept to be kept to
minimum while fixing these bags in unit.
2. While fixing the bag check the smoothness of tube sheet holes and ensure that no
burr is left on the bag hole.
3. Insert the bag and press the bag-snap ring to kidney shape. Locate the snap-ring
and press the snap ring on the bag hole ensuring firm gripping of bag.
4. Insert the cage slowly and slide it down. Ensure that no jerks are given while
inserting cage and it slides smoothly into the bag.
5. See internally that bag bottoms are not touching each other. In such case remove
such cage and rotate by 90 degree.
6. During removal of the bag for replacement remove the compartment manifold of
compressed air inside the bag filter.
7. Slide the cage out from the top. If there is resistance for easy sliding of cage, hold
the bag from bottom, with the help of hooks at bottom.
8. For Collar type of bag, insert cage in new bag and make sure that the collar of
bag is properly folded below the flange of cage.
9. Tighten nuts and hold-down washers for securing bags in place. Place venture
over cage opening.
10. Do not apply excessive force to cage, while removing it must slide out easily,
without wrinkle formation on bag.
11. Press snap ring and remove bag for checking/inspection/replacement.
12. Install the bag back as per the procedure explained above.
13. Seek for expert advice for any trouble. Undue forces applied while handling the
bags may damage the bag permanently.

40
 14. Electrical and Instruments installation

Following instruments are used for Boiler Bag filter. All instruments are to be fixed in it’s
proper location described below

• Water tube manometer / DP gauges/ Magnehelic Gauge: For measuring the

differential pressure between
(a) Hopper and modules, one line is to be connected to module and other to
the hopper.
(b) Inlet and Outlet. One line is to be connected to the inlet of PJBF and other
to the outlet of PJBF

• DP Transmitter: This instrument given DP reading across module or across Bag

filter in DCS. Cleaning operation started based on this DP reading. One line is to
be connected to the outlet and other line to Inlet. Taping should be only at the top
face of duct

• D.P. switch: It gives an alarm in DCS if DP across module exceed set limit. One
line is to be connected to module and other to the hopper. Module line is
considered as LP line and Hopper line is considered as HP line. Setting should be
at 150 mm WC.

• Hopper Level Switches. : It gives alarm in DCS if dust level reaches beyond
probe level. It should be fixed 500 mm above the hopper access door level is
approachable location. Probe should be 60 degree taper inside hopper facing
downward.

41
• Zero Speed switches: It gives alarm in DCS and stops RAV motor if there is
jamming or chain snapping or sprocket’s slippage.

• Thermostats: It automatically OFF or ON the starter for heating pads. Normally

set point is 800C and once the hopper inlet temperature reaches beyond. Location
of installation could be beside hopper level sensor.

ZSS hook up assembly Thermostat fixing hook up

Hopper heater fixing arrangement Pressure switch fixing arrangement

• Inlet RTD : These are temperature indicating sensors gives Bag filter inlet
temperature. Location should be 2 mtrs away from ICBD chamber in the inlet
duct.
• Limit switches: These are used for OPEN/CLOSE indication for poppet dampers.
Location could be suit to site after checking the damper movement.

42
 • Sequence controller card : The programmed sequential controller gives the
signal, based on a fixed time basis, which actuates the solenoid coil, which
in turn opens the pulse valve. The blast of compressed air is admitted at the
top of the bag through a compressed air pipe (compartment manifold) and
specially designed venturi. One signal helps in cleaning all the bags in one
row. Followed by OFF TIME; after which the second row is cleaned with a
pulse of compressed air, the operation is repeated till all the rows are
cleaned. The time during which the pulse is operated is generally called
pulse duration or ON TIME. OFF TIME is the time between two consecutive
ON TIME. It is also known as Pulse Frequency. ON TIME : 20 to 200 msec.
& OFF TIME : 2 to 60 sec.

All the above instruments are to be erected as per the hook up diagrams. All the socket
provisions for these are to be completed before application of insulation.

FAULT FINDING AND REMEDIES :

SR. CORRECTION /
FAULT CAUSE
NO. ACTION
1. Check 1 Amp. 1. Replace fuse if
Power switch ON but Neon (mains) and
1. fuse. 2. Loose faulty. 2. Do firm
controller not working.
mains connections connections.
Replace if faulty or
2. Power ON mains LED not glows. Check 1 Amp fuse. tighten fuse cap
firmly.
Electrical PH & N
Equipment give shocks when touched to Connect PH To PH
3. are not connected
electronic parts. and N to N (cold).
properly.
Clear any short
Short circuit in
circuit or replace
4. 1 Amp. fuse F1 blows off frequently. solenoid or solenoid
faulty solenoid by
or solenoid line
new one.

TECHNICAL SPECIFICATIONS FOR 10 WAY MICRO CONTROLLER BASED

SEQUENTIAL TIMER CARD
Sr.No. Description Details
1. Item 10 way Micro controller Base Sequential Timer Card
2. Application To provide timed seq. energisation of pilot Solenoid valve
Detail of controller
3.
(PCB)
4. Input supply 110V AC or 220V AC*, 50 or 60 Hz.
4.1 Output 110V AC or 220V AC, To pulse sol. valve
4.2 Input fuse ( Enclosed 1Amp. 110, 220V AC, (Glass 20mm)
43
 Type )
4.3 On Time 20 to 200 milliseconds
4.4 Off time 2 to 60 seconds.
Number of sequence
4.5 1 to DJ. through flying Lead
steps
4.6 Temp. Range operation O0 to 550 C
4.7 Current ratting per seq. :
a) Maximum Inrush
4.8 10 Amps.
current
b)Max. continuous 2 Amps. (1”, 2 Nos.(Max. of Solenoid valves per channel
current **)
4.9 Mains Isolation switch Provided on PCB
PR. SW. terminals (P1,P2) sequence controller stops
On demand control when contact at PR. SW. opens.(PR. LED glow, & clock
4.10
(Pressure sw. contact) LED steady on) seq. continues from point where It had
stopped, when contact recloses.
4.11 Led visual indications :
a) Power on
1 no. LED (5 mm- RED COLOR)
indication
b) Output on indication 10 nos. LED (5 mm - RED COLOR )
c) On demand mode 1no. LED (5 mm - RED COLOR)
d) Manual pulsing 1no. LED (5 mm - RED COLOR)
5. Manual pulsing Facility provided (P. B. SW)
6. Feed back relay Potential free contact, 5A @230V AC
Single side, Green masked, ident, with anti corrosive spray
7. PCB Details :
coating.
a) P.C.B. dimensions 215 (L) x 145mm (W) x 50 (D) mm
b) P.C.B. mounting
205 (L) x 135 (W) mm (mounting holes 4 nos.4mm)
size
8. Enclosure details Type- IP-55, siemens grey powder coated
b) Enclosure over all
360 (W) x 315 (H) x 150 (D) mm
size

Note : Supplied as 110V AC only or 220V AC only. Only solenoid makes ASCO must be
used which are pulse duty. Bag filter application Solenoids. MANIUS/ NORGEN
HERION/ ROTEX

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