Sha 14 M - C05 MM 100 A

MM
SHA 14 M --- C05 MM 100, Rev A. Page 1 of 361
abcd
KKS-No
14
14
14
14
14
14
14
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14
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14
PAB
PAB
PAB
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PAB
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Shoaiba Steam Power Plant

Stage III
Doc. No. : SHA 14 M---C05MM100
Cust. Doc. No.: 14-P-M-35243
Revision: A
MAINTENANCE MANUAL
List of documents
Designation / Type
Type of document
Document No.
Revision
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Operation & Maintenance Manual

Sectional drawing / Parts list
General Arrangement Drawing
Signal Exchange list
Cable Schedule
Electrical Load List
Piping & Instrumentation Diagram
Wiring Diagram
System Description
Handling Drawings
Lubrication Schedule
Data Sheet
Data Sheet
Data Sheet
Data Sheet
SHA/14/M/---C05/MM/001
SHA/14/M/---C05/DD/001
14-P-M-35139
SHA/14/M/---C05/IO/001
SHA/14/M/---C05/LC/001
SHA/14/M/---C05/EL/001
SHA/14/M/---C05/FD/001
SHA/14/M/---C05/WD/001
SHA/14/M/---C05/DM/001
SHA/14/M/---C05/MD/003
SHA/14/M/---C05/DS/100
SHA/14/M/---C05/DS/001
SHA/14/M/---C05/DS/002
SHA/14/M/---C05/DS/003
see 14 PAB 41AA015
B
A
H
C
B
D
C
E
B
A
A
B
D
C
41
41
41
41
41
41
41
41
41
41
41
41
41
41
41
AT
AT
AA
AA
010
010
015
201
14 PAB 41
CP
010 Condensor Debris Filter- Pressure Transmitter /1151 DP4
Taprogge
Data Sheet
SHA/14/M/---C05/DS/004
14 PAB 41
001 Condensor Debris Filter- Actuator
Taprogge
Data Sheet
SHA/14/M/---C05/DS/005
14
14
14
14
14
42
42
42
42
41
AT
AT
AA
AA
010
010
015
201
14 PAB 42
CP
see 14PAB41CP010
14 PAB 42
see 14PAB41M001
PAB
PAB
PAB
PAB
PAB
13 PAB 41
Condensor Debris Filter System

Debris Filter- Condenser & CCW Exchanger
Condensor Debris Filter/PR-BW 800
Condensor Debris Filter- LV Motor/ RA500/280
Condensor Debris Filter- Valves/DN 350
Condensor Debris Filter- Valves /DN 50
Supplier

see 14PAB41
see 14PAB41AT010
see 14PAB41AT010
see 14PAB41AA015
see 14 PAB 41AA015
see 14PAB41
page: 1/5
Issued:
Supplier :__________
Checked and released:


Consortium member :__________
abcd
KKS-No
13
13
13
14
PAB
PAB
PAB
PAB
MAINTENANCE MANUAL
List of documents
Designation / Type
Supplier
Type of document
Document No.
41
41
41
41
AT
AT
AA
AA
010
010
015
201
13 PAB 41
CP
see 14PAB41CP010
13 PAB 41
see 14PAB41M001
13
13
13
13
14
42
42
42
42
41
AT
AT
AA
AA
010
010
015
201
13 PAB 42
CP
see 14PAB41CP010
13 PAB 42
see 14PAB41M001
12
12
12
12
14
41
41
41
41
41
AT
AT
AA
AA
010
010
015
201
12 PAB 41
CP
see 14PAB41CP010
12 PAB 41
see 14PAB41M001
12
12
12
12
AT
AT
AA

010 Condensor Debris Filter/PR-BW 800
010 Condensor Debris Filter- LV Motor/ RA500/280
015 Condensor Debris Filter- Valves/DN 350
see 14PAB41
see 14PAB41AT010
see 14PAB41AT010
see 14PAB41AA015
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
42
42
42
42


Stage III
Cust. Doc. No.: 14-P-M-35243
Revision: A
Revision
see 14PAB41AT010
see 14PAB41AT010
see 14PAB41AA015
see 14 PAB 41AA015

see 14PAB41
see 14PAB41AT010
see 14PAB41AT010
see 14PAB41AA015
see 14 PAB 41AA015

see 14PAB41
see 14PAB41AT010
see 14PAB41AT010
see 14PAB41AA015
see 14 PAB 41AA015
page: 2/5
Issued:


abcd
KKS-No

Stage III
Cust. Doc. No.: 14-P-M-35243
Revision: A
MAINTENANCE MANUAL
List of documents
Designation / Type
Supplier
Type of document
Document No.
14 PAB 41
AA
201 Condensor Debris Filter- Valves /DN 50
see 14 PAB 41AA015
12 PAB 42
CP
see 14PAB41CP010
12 PAB 42
see 14PAB41M001
14
14
14
14
14
14
14
14
14
14
14
14
14
14
15
15
15
15
15
15
15
15
15
15
15
15
15
15
AT
AA
AA
010
016
201
14 PCB 15
AT
010
14 PCB 15
CP
010
14 PCB 15
002
AT
AA

CCW Exchanger Debris Filter System
010 CCW Exchanger Debris Filter/PR-BW 100
016 CCW Exchanger Debris Filter- Valves/DN 150
14
14
14
14
14
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
16
16
16
16
16

CCW Exchanger Debris Filter/PR-BW 100
CCW Exchanger Debris Filter- Valves/DN 150
CCW Exchanger Debris Filter- LV Motor /SK02F-IEC80L/4
CCW Exchanger Debris Filter- Pressure
Transmitter/1151 DP4
CCW Exchanger Debris Filter- Actuator
Revision
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge

Sectional drawing / Parts list
Piping & Instrumentation Diagram
General Arrangement Drawing
Signal Exchange list
Cable Schedule
Wiring Diagram
System Description
Handling Drawings
Data Sheet
Data Sheet
Data Sheet
SHA/14/M/---C05/MM/002
SHA/14/M/---C05/DD/002
SHA/14/M/---C05/EL/002
SHA/14/M/---C05/FD/002
14-P-M-35140
SHA/14/M/---C05/IO/002
SHA/14/M/---C05/LC/002
SHA/14/M/---C05/WD/002
SHA/14/M/---C05/DM/002
See 14 PAB 41
See 14 PAB 41
SHA/14/M/---C05/DS/011
SHA/14/M/---C05/DS/013
See 14 PCB15AA016
B
A
D
C
G
C
B
G
B
Taprogge
Data Sheet
SHA/14/M/---C05/DS/012
Taprogge
Data Sheet
SHA/14/M/---C05/DS/014
Taprogge
Data Sheet
SHA/14/M/---C05/DS/015
Handling Drawings
See 14 PAB 41
See 14 PAB 41
see 14PCB15
See 14 PCB15AT010
See 14 PCB15 AA016
B
C
page: 3/5
Issued:


abcd
KKS-No
14 PCB 16
AA
14 PCB 16
AT
14 PCB 16
CP
14 PCB 16
13
13
13
13
13
13
Designation / Type
AT
AA
AA
010
016
201
13 PCB 15
AT
010
13 PCB 15
CP
010
13 PCB 15
002
PCB
PCB
PCB
PCB
PCB
PCB
Supplier
Type of document
201 CCW Exchanger Debris Filter- Valves/DN 50

CCW Exchanger Debris Filter- LV Motor /SK02F-IEC010
80L/4
010
002 CCW Exchanger Debris Filter- Actuator
15
15
15
15
15
15
13
13
13
13
13
13
PCB
PCB
PCB
PCB
PCB
PCB
MAINTENANCE MANUAL
List of documents
16
16
16
16
16
16
AT
AA
AA
010
016
201
13 PCB 16
AT
010
13 PCB 16
CP
010
13 PCB 16
002

Stage III
Cust. Doc. No.: 14-P-M-35243
Revision: A
Document No.
Revision
See 14 PCB15AA016
See 14 PCB15 AT010
See 14 PCB15 CP010
See 14 PCB15 M002

Handling Drawings

Handling Drawings
See 14 PAB 41
See 14 PAB 41
see 14PCB15
See 14 PCB15AT010
See 14 PCB15 AA016
See 14 PCB15AA016
See 14 PCB15 AT010
See 14 PCB15 CP010
See 14 PCB15 M002
See 14 PAB 41
See 14 PAB 41
see 14PCB15
See 14 PCB15AT010
See 14 PCB15 AA016
See 14 PCB15AA016
See 14 PCB15 AT010
See 14 PCB15 CP010
See 14 PCB15 M002
page: 4/5
Issued:


abcd
KKS-No
12
12
12
12
12
12
Designation / Type
15
15
15
15
15
15
AT
AA
AA
010
016
201
12 PCB 15
AT
010
12 PCB 15
CP
010
12 PCB 15
002
12
12
12
12
12
12
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
MAINTENANCE MANUAL
List of documents
16
16
16
16
16
16
AT
AA
AA
010
016
201
12 PCB 16
AT
010
12 PCB 16
CP
010
12 PCB 16
002
Supplier

Stage III
Cust. Doc. No.: 14-P-M-35243
Revision: A
Type of document
Document No.

Handling Drawings
See 14 PAB 41
See 14 PAB 41
see 14PCB15
See 14 PCB15AT010
See 14 PCB15 AA016
See 14 PCB15AA016

Handling Drawings
Revision
See 14 PCB15 AT010

See 14 PCB15 CP010
See 14 PCB15 M002
See 14 PAB 41
See 14 PAB 41
see 14PCB15
See 14 PCB15AT010
See 14 PCB15 AA016
See 14 PCB15AA016
See 14 PCB15 AT010
See 14 PCB15 CP010
See 14 PCB15 M002
page: 5/5
Issued:


02.06.2010
Schmidlin
Gller
19.10.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
APPROVED
Revised acc. clients comments
FUS
First issue / Preliminary
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT
SHOAIBA POWER PLANT STAGE III

CONTRACT No. 20821102/00
CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
MP
Title :
Language
:E
for
Consortium Participant or Subcontractor Document No. : N/A
abcd
Condenser Debris Filter

No of
sheet : 87
Power Systems
Sheet :
Plants
Alstom document no :
SHA/14/M/---C05/MM/001
Client Document No. :
SHA/14/M/---C05/ MM/001
Rev. A
Maintenance manual number :
SHA/14/M/---C05/MM/001
Equipment component code :
See equipment schedule
Equipment description :
Filter System
Subcontractor name :
Taprogge
Subcontractor document N. :
K2009/20/1367
List of contents
1.
EQUIPMENT DESCRIPTION & OPERATING INSTRUCTIONS ..................................................................... 5

1.1. Task and function description of the TAPROGGE filter system ............................................................... 5
1.1.1.
Task of the TAPROGGE filter system ..........................................................................................................5
1.1.2.
Function description of the TAPROGGE filter system ................................................................................6
1.2. Description of the filter system .................................................................................................................. 10
1.2.1.
Assembly Debris Filter ................................................................................................................................10
1.2.1.1.
Debris Filter PR-BW 800 .......................................................................................................................10
1.2.1.2.
Differential pressure measuring system ...............................................................................................12
1.2.1.3.
Gear motor..............................................................................................................................................14
1.2.2.
Discharge valve ...........................................................................................................................................15
1.2.3.
Control ..........................................................................................................................................................16
1.3. Operating instructions................................................................................................................................ 19
1.3.1.
General .........................................................................................................................................................19
1.3.1.1.
Definition of basic position .....................................................................................................................20
1.3.2.
Description of operating modes ..................................................................................................................21
1.3.2.1.
Operating mode AUTOMATIC LOCAL .................................................................................................21
1.3.2.2.
Operating mode MANUAL .....................................................................................................................22
1.3.3.
Pre-commissioning settings and checks....................................................................................................23
1.3.3.1.
Testing and setting of the control panel ................................................................................................24
1.3.3.2.
Dry function test......................................................................................................................................26
1.3.3.3.
Commissioning of the actuators ............................................................................................................27
1.3.3.3.1. Pneumatic actuator of discharge valve ............................................................................................27
1.3.3.3.2. Gear motor for backwash rotor .........................................................................................................27
1.3.4.
Commissioning of the filter system.............................................................................................................28
1.3.4.1.
Flooding of the debris filter ....................................................................................................................28
1.3.4.2.
Venting of the differential pressure measuring system ........................................................................28
1.3.4.3.
Commissioning of the differential pressure measuring system ..........................................................29
1.3.4.4.
Functional test of the control and setting of the limit values at the differential pressure measuring
system
30
1.3.4.5.
Filter system start-up..............................................................................................................................32
1.3.5.
Operation of the filter system ......................................................................................................................33
1.3.5.1.
Routine filter operation (AUTOMATIC): ................................................................................................33
1.3.5.2.
Filter backwash in the operating mode Automatic ...............................................................................34
1.3.5.2.1. Programme "filter backwash"............................................................................................................35
1.3.5.2.2. Programme "filter extended backwash" ...........................................................................................36
1.3.5.3.
Filter backwash in the operating mode MANUAL ................................................................................37
1.3.6.
Filter system shut-down ..............................................................................................................................38
1.3.7.
Measures to prevent corrosion due to stagnation .....................................................................................39
1.3.8.
Filter system restart after shut-down ..........................................................................................................40
1.3.9.
Operating Record ........................................................................................................................................41
Originator
Identification number
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
2/87
ALSTOM 2006. All rights reserved.

Rev. A
1.3.10.
"Indication" and Operation"; Operator terminal screens ...........................................................................43
1.3.11.
Operational trouble-shooting.......................................................................................................................44
1.3.11.1. Backwash rotor fault...............................................................................................................................45
1.3.11.2. Fault of actuator of discharge valve ......................................................................................................46
1.3.11.3. Fault of differential pressure measuring system ..................................................................................47
1.3.11.4. p EXCESSIVE HIGH ...........................................................................................................................48
1.3.11.5. Voltage breakdown.................................................................................................................................49
1.3.11.6. PLC fault .................................................................................................................................................50
1.3.11.7. Battery low ..............................................................................................................................................51
2. ENVIRONMENTAL, HEALTH AND SAFETY .................................................................................................. 52
3. MAINTENANCE ................................................................................................................................................. 53
3.1. Preventive maintenance ............................................................................................................................ 53
3.1.1.
PREVENTIVE MAINTENANCE INSTRUCTIONS ....................................................................................53
3.1.1.1.
Debris filter ..............................................................................................................................................54
3.1.1.1.1. Filter section .......................................................................................................................................55
3.1.1.1.2. Backwash rotor ..................................................................................................................................56
3.1.1.1.3. Backwash pipe ...................................................................................................................................57
3.1.1.1.4. Rotor actuation...................................................................................................................................58
3.1.1.1.5. Bearing ...............................................................................................................................................60
3.1.1.2.
3.1.1.3.
Gear motor for backwash rotor .............................................................................................................68
3.1.1.4.
Pneumatic actuator of the discharge valve...........................................................................................69
3.1.1.5.
Valves......................................................................................................................................................70
3.1.1.5.1. Shut-off flap of discharge valve ........................................................................................................70
3.1.1.5.2. Isolation valves of differential pressure measuring system ............................................................71
3.1.1.5.3. Filter drain valve.................................................................................................................................72
3.1.1.6.
Control panel ..........................................................................................................................................73
3.1.2.
PREVENTIVE MAINTENANCE SCHEDULE ............................................................................................74
3.1.3.
LUBRICATION INSTRUCTIONS AND SCHEDULE .................................................................................78
3.1.4.
SPECIAL TOOLING AND HANDLING DEVICES .....................................................................................79
3.1.5.
STORAGE INSTRUCTIONS ......................................................................................................................80
3.1.6.
PRESERVATION INSTRUCTIONS ...........................................................................................................81
3.2. CORRECTIVE MAINTENANCE INSTRUCTIONS.................................................................................. 82
3.2.1.
Debris filter ...................................................................................................................................................82
3.2.2.
Differential pressure measuring system .....................................................................................................83
3.2.3.
Gear motor for backwash rotor ...................................................................................................................84
3.2.4.
Valves ...........................................................................................................................................................85
4. ACCESSORIES ................................................................................................................................................. 86
5. DRAWING AND PART LISTS .......................................................................................................................... 87
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
3/87

Rev. A
EQUIPMENT SCHEDULE
KKS No.
DESCRIPTION
REFERENCE PROCEDURE
EQUIPMENT TYPE
AP-Code
V : Valve
E : Equipment
I : Instrumentation
PARTICIPANT
UNIT
SYSTEM
COMPONENT
FUNCTION
SEQUENCE
NUMBER
010
TAPROGGE
12/13/14 PAB41
AT
Debris filter PR-BW 800
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB42
AT
TAPROGGE
12/13/14 PAB41
CP
010
SHA/14/M/---C05/MM/001
010
Differential pressure measuring system
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB42
CP
010
TAPROGGE
12/13/14 PAB41
AA
015
SHA/14/M/---C05/MM/001
Discharge valve with actuator
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB42
AA
015
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB41
GH
001
Control panel
SHA/14/M/---C05/MM/001
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
4/87

Rev. A
1.
EQUIPMENT DESCRIPTION & OPERATING INSTRUCTIONS
1.1.
Task and function description of the TAPROGGE filter system
1.1.1.
Task of the TAPROGGE filter system
A TAPROGGE debris filter is installed to prevent clogging of cooling tubes and all related
problems.
Schematic Arrangement
1
Filter
2
Discharge valve
3
Discharge pipe
4
Condenser / Heat exchanger
For scope of supply please see flow diagram SHA/14/M/---C05/FD/001.
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
5/87

Rev. A
1.1.2.
Function description of the TAPROGGE filter system
Debris filter type PR-BW 800

1
2
3
4
Filter PR-BW 800

Gear motor
Discharge valve
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
6/87

Rev. A
The cooling water to be filtered enters the debris filter's 1 "dirty side" A through the filter section.
The filtered water leaves the debris filter at side B. The debris is retained on the filter section.
The differential pressure increases.
The differential pressure is continuously monitored; upon reaching a specified value, the filter
section is cleaned by backwashing. Since the discharge valve connects the debris filter via the
discharge pipe to a zone of lower pressure (e.g. open discharge channel, cooling water
discharge line downstream of the condenser / heat exchanger), a strong reverse flow is created
in that area of the filter section which is covered by the backwash rotor. The entire filter section
is effectively cleaned by the rotation of the backwash rotor.
The debris is either carried directly into the discharge channel or reintroduced to the cooling
water discharge line downstream of the condenser / heat exchanger.
Due to the pressure drop across the discharge pipe, the water quantity required for
backwashing the debris filter is only 3 - 8 % of the cooling water to be filtered.
This amount of water required for backwashing is minimal and therefore does not significantly
affect the cooling water supply to the condenser / heat exchanger during the short time it takes
to backwash the debris filter.
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
7/87

Rev. A
The special performance of the debris filter is based on the concept of
PRESSURE-RELIEVED BACKWASH (PR-BW)

The PR-BW procedure works as follows (see sketches on the following page):
During the backwash procedure, the backwash rotor is moving over the entire filter section. The
debris, which had been collected in that area of the filter section which is covered by the
backwash rotor, is relieved from flow pressure. Simultaneously, the flow direction in this area
reverses and the pressure-relieved debris is flushed away by the backwash flow of the filtered
water.
The PR-BW procedure easily handles all kind of debris, especially fibrous debris which is easily
removed from the filter section.
Since the area of the filter section covered by the backwash rotor is completely isolated from
the differential pressure of the cooling water during backwashing, the debris filter is fully
operational even if it is loaded with high amount of debris.
If extremely large debris like twigs or pieces of wood block the backwash rotor, the control
system initiates the
automatic reverse of the backwash rotor
Should the backwash rotor drive against an obstacle which impedes the rotor's path, the
direction of rotor revolution is reversed automatically! The automatic reverse feature functions
in each operating mode. This results in the extraordinary operational reliability of the debris
filter.
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
8/87

Rev. A
Pressure-relieved backwash (PR-BW procedure)

FILTRATION
water flow
fibres are retained

filter section
flow pressure forces fibres and debris onto
the filter section
PRESSURE-RELIEF
freeing and lifting of fibrous debris

the covering backwash rotor causes a
pressure-relieved area
backwash rotor
FILTER BACKWASH
flow pressure relief and initial flow reversal

produced by the opened discharge valve
help to untangle and flush out fibrous
debris from the filter section.
Backwash process
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
9/87

Rev. A
1.2.
Description of the filter system
The filter system contains all components and subassemblies required to efficiently filter the
cooling water, to backwash the debris filter and to ensure trouble-free operation of the system.
1.2.1.
Assembly Debris Filter
1.2.1.1.
Debris Filter PR-BW 800

1
2
3
4
5
6
Filter housing
Filter section
Backwash rotor
Backwash pipe
Rotor actuation
Bearing
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
10/87

Rev. A
Filter section
consists of a bearing block with radially arranged partition sheets. The

bearing block houses the bearing 6. Filter elements are fixed between
the partition sheets thus forming the individual filter segments.
The filter elements are made of perforated stainless steel sheets with a
semiconical design to ensure proper stiffness.
Backwash rotor
is connected to the backwash pipe 4. During the backwash procedure,

the backwash rotor successively covers each filter segment.
Backwash pipe
Considering the pressure ratio, the diameter of the backwash pipe is

designed for the proper water discharge required for filter backwash.
Rotor actuation
consists of the gear box flanged to the bearing block (housing of bearing
6), a cardan shaft and the gear motor. The rotor actuation is isolated
from the cooling water.
Bearing
The bearing of the backwash rotor is equipped with multiple seals to

protect the bearing against penetration of water and debris particles.
This protection results in enhanced product life.
By the arrangement of the seals at the bearing, two chambers are
formed which are connected to the atmosphere by means of two
coloured indicator hoses. The indicator hoses - one white and one red
hose - lead to the outside of the debris filter. The proper sealing of the
bearing can be checked by means of these indicator hoses even during
the filter operation.
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
11/87

Rev. A
1.2.1.2.

1
2
3
6
7
9
Differential pressure transmitter

Remote seal PLUS
Remote seal with capillary tube MINUS
Isolation valves
Measuring nozzles
Operator terminal
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
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Rev. A
The differential pressure measuring system (p system) monitors the amount of debris on the
filter by constantly measuring the differential pressure (p).
Differential pressure transmitter 1
The differential pressure is electronically converted to a

signal.
Operator terminal 9
indicates:
the actual differential pressure

the programmed limit values
initiates:
signalling upon reaching or falling below

limit value 1:
(test function)
IN-SERVICE MONITORING
The proper functioning of the measuring system is
electrically monitored constantly. In the event of a fault,
the differential pressure falls below limit value INSERVICE MONITORING and an alarm message will be
signalled by the control system.
limit value 2:
(service function)
FILTER BACKWASH
If debris accumulates on the filter section, the
differential pressure increases. If the limit value FILTER
BACKWASH is reached, the automatic control system
initiates filter backwash, until the differential pressure
falls below the pre-set limit value.
limit value 3:
(security function)
p EXCESSIVE HIGH
If the differential pressure continues to increase in spite
of the existent backwash and reaches the limit value p
EXCESSIVE HIGH, the automatic control system
continues filter backwash. Simultaneously, a signal and
an alarm message are indicated. The customer can
connect the potential free alarm from the control panel
to the control room.
Isolation valves 6
The differential pressure measuring system can be

isolated from the cooling water flow for maintenance
purposes by means of the isolation valves.
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
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Rev. A
1.2.1.3.
Gear motor
The backwash rotor is operated by a special gear motor designed for 100 % continuous
operation. It is equipped with a slip clutch, which protects the backwash rotor, the actuation and
the gear motor against overload by power interruption, if a pre-set torque is exceeded.
The automatic reverse of the backwash rotor is initiated when the rotation monitoring switch
has tripped. The rotation monitoring switch is coupled to the gear motor of the backwash rotor.
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
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19.10.2009
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Rev. A
1.2.2.
Discharge valve
The discharge valve in this filter system is a shut-off flap operated by a specially designed
pneumatic actuator with short running time. In the open position, the valve allows an
unrestricted flow of the debris laden water.
The pneumatic actuator is equipped with limit switches signalling the end positions to the
control panel. It is electro-magnetically actuated. In case of voltage breakdown the shut-off flap
closes automatically.
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
en
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Rev. A
1.2.3.
Control
The control system serves to operate, control and monitor the filter system. The control is a
programmable logic controller (PLC). All control and monitoring functions required for automatic
operation (programmes) are stored in a single programme (EEPROM).
By means of a selector switch at the control panel the operating mode AUTOMATIC or
MANUAL is selected.
All further operations are effected via function keys at the operator terminal.
Operating mode AUTOMATIC

The control system monitors the filter system and initiates filter backwash in any of the following
cases:
p limit value FILTER BACKWASH
control command FILTER BACKWASH from control room
function key FILTER BACKWASH
function key FILTER EXTENDED BACKWASH
malfunction differential pressure measuring system (intermittent backwash every 3

minutes)
every 24 hours, initiated by a timer
Backwash
Backwash of the debris filter proceeds as follows:
The pneumatic actuator opens the discharge valve
Simultaneously, the backwash rotor starts

The filter section is cleaned by backwashing. The debris is carried away through the
discharge pipe.
In the operating mode AUTOMATIC the actual differential pressure is processed by the
control system
After backwashing, the actual differential pressure is checked by the control system
If p < limit value FILTER BACKWASH, the backwash rotor stops and the discharge
valve closes
Originator
Rev.
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19.10.2009
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Rev. A
Operating mode MANUAL
Note:
The operating mode MANUAL is not permitted for routine filter operation and may be
selected for commissioning and in case of trouble in the operating mode AUTOMATIC
only!
All operations are initiated by the operating personnel by means of function keys at the operator
terminal.
Backwash
Filter backwash must be initiated if:
p limit value p EXCESSIVE HIGH
Backwash of the debris filter shall be executed as follows:

Open the discharge valve
Start the backwash rotor

discharge pipe.
Carefully check indication of differential pressure
If p < limit value FILTER BACKWASH:

stop the backwash rotor
close the discharge valve
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
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Rev. A
Control panel
The control panel consists of all necessary devices for ...

...
control and operation of the filter system
...
transmission of control commands between the control room and control panel
...
control and power supply to the external electrical consumers
On the control panel front are:

main switch
selector switch for operating mode AUTOMATIC / MANUAL
signal lamp for indication of common alarm
operator terminal for

indication:
operation:
of the actual operational system status
of the actual differential pressure
individual alarms
running time meter of backwash rotor
reverse operation counter of the backwash rotor
limit values of the differential pressure measuring system
timers of control
information regarding trouble shooting
execution of all operations
setting of limit values
setting of timers
The control panel contains potential-free contacts which should be connected to the
control room by the customer.
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
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Rev. A
1.3.
Operating instructions
1.3.1.
General
The filter system is automatically operated. The differential pressure measuring system
monitors debris accumulation on the filter section. When the differential pressure reaches the
pre-set limit value FILTER BACKWASH, the automatic control initiates the filter backwash.
If the automatic control failed, backwashing must be manually initiated upon reaching the limit
value FILTER BACKWASH.
Caution:
Operation of the cooling water circuit without the control panel switched on will lead to
mechanical damage of the filter.
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
en
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Rev. A
1.3.1.1.
Definition of basic position
Operation starts from the basic position, which is defined as follows:
KKS *)
Component / subassembly
12/13/14PAB41 GH001
Status
selector switch MANUAL /
AUTOMATIC
in position AUTOMATIC
Control panel
main switch Q01 in position I

12/13/14PAB41 AT010
12/13/14PAB42 AT010
Gear motor for backwash rotor
12/13/14PAB41 AA015
12/13/14PAB42 AA015
Discharge valve
12/13/14PAB41 AA301
12/13/14PAB42 AA301
12/13/14PAB41 AA302
12/13/14PAB42 AA302
Isolation valves of differential

pressure measuring system
OFF
CLOSE
OPEN
*) see flow diagram SHA/14/M/---C05/FD/001

The filter system leaves the basic position under one of the following conditions:
p reaches the limit value FILTER BACKWASH
function key FILTER BACKWASH is pressed at the operator terminal
function key FILTER EXTENDED BACKWASH is pressed at the operator terminal
control command filter backwash is sent from the control room
filter backwash is initiated by timer
alarm message p SYSTEM DEFECT
Alarm messages are indicated at the control panel and at the control room
Originator
Rev.
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19.10.2009
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Rev. A
1.3.2.
Description of operating modes
1.3.2.1.
Operating mode AUTOMATIC LOCAL
In the operating mode AUTOMATIC LOCAL, all motor-operated components are actuated via
the control programmes. The isolation valves of the differential pressure measuring system
must be manually actuated. The operator terminal indicates the actual operating status of the
motor-operated components.
The accumulation of debris on the filter section causes an increasing differential pressure which
is constantly monitored by the differential pressure measuring system. During routine filter
operation the filter system is monitored by the differential pressure measuring system.
As a standard the debris filter must be backwashed once a day, unless operational experiences
require other backwash sequences. The debris filter can be backwashed by the function key
FILTER BACKWASH.
When the alarm p SYSTEM DEFECT is activated, a filter backwash cycle is initiated for a
pre-set duration (intermittent backwash).
Originator
Rev.
Date
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Sheet
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19.10.2009
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Rev. A
1.3.2.2.
In the operating mode MANUAL, all motor-operated components are individually actuated via
the appropriate function keys at the operator terminal. The actual operating status of the motoroperated components is indicated at the operator terminal.
The operating mode MANUAL is selected :
for commissioning
in the event of problems in the operating mode AUTOMATIC
Note:
The operating mode MANUAL is not permitted for routine filter operation !
In the operating mode MANUAL the differential pressure on the filter section is indicated.
However, the debris filter is not automatically backwashed upon reaching the limit value
FILTER BACKWASH.
Upon reaching the limit value FILTER BACKWASH, filter backwash must be manually initiated.
Upon reaching the limit value p EXCESSIVE HIGH, an alarm message is indicated at the
control panel and at the control room. The debris filter must be backwashed in the operating
mode MANUAL (for details see section 1.3.5.3). In operating mode MANUAL the filter
backwash programme will not be automatically initiated.
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
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Rev. A
1.3.3.
Pre-commissioning settings and checks
Conditions:
All components are installed
All electrical connections have been made and checked to be in accordance with the
specified circuit diagram, operating voltage and frequency. For more information see
electrical documentation in section 5.
Verify rotating magnetic field of three-phase connection for clockwise rotation.
Cooling water line is not flooded
Originator
Rev.
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19.10.2009
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Rev. A
1.3.3.1.
Testing and setting of the control panel
Check the actual operating voltage; change transformer connection(s), if necessary
All manual motor starters in the position I
Connection of terminals checked
All fuses in working order
Insert main fuse F 01.
Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the

position MANUAL
Main switch Q01 in position
All miniature circuit breakers in the position ON
Connect voltage supply
Put selector switch on CPU 1 to RUN / REM / PROG on CPU to RUN:

RUN
lights up (CPU)

DH+
lights up (CPU)

PRI
lights up on BACKUP SCANNER 1/1 (D1BSN)

RIO
lights up on BACKUP SCANNER 1/1 (D1BSN)

HSSL
flashing on BACKUP SCANNER 1/1 (D1BSN)

PRI
lights up on BACKUP SCANNER 1/2 (D1BSN1)

HSSL
flashing on BACKUP SCANNER 1/2 (D1BSN1)
CPU 1 is now in operating status as MASTER (PRIMARY)
Put selector switch on CPU 2 to to RUN / REM on CPU to RUN:

RUN
lights up (CPU)

DH+
lights up (CPU)

SEC
lights up on BACKUP SCANNER 2/1 (D2 BSN)

RIO
lights up on BACKUP SCANNER 2/1 (D2 BSN)

HSSL
flashing on BACKUP SCANNER 2/1 (D2 BSN)

SEC
lights up on BACKUP SCANNER 2/2 (D2 BSN1)

HSSL
flashing on BACKUP SCANNER 2/2 (D2 BSN1)
CPU 2 is now in stand-by status as SLAVE (SECONDARY)
COMM lights up on ADAPTER on INPUT / OUTPUT CHASSIS
RUN lights up on ADAPTER on INPUT / OUTPUT CHASSIS
Check lamp for proper functioning by push-button LAMP TEST
Preliminary programming of limit values at the operator terminal (see section 4), as
follows:
limit value FILTER BACKWASH

limit value p EXCESSIVE HIGH
p = 145 mbar
p = 181 mbar
Set the timers to the following values; after commissioning, record timer settings and
send one copy to TAPROGGE
Originator
Rev.
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Lang.
Sheet
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19.10.2009
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Rev. A
Time Table
Timer
(adjustable
by function
key)
Denomination
Factory set
value
time filter backwash
30 sec.
time filter backwash after start filter backwash

from the control room
300 sec.
start filter backwash, if differential pressure

measuring system is defective
180 sec.
start filter backwash
Value after
commissioning
24 h
execution time check: running time of discharge

valve
30 sec.
time filter extended backwash
900 sec.
The following internal timers are already factory pre-set, alterations are not permitted:
Timer
Denomination
Value
iT
execution time check: test contact of differential pressure

measuring system
5 sec.
iT
rotation monitoring time
10 sec.
iT
delay time direction of rotation left / right

of backwash rotor
2 sec.
iT
delay time limit value filter backwash
5 sec.
iT
delay time limit value "p excessive high"
10 sec.
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
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Rev. A
1.3.3.2.
Dry function test
Before flooding the filter system, the function of the backwash rotor and the discharge valve
must be checked.
Conditions:
the check must be performed without water in the filter system
selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in position

MANUAL
main switch Q01 in position I = ON
Discharge valve
The pneumatic actuator of the discharge valve has already been factory pre-adjusted.
The running times for the pneumatic actuator can be adjusted at the exhaust regulator with
sound absorber.
Backwash rotor
Warning:
During the following functional test do not reach into the filter housing.
Otherwise severe injury will result due to rotating parts!
Start the backwash rotor by the function key backwash rotor ON at the operator
terminal. The backwash rotor should now rotate. The proper rotation should be visually
checked through the inspection hole.
Close the inspection hole and tighten bolts.
Turn the backwash rotor off by pressing the function key backwash rotor OFF at the
operator terminal.
Originator
Rev.
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Lang.
Sheet
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19.10.2009
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Rev. A
1.3.3.3.
Commissioning of the actuators
selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the position

MANUAL
main switch Q01 in the position I
1.3.3.3.1.
Pneumatic actuator of discharge valve
1.3.3.3.2.
The torque (automatic reverse) at the slip clutch of the gear motor has been factory preadjusted to approximately 279 Nm.
The switching point (reference frequency) has been factory pre-set.
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
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Rev. A
1.3.4.
Commissioning of the filter system
1.3.4.1.
Flooding of the debris filter
Check the following prior to flooding:
Remove coarse debris from the cooling water system.
Inspection hole of the filter closed
Isolation valves of the differential pressure measuring system are closed
Flooding:
1.3.4.2.
Flood the cooling water pipe and vent the entire cooling water system.
Venting of the differential pressure measuring system
Venting of the differential pressure measuring system is not applicable.
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
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Rev. A
1.3.4.3.
Commissioning of the differential pressure measuring system
Conditions :
Cooling water flow per filter as specified:

minimum

normal

maximum admissible
4993 kg/s
8336 kg/s
9125 kg/s
Filter system in basic position (see section 1.3.1.1)
Isolation valves of differential pressure measuring system are open
Setting of the differential pressure transmitter and programming at the operator

terminal:
Zero point and measuring range of the differential pressure transmitter have already been set.
The limit values shall be programmed at the operator terminal by selecting the screen "Setting"
(see section 1.3.10).
Determination of pclean:
Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in position

AUTOMATIC LOCAL
Main switch Q01 at the control panel in the position I
Backwash the filter repeatedly by means of the function key FILTER BACKWASH.
Read the differential pressure directly after each filter backwash. The mean value is
determined as the differential pressure of the clean filter (pclean).
Programming of the limit values at the operator terminal:

limit value FILTER BACKWASH:
p = 2.0 x pclean (preliminary value)
limit value p EXCESSIVE HIGH:
p = 2.5 x pclean (preliminary value)
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
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29/87

Rev. A
1.3.4.4.
Functional test of the control and setting of the limit values at the differential
pressure measuring system
Conditions :

minimum

normal

maximum admissible
4993 kg/s
8336 kg/s
9125 kg/s

position AUTOMATIC LOCAL
Main switch Q01 at the control panel in position I
Check limit value FILTER BACKWASH

Programming of limit value FILTER BACKWASH at the operator terminal to a value <
pclean.
The programme "Filter backwash is initiated according to section 1.3.5.2.
Programming of limit value FILTER BACKWASH to the preliminary value (see section
1.3.4.3)
After the backwash procedure the differential pressure of the clean filter (pclean) will be
indicated (see section 1.3.4.3).
Check limit value p EXCESSIVE HIGH in the operating mode MANUAL


position MANUAL
Programming of limit value p EXCESSIVE HIGH at the operator terminal to a value <
pclean.
The following alarm messages are indicated:
individual alarm
(fault list at the operator terminal)
common alarm
at the control panel
at the control room
p EXCESSIVE HIGH
p EXCESSIVE HIGH
ALARM
common alarm
Programming of limit value p EXCESSIVE HIGH to the preliminary value (see section
1.3.4.3)
Reset the alarms by means of the push-button ALARM RESET according to section
1.3.11. If the alarm messages continue, trouble shooting must be carried out according
to the event messages of the operator terminal or section 1.3.11.
Originator
Rev.
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19.10.2009
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Rev. A
Check limit value p EXCESSIVE HIGH in the operating mode AUTOMATIC


pclean.
The control initiates filter backwash according to section 1.3.5.2. Moreover, the following
alarm messages are indicated:
individual alarm
common alarm
at the control room
p EXCESSIVE HIGH
p EXCESSIVE HIGH
ALARM
common alarm
1.3.4.3)

limit value FILTER BACKWASH:
= 2.0 x pclean
limit value p EXCESSIVE HIGH:
= 2.5 x pclean
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
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Rev. A
1.3.4.5.
Filter system start-up


minimum

normal

maximum admissible
4993 kg/s
8336 kg/s
9125 kg/s

Main switch at the control panel in position I
The filter system is in the basic position (see section 1.3.1.1).
Filter backwash by the function key FILTER BACKWASH

Filter backwash according to section 1.3.5.2
The filter system is now ready for operation.
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
en
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Rev. A
1.3.5.
Operation of the filter system
1.3.5.1.
Routine filter operation (AUTOMATIC):
In the basic position the debris filter separates debris from the cooling water
KKS*)
Component to be
operated
filter system
*)
Position
basic
position
12/13/14
PAB41
GH001
control panel
12/13/14
PAB41
AT010
12/13/14
PAB42
AT010
gear motor for

backwash rotor
OFF
12/13/14
PAB41
AA015
12/13/14
PAB42
AA015
discharge valve
CLOSE
12/13/14
PAB41
AA301
12/13/14
PAB42
AA301
12/13/14
PAB41
AA302
12/13/14
PAB42
AA302
isolation valves of
differential pressure
measuring system
OPEN
Action
Indication
according to section 1.3.1.1
p < limit value FILTER BACKWASH
selector switch MANUAL / AUTOMATIC LOCAL

/ AUTOMATIC REMOTE in the position
AUTOMATIC LOCAL
backwash rotor OFF
discharge valve CLOSE
see flow diagram SHA/14/M/---C05/FD/001
Originator
Rev.
Date
Lang.
Sheet
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19.10.2009
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Rev. A
1.3.5.2.
Filter backwash in the operating mode Automatic
Under the following operating conditions, the debris filter must be backwashed several
times as a precautionary measure:
during start of the cooling water pump
before start of another condenser / heat exchanger
before start of another cooling water pump
during or after cleaning work at the cooling water pipe or at the cooling water pump
sump
when high tide
Backwash of the debris filter can be accomplished as follows:

in the operating mode AUTOMATIC LOCAL: repeatedly press the function key FILTER
EXTENDED BACKWASH at the operator
terminal
Before shutdown of the filter system the debris filter must be backwashed several times as
a precautionary measure:
in the operating mode AUTOMATIC LOCAL: repeatedly press the function key FILTER
BACKWASH at the operator terminal
or
by means of repeating the control

commands filter backwash from the
control room in AUTOMATIC REMOTE
Originator
Rev.
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19.10.2009
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Rev. A
1.3.5.2.1.
KKS*)
Programme "filter backwash"
Component to be
operated
Position
Action
Indication
initiated by one of the following conditions:
12/13/14
PAB41
AA015
12/13/14
PAB42
AA015
discharge valve
OPEN
12/13/14
PAB41
AT010
12/13/14
PAB42
AT010
gear motor for

backwash rotor
ON
p-indication reaches the limit value

FILTER BACKWASH

FILTER BACKWASH
timer (recommended setting 24 h)
FILTER BACKWASH
FILTER BACKWASH
discharge valve OPEN
backwash rotor ON
backwash rotor RIGHT or
backwash rotor LEFT
after the pre-set backwashing period:
*)
12/13/14
PAB41
AT010
12/13/14
PAB42
AT010
gear motor for

backwash rotor
OFF
12/13/14
PAB41
AA015
12/13/14
PAB42
AA015
discharge valve
CLOSE

backwash rotor OFF
Even after the pre-set backwash period has elapsed, the filter will automatically continue backwashing until the
differential pressure measured across the filter section falls below the limit value FILTER BACKWASH. The
backwash rotor then stops and the discharge valve closes.
Originator
Rev.
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Rev. A
1.3.5.2.2.
KKS*)
Programme "filter extended backwash"
Component to be
operated
Position
12/13/14
PAB41
AA015
12/13/14
PAB42
AA015
discharge valve
OPEN
12/13/14
PAB41
AT010
12/13/14
PAB42
AT010
gear motor for

backwash rotor
ON
Action
Indication
initiated by
- function key FILTER CONTINUOUS

BACKWASH
FILTER EXTENDED BACKWASH
- p reaches limit value p excessive high

backwash rotor ON
backwash rotor LEFT
after the pre-set time (filter extended backwash):

12/13/14
PAB41
AT010
12/13/14
PAB42
AT010
*)
gear motor for

backwash rotor
OFF
discharge valve
CLOSE

backwash rotor OFF
Originator
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Rev. A
1.3.5.3.
KKS*)
12/13/14
PAB41
GH001
Component to be
operated
Position
control panel
Action
Indication

/ AUTOMATIC REMOTE in the position MANUAL
12/13/14
PAB41
AA015
12/13/14
PAB42
AA015
discharge valve
OPEN
12/13/14
PAB41
AT010
12/13/14
PAB42
AT010
gear motor for

backwash rotor
ON
12/13/14
PAB41
AT010
12/13/14
PAB42
AT010
*)
Filter backwash in the operating mode MANUAL
gear motor for

backwash rotor
OFF
12/13/14
PAB41
AA015
12/13/14
PAB42
AA015
discharge valve
CLOSE
12/13/14
PAB41
GH001
control panel
p-indication reaches the limit value FILTER

BACKWASH
function key discharge valve OPEN
function key backwash rotor ON
backwash rotor ON
backwash rotor LEFT
after approximately 1 minute of backwash rotor

operation, check:
function key backwash rotor OFF
backwash rotor OFF
function key discharge valve CLOSE
selector switch MANUAL / AUTOMATIC LOCAL /

AUTOMATIC REMOTE in the position
AUTOMATIC LOCAL
Note:
The operating mode MANUAL is not permitted for routine filter operation. It is only intended for
commissioning and in case of trouble in the operating mode AUTOMATIC!
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Rev. A
1.3.6.
Filter system shut-down
KKS*)
12/13/14
PAB41
GH001
Component to be
operated
Position
Action
Indication
Filter backwash:
AUTOMATIC LOCAL
control panel
FILTER BACKWASH
or
FILTER BACKWASH
control command FILTER BACKWASH
(from the control room)
12/13/14
PAB41
AA015
12/13/14
PAB42
AA015
discharge valve
OPEN
12/13/14
PAB41
AT010
12/13/14
PAB42
AT010
gear motor for

backwash rotor
ON
12/13/14
PAB41
AT010
12/13/14
PAB42
AT010
12/13/14
PAB41
AA015
12/13/14
PAB42
AA015
backwash rotor ON
backwash rotor LEFT

gear motor for
backwash rotor
OFF
discharge valve
CLOSE
backwash rotor OFF
check:
filter system
basic
position
after filter backwash:

cooling water pump
12/13/14
PAB41
GH001
*)
control panel
OFF
The filter system is now out of operation
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Rev. A
1.3.7.
Measures to prevent corrosion due to stagnation

During prolonged shut-down periods the following must be strictly observed:
The corrosion resistance of stainless steel in aggressive water can be affected by the conditions
prevailing during shut-downs.
During shut-down periods, stagnant water, as well as evaporation of remaining water (e.g. drops),
is to be avoided.
The following measures are necessary to prevent corrosion damage :
Shut-downs up to 3 days:
Run the cooling water pump for a few minutes each day to circulate the cooling water and
to rinse deposits away.
If a high amount of debris is expected during operation of the cooling water pump turn the
main switch Q01 in the position I and backwash the debris filter according to section
1.3.5.3.
Shut-downs over 3 days require a dry conservation

Drain the TAPROGGE components
Clean the internals of the filter system with fresh water
Dry by natural aeration
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Rev. A
1.3.8.
Filter system restart after shut-down
For shut-downs up to 3 days or maintenance of the debris filter

(with water in the filter system):
Functional test of control and

setting of the limit values at the
differential pressure measuring system
Resume routine filter operation
For shut-downs over 3 days or after maintenance of

the drained debris filter
according to section 1.3.3
Resume of routine filter operation
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Rev. A
1.3.9.
Operating Record
For documentation of the debris filter operation please use the attached form.
The documentation of the operational parameters of the TAPROGGE filter system on a regular
basis is helpful to evaluate special operational conditions, to optimize settings of the differential
pressure measuring system and timers and to trace the cause of damages.
We recommend recording the indicated differential pressure of the clean debris filter every 2
weeks and after each alarm p EXCESSIVE HIGH (potential-free contact)
We kindly ask you to have one completed copy of the form ready for information of the
TAPROGGE service department.
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Rev. A
Operating Record
Date
Differential pressure
after last filter
backwash (pclean)
Backwash rotor
operation hours
Reverse operation
counter of
backwash rotor
Remarks
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Rev. A
1.3.10. "Indication" and Operation"; Operator terminal screens
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Rev. A
1.3.11. Operational trouble-shooting
Note:
Alarm messages are indicated at the operator terminal of the control panel and at the control room
(common alarm) and can be reset in operating mode MANUAL* / AUTOMATIC* by means of the
push-button ALARM RESET. If operational trouble cannot be solved by following the procedures
described herein, or if alarm messages continue, kindly inform the TAPROGGE Service
Department. After trouble shooting, continue filter operation according to section1.3.5.1.
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Rev. A
1.3.11.1.
Backwash rotor fault
Indication at
operator terminal
manual motor starter
tripped
Potential-free
contact to
control room
common alarm
backwash rotor
blocked
Probable cause
Remedy

tripped
Reclose the manual motor starter. If the manual motor

starter trips again, electrically and mechanically check
the gear motor for backwash rotor according to section
9 "Gear motor for backwash rotor
rotation monitoring
time elapsed
Electrically and mechanically check the gear

motor for backwash rotor according to section 9
"Gear motor for backwash rotor"
Technically check the timer rotation monitoring
time
Check setting of rotation monitoring time, see
time table in section 1.3.3.1.
If the rotation monitoring time is set by means of
an internal timer:

Inform the TAPROGGE Service
Department for checking and setting of timer
Check torque according to section 3.2.3 and section 4

"Gear motor for backwash rotor".
Check movability of backwash rotor by means of crank
handle (= special tool within scope of supply). In the
event that the rotor is difficult to move or blocked,
check the filter internals according to section 3.1.1.1
and remove coarse parts, if necessary.
After trouble shooting: restart the filter system according to section 1.3.8
safety switch not
actuated
Check the safety switch for crank handle actuation,

according to section 4 "Gear motor for backwash
rotor"
-
remove the crank handle and screw the cover to

the gear motor so that the electric circuit of the
motor is closed
check cabling
check electrical connections
check function of switching amplifier according to

section 4 "Switching amplifier"
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Rev. A
1.3.11.2.
Fault of actuator of discharge valve
Indication at
operator terminal
Potential-free
contact to
control room
Probable cause
Remedy
miniature circuit
breaker tripped
common alarm
...........................
Reclose the miniature circuit breaker, if the miniature

circuit breaker trips again, electrically and
pneumatically check the pneumatic actuator of the
discharge valve according to section 4 "Pneumatic
actuator discharge valve".
Check cabling according to the electrical
documentation"
malfunction both travel

limit switches actuated
not adjusted
defective cabling
running time exceeded
OPEN
CLOSE
restricted movability
Check setting travel limit switches according to section

4 "Pneumatic actuator discharge valve".
Check the electrical connections
Check compressed air supply
Check running time of discharge valve according to
the time table, section 1.3.3.1
Check the actuator of discharge valve electrically and
pneumatically
according
to
section
4
"Pneumaticactuator discharge valve".
documentation"
Caution:
If the discharge valve has not opened due to a defect of the pneumatic actuator, the discharge
valve must be turned to the position OPEN by means of the emergency actuation at the solenoid
valve of the actuator. Precondition: compressed air is available.
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Rev. A
1.3.11.3.
Fault of differential pressure measuring system
The filter is running in "intermittent backwash", i.e. the filter is backwashing every 180
seconds.
Indication at
operator terminal
Potential-free
contact to
control room
p SYSTEM DEFECT
common alarm
Probable cause
no signal from
transmitter
measuring range fault
p below limit value

IN-SERVICEMONITORING for
more than 5 sec.
current loop of transmitter interrupted
Remedy
Check the calibration of the differential pressure

transmitter according to section 4 "Differential
pressure transmitter"
documentation in section 5.
Check the differential pressure transmitter according
to section 4 "Differential pressure transmitter".
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Rev. A
1.3.11.4.
p EXCESSIVE HIGH
Indication at
operator terminal
Potential-free
contact to
control room
Probable cause
Remedy
p excessive high
common alarm
Check setting of limit values according to section

1.3.4.4
p excessive high
extraordinary amount
of debris
Check the pre-screening system
cooling water flow

increased
change in load and
type of debris:
deviation from design
data
discharge flow fallen
below the design data

1.3.4.4

Inform the TAPROGGE Service Department
Verify that the

- discharge valve is fully opened
- backwash pipe is not clogged
cooling water flow rate
is less than the design
data (insufficient
backwash)
continuous reversal of Check the rotation monitoring switch according to

the backwash rotor
section 4 "Gear motor for backwash rotor":
frequent reversal of
the backwash rotor
Distance between proximity switch and rotor

Wiring between proximity switch of impulse generator and control panel
Take filter system out of operation at the next

opportunity according to section 1.3.6
Check the filter internals according to section
6.1.1 and remove coarse parts, if necessary
After trouble shooting: restart the filter system according to section 1.3.8
Complete the operating record after each alarm p EXCESSIVE HIGH
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Rev. A
1.3.11.5.
Voltage breakdown
Caution:
In case of a voltage breakdown of more than 60 minutes the cooling water flow must be reduced to
ensure, that the design pressure of the filter section (1,0 bar) will not be exceeded. We recommend
an emergency power supply of the control panel.
Indication/Signal
at control panel
Potential-free
contact
to control room
no indication
common alarm
Probable cause
Remedy
no supply voltage to
the control panel
Check the main supply voltage

Clear any short-circuits
no control voltage
Check the manual motor starter of the control

voltage transformer
Check miniature circuit breaker(s)

no auxiliary voltage
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Rev. A
1.3.11.6.
PLC fault
Indication at
operator terminal
and CPU
Potential-free
contact to
control room
no indication
LED at CPU:
FLT
Probable cause
Remedy
common alarm
Replace fuse, check wiring according to the electrical

documentation in section 8 and section 9
"Programmable controller"
common alarm
CPU fault
Check hardware according

documentation in section 8
to
the
electrical
data bus fault

documentation section 5
to
the
electrical
at operator terminal:
no active nodes found
on network
Compare error number, section 4, "Operator Terminal"
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Rev. A
1.3.11.7.
Battery low
Indication at
operator terminal
and CPU
Potential-free
contact to
control room
battery low
common alarm
Probable cause
Remedy
battery of PLC has run Replace / add the battery of the CPU as soon as
out
possible
(see
also
manufacturer's
manual
"programmable logic controller")
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Rev. A
2.
ENVIRONMENTAL, HEALTH AND SAFETY
The operating instructions contain basic information on erection, operation and maintenance. For
this reason it is essential that the operating instructions are carefully read before erection and
commissioning by both the installation personnel as well as those responsible for operation and
maintenance. The operation manual must always be available.
In order to prevent personal injury or property damage particular note must be taken of the
following:
the technical data and information as described in the operating instructions
accident prevention regulations
safety regulations of plant operator
electric protective measures acc. to local safety regulations
technical information on manufacturing plates
warning plates at components
regulations concerning environmental protection
all work on or near the system is to be done by qualified personnel
Moreover, the operating instructions contain safety notes which, if ignored, may cause
damage to persons, machinery or environment and which can be identified by the
following symbols:
Warning:
means that danger to life may result if corresponding measures are

not taken or ignored.
Caution:
means that personal injury or considerable material damage may

result if corresponding measures are not taken or ignored.
Note:
points out important information to which the readers specific

attention is drawn.
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Rev. A
3.
MAINTENANCE
3.1. Preventive maintenance
3.1.1.
PREVENTIVE MAINTENANCE INSTRUCTIONS
In general the following must be observed during maintenance work:
Lightly grease metal parts before assembly.
In order to avoid crevice corrosion, the non-rubberlined sealing surfaces are to be

cleaned and completely covered with a permanently flexible sealing material during
maintenance work.
Only lubricate and grease o-rings with a silicone-based valve grease free of
hydrocarbons (see lubrication list)
Avoid excessive force, especially in case of rubberlined components
Pipes shall be connected stress-free. Take care of fixing points and expansion joints
to avoid unexpected forces at the components.
Restart the filter system according to section 1.3.8. after the maintenance work has been
completed.
If maintenance work cannot be performed according to the procedures described herein

kindly inform the TAPROGGE Service Department.
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Rev. A
3.1.1.1.
Debris filter
For execution of maintenance work described in section 3.1.1.1, it is not necessary to remove
the filter from the cooling water pipe.
Warning:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and
make it safe. Ensure that the voltage supply to the electric actuators and the
compressed air supply for the discharge valve has been interrupted. Voltage-carrying
adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
has been drained. It is absolutely necessary to ensure that people are not exposed to
danger due to an inrush of water into the filter during maintenance work.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.
To replace wear parts, several subassemblies of the filter must be completely disassembled.
We recommend to have this work done by the TAPROGGE Service Department.
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Rev. A
3.1.1.1.1.
Filter section
(see drawing K2009/20/1367-0503, subassembly 4)
Replacement of filter elements
Filter elements 4.9 are not wear parts. However, if an element has been damaged, please
replace as follows:
Dismantling
hexagon bolt 4.19, 4.25, washer 4.21, 4.26, 4.27 and hexagon nut 4.22, 4.28
bracket 4.2 (consisting of a round steel and 2 clamping sheets with

right / left hand execution) and support 4.3 and 4.4
hexagon bolt 4.29, washer 4.21 and hexagon nut 4.22
replace filter element 4.9
Assembly:
Apply securing for bolts and nuts 4.18 (Loctite 242)

to the thread and contact surfaces of the screw heads and nuts
filter element 4.9 (attach to flange pipe of bearing block 4.1 without clearance)
support 4.3, 4.4 and bracket 4.2 (observe arrangement of clamping sheets)
hexagon bolt 4.19, 4.25, 4.29, washer 4.21, 4.26, 4.27 and hexagon nut 4.22, 4.28
(Do not tighten yet!)
Press bracket 4.2 against the filter element without clearance, secure the hexagon nut 4.22 and
4.28 according to tightening torque listed in the drawing.
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Rev. A
3.1.1.1.2.
Backwash rotor
Wear part: head piece 5.4
For assembly, you will need securing for bolts and nuts (Loctite 270).
Dismantling
remove hexagon bolt 5.13 *)
remove sheet 5.7 and head piece 5.4
Assembly
Loosely screw the new head piece 5.4 together with the sheet 5.7 and hexagon bolt 5.13
carefully adjust the head piece 5.4 to filter section 4
fix hexagon bolt 5.13
secure hexagon bolt 5.13 (and 5.11, if necessary) with securing for bolts and nuts 5.20
(Loctite 270)
*)
If it is not possible to remove the hexagon bolts 5.13 during dismantling, please proceed
as follows:
remove the parallel pin 5.9
support the backwash nozzle 5.2
remove the hexagon nut 5.15 and hexagon bolt 5.11
remove the backwash nozzle far enough such that the hexagon bolt 5.13, sheet
5.7 and head piece 5.4 can be dismantled
for the assembly with new head piece, proceed in reverse order and strictly
observe instructions given under Assembly
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Rev. A
3.1.1.1.3. Backwash pipe

Wear part:
flange
bearing housing
o-ring
6.2
6.4
6.5
For assembly, you will need securing for bolts and nuts (Loctite 270 and Loctite 242).
Dismantling:
support the backwash pipe 6.1
loosen screw connection 6.20, 6.21, 6.22 and 6.18, 6.19 and remove support 6.16
remove the hexagon bolt 6.11
remove the hexagon bolt 6.7 and washer 6.8
remove backwash pipe 6.1 with gasket 6.12 and remove bearing housing 6.4
dismantle the slotted set screw 6.9, flange 6.2 and bearing flange 6.3, replace the
bearing housing 6.4 and flange 6.2
replace the o-ring 6.5 of the bearing flange 6.3
remove the o-ring 6.6, check for damage and replace, if necessary
Assembly:
insert the o-ring 6.5 into the bearing flange 6.3
assemble the bearing flange 6.3, flange 6.2 with slotted set screw 6.9. Secure the
slotted set screw 6.9 with securing for bolts and nuts 6.13 (Loctite 270)
assemble the bearing housing 6.4 with the o-ring 6.6 with the backwash pipe 6.1; secure
with the hexagon bolt 6.7 and washer 6.8; ensure correct position of the hexagon bolt
6.7 and the threaded rod 6.10 with hexagon nut 6.14! Observe the tightening torque and
secure with securing for bolts and nuts 6.13 (Loctite 270).
assemble backwash pipe 6.1 with gasket 6.12 and fix with hexagon bolt 6.11. Secure
with securing for bolts and nuts 6.15 (Loctite 242).
assemble support 6.16 with screw connection 6.20, 6.21, 6.22 and 6.18, 6.19
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Rev. A
3.1.1.1.4.
Rotor actuation
Wear parts:
washer
cardan joint
cardan joint
bush
spring pin
washer
securing for bolts and nuts
corrosion protection
surface seal
7.18
7.22
7.23
7.25
7.28
7.29
7.32
7.38
7.43
Dismantling
Note:
During execution of work ensure that the white and red indicator hoses 7.39 and 7.40 will
not be damaged!
Remove the gear motor according to section 9 Gear motor for backwash rotor.
Remove the hexagon nut 7.24 and washer 7.26.
Loosen the pipe union 7.48 from connection piece 7.47 and remove lantern 7.5, washer
7.29, bush 7.25 and seal washer 7.4 with o-ring 7.11 and gasket 7.27.
Completely remove the cardan shaft, consisting of 7.8, 7.22, 7.23, 7.28.
Remove the hexagon bolt 7.13 and carefully remove pipe channel 7.3; note position of
channel for protection hoses 7.54.
Remove the hexagon bolt 7.17 and gear housing 7.2.
Remove the cardan joints 7.22 and 7.23 and spring pins 7.28.
Remove the connector 7.42, remove hoses
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Rev. A
Remove the hexagon bolt 7.19 and hexagon nut 7.20.
Remove the planetary reduction gear 7.1 together with intermediate flange 7.9; loosen
the connection of planetary reduction gear 7.1 and intermediate flange 7.9 only if fixing
parts 7.15, 7.16, 7.18, 7.30 and 7.55 are no longer in an acceptable condition!
Check tightness of the planetary reduction gear 7.1. In the event of considerable grease
leakage, it is necessary to repair or replace the gear. We strongly recommend informing
the TAPROGGE Service Department.
Check the o-rings 7.10, 7.11, 7.12, gasket 7.27, hoses 7.39, 7.40 as well as connector
7.42 for damage and replace, if necessary.
Clean those surfaces to which surface seal 7.43 has been applied to.
Assembly
Observe the following while reassembling in reverse order:
Carefully mount the connector 7.42 for connection of the indicator hoses
Pay attention to the exact positioning of the spring pins 7.30 and 7.55 according to the
drawing.
Clean the shaft 7.8 and check for damages.
Assemble the new cardan joints 7.22 and 7.23 with spring pins 7.28.
Provide the shaft 7.8 with corrosion protection 7.38 (Chesterton 740).
Apply surface seal 7.43 according to the above mentioned drawing
Assemble the pipe channel 7.3.
Replace the washer 7.29 and bush 7.25 and secure all bolts with Loctite 270 (Pos. 7.32)
according to the instructions in the drawing.
Mount the gear motor according to section 4 Gear motor for backwash rotor.
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Rev. A
3.1.1.1.5.
Bearing
groove ball bearing

wiper
needle bearing
o-ring
o-ring
Wear parts:
11.3
11.6
11.8
11.9
11.10
o-ring
11.11
surface seal
11.12
V-seal
11.14
wearing ring
11.21
special-purpose grease
11.26
11.28
sealing adhesive
11.29
sealing tape
11.32
adhesive
11.33
For assembly of the bearing you need special-purpose grease (Klber, Syntheso GLEP1)
11.26, multi-purpose grease (see lubrification list; grease G5) 11.27, sealing adhesive (Loctite
577) 11.29 and surface seal (Loctite 510) 11.12.
The bearing of the backwash rotor is multiple sealed. Leakage from the sealing system can be
traced via the two indicator hoses (white and red). When the white indicator hose 11.19
indicates leakage, the wear parts of the sealing system (i.e. 11.6, 11.9, 11.10, 11.11, 11.14,
11.21, 11.28, 11.32, 11.33) must be replaced with the next repair.
Caution:
When the red indicator hose 11.20 indicates leakage, the sealing system must be
replaced immediately. Please contact the TAPROGGE Service Department.
Before dismantling the rotor bearing the following subassemblies must be removed in
the following sequence:

backwash pipe, subassembly 6

backwash rotor, subassembly 5
rotor actuation, subassembly 7
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Rev. A
Note:
When dismantling / assembling the bearing ensure that the two indicator hoses (white
hose 11.19 and red hose 11.20) will not be damaged or switched.
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Rev. A
Dismantling
Loosen the three locking screws at the circumference of the slotted round nut 11.13 with
a hexagon socket screw key.
Loosen the locking screws by careful blows with a plastic tip hammer onto the surface
area of the slotted round nut.
Loosen the slotted round nut 11.13 with the respective socket wrench (Taprogge supply)
and remove it.
Remove o-ring 11.11 and wiper 11.6
Pull out the rotor shaft 11.1 with the inner ring of the needle bearing 11.8 in direction of
backwash rotor; use existing tap holes, if necessary
Remove hexagon nut 11.24, screwed to stud 11.36
Loosen hexagon nut 11.24, screwed to hexagon bolt 11.17.
Tighten hexagon bolt 11.17 to push out the subassembly consisting of items 11.5, 11.3,
11.7, 11.25, 11.35. By removing the retaining ring 11.35, the groove ball bearing 11.3
can be taken out easily.
Remove the inner ring of needle bearing 11.8 from rotor shaft; warm up before removing
as the inner ring is press-fit
Remove hexagon socket head cap screw 11.23, then remove the wearing ring 11.21
from the seal housing 11.4 together with the V-seal 11.14.
Remove the V-seal 11.14
Check wearing ring 11.21 and replace according to maintenance schedule, section
6.3.1.
Loosen connector 11.39.
Remove hexagon bolt 11.15
Remove seal housing 11.4 with o-ring 11.9, 11.10 and indicator hoses 11.19, 11.20
using existing tap holes.
Loosen pipe union 11.18 of indicator hoses 11.19, 11.20
Remove hexagon socket head cap screw 11.31
Remove bearing housing 11.30, outer ring and needle ring of the needle bearing 11.8
Remove (push out) needle bearing 11.8
Carefully clean all parts. Check rotor shaft and overhaul, if necessary.
Replace all wear parts according to the maintenance schedule in section 3.2.1.
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Rev. A
Assembly
Assemble in reverse order; tolerances and tightening torque must be followed according to
drawing K2009/20/1367-0503.
During re-assembly, seal the pipe unions 11.18 of the indicator hoses with sealing tape 11.32.
For positions with indices 11.28 use LOCTITE 242, for position 11.12 surface seal Loctite 510.
For positions with indices 11.26 use grease KLBER Syntheso GLEP1.
V-seal 11.14 to be glued in with LOCTITE 495 11.33.
Grease needle bearing 11.8 with special grease 11.26 (KLBER Syntheso GLEP1)
Grease groove ball bearing 11.3 with multi-purpose grease 11.27.
Clean bearing surfaces of slide bush 11.5 and bearing housing 11.30 of debris and
grease.
Grease rotor shaft 11.1 with special-purpose grease 11.26 and move a few times
forward and backward in the bearing in order to allow grease to spread
Rotate rotor shaft 11.1 for ten times
Adjust flange of rotor shaft 11.1 with wearing ring 11.21 (see drawing):
In order to move the flange of the rotor shaft 11.1 towards backwash pipe, tighten
hexagon nut 11.24 screwed onto stud 11.36.
In order to move the flange of the rotor shaft 11.1 in opposite direction, tighten
hexagon bolt 11.17.
Screw slotted round nut 11.13 with the stepped side (contact surface) onto the exterior
thread and firmly tighten by means of the socket wrench.
Secure slotted round nut against loosening by evenly and step-wise tightening the
locking screws at the circumference.
Check sealings for leakage

Connect a valve with a gauge to the connector 11.39 for the indicator hoses
(white and red) and expose the union under an air pressure of 2,0 bar (20000 Pa;
30 psi 5), close the valve and check the pressure by gauge for 15 minutes.
There is no pressure decrease allowed in this time.
Insert wiper 11.6 and o-ring 11.11
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Rev. A
After assembly of bearing, reassemble in the following sequence according to operating

instructions and relevant drawings
rotor actuation
backwash rotor
backwash pipe
Again, check rotor for correct running and pay attention to clearance between backwash
rotor and filter section!
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Rev. A
3.1.1.2.
(see drawing K2009/20/1367-0501)
Caution:
As long as the differential pressure measuring system is out of order the debris
accumulated on the filter section cannot be monitored.
Therefore the filter shall be backwashed continuously while performing the following
work in the operating mode MANUAL (see section 1.3.5.3).
After the work has been completed, resume the operating mode AUTOMATIC.
Check tightness of the differential pressure measuring system as follows:

Simultaneously close the isolation valves of the differential pressure measuring system.
The p indication must remain at the present value, otherwise the leakage must be traced and
eliminated.
If the p indication decreases:

check PLUS side of the differential pressure measuring system for leakage and repair it
accordingly.
If the p indication increases:

check MINUS side of the differential pressure measuring system for leakage and repair
it accordingly.
If it may become necessary to replace parts or the complete isolation, see section
3.1.1.5.2 as well as section 9.
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Rev. A
Cleaning of the differential pressure measuring system
Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and make
it safe. Ensure that the voltage supply to the electric consumers has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
must be drained.
Close and lock the isolation valves of the differential pressure measuring system.
Remove differential pressure transmitter with remote seal / remote seal with capillary
tube. Take care, that the measuring diaphragm will not be damaged.
Caution:
Do not use the capillary tube for carrying and do not bend it. Do not loosen the
connection between capillary tube and remote seal. Deposits may not be removed using
sharp objects.
Clean the isolation valves of the differential pressure measuring system and the
diaphragm of the differential pressure transmitter.
Clean the sealing between remote seal and isolating valve
Assemble differential pressure transmitter and remote seal, tighten bolts crosswise.
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Rev. A
Calibration of the differential pressure measuring system
Caution:
must be drained.
tube. Take care, that the diaphragm will not be damaged.
Caution:
sharp objects.
Calibration according to manufacturer's instructions "Differential pressure transmitter",

section 4.
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Rev. A
3.1.1.3.
Caution:
make it safe. Ensure that the voltage supply to the electric consumers has been
interrupted. Voltage-carrying adjoining parts must be covered or kept separate.
must be drained because the debris accumulation at the filter section cannot be
monitored or discharged.
After the work is completed, restart the filter system according to section 1.3.8 of
these operating instructions.
Electric motor
Repairs according to the manufacturers instructions (see section 4, Gear motor for backwash
rotor).
Worm gear
For replacement of wear parts listed in section 3.2.3 as well as to check and adjust the slip
clutch of the worm gear, see the manufacturers instructions in section 4: Gear motor for
backwash rotor.
Caution:
Do not increase the torque of the slip clutch of the gear motor without consulting
TAPROGGE Service Department.
Rotation monitoring switch

For replacement of parts as well as for the electrical function test and adjustment of the rotation
monitoring switch, see electrical documentation (see section 5) and manufacturers instructions
(section 4, Gear motor for backwash rotor).
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Rev. A
3.1.1.4.
Pneumatic actuator of the discharge valve
(see drawing K2009/20/1367-0502)

The pneumatic actuator has no wear parts and should be completely replaced in case of
defect.
Caution:
As long as the discharge valve is closed the debris accumulated cannot be removed.
Therefore the filter shall be backwashed in the operating mode MANUAL before
starting maintenance work. During replacement of actuator the differential pressure
must not reach the limit value p EXCESSIVE HIGH.
Replacement and repairs according to section 4 "Pneumatic actuator discharge valve "
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Rev. A
3.1.1.5.
3.1.1.5.1.
Valves
Shut-off flap of discharge valve
(see drawing K2009/20/1367-0502)
Warning:
make it safe. Ensure that the voltage supply to the electric actuators has been
danger due to an inrush of water during maintenance work.
To replace parts or make repairs on the valves, please proceed as follows:
Remove the pneumatic actuator of discharge valve (see section 3.1.1.4)
Drain the discharge pipe
Remove the valve from the discharge pipe
Repairs according to section 4 Shut-off flap
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Rev. A
3.1.1.5.2.
Isolation valves of differential pressure measuring system
(see drawing K2009/20/1367-0501)
Caution:
it safe. Ensure that the voltage supply to the electric actuators has been interrupted.
must be drained.
Replace the wear parts (section 3.2.4) or perform repairs according to section 4 Diaphragm
valve
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Rev. A
3.1.1.5.3.
Filter drain valve
Warning:
has been drained.
valve
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Rev. A
3.1.1.6.
Control panel
Caution:
To begin work, the filter must run in emergency actuation according to section 1.3.5.4.
The control panel contains no wear parts. Signal lamps are spare parts and are included in the
control panel.
For repairs of the electrotechnical components see the electrical documentation, section 5 and
the manufacturers' instructions, section 4.
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Rev. A
3.1.2.
PREVENTIVE MAINTENANCE SCHEDULE
DESCRIPTION
ITEM No.
PARTICIPANT
UNIT
SYSTEM
COMPONENT
SEQUENCE
FUNCTION
NUMBER
PERIO
D
ACTION
SPARES
REQUIREMENT
REFERENCE PROCEDURE
TAPROGGE
12/13/14 PAB41/42
AT
010
filter housing
(Debris filter)
coating of housing, external damage,

signs of corrosion
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB41/42
AT
010
sealings (Debris
filter)
tightness of flange connections
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB41/42
AT
010
bearing (Debris
filter)
tightness of bearing (check by means

of indicator hoses)
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB41/42
AT
010
rotor actuation
(Debris filter)
movability : filter backwash in the

operating mode MANUAL (section
1.3.5.3) differential pressure must
drop
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB41/42
AT
010
rotor actuation
(Debris filter)
3Y
tighness of planetary reduction gear
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB41/42
AT
010
filter section,
backwash rotor
and backwash
pipe (Debris
filter)
3Y
fastening of internals, rubberlining of

internal filter housing, damage of
internal parts
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB41/42
AT
010
drain valve
(Debris filter)
coating, external damage, signs of

corrosion, internals
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB41/42
AT
010
drain valve
(Debris filter)
movability of actuation
SHA/14/M/---C05/MM/001
TAPROGGE
12/13/14 PAB41/42
AT
010
drain valve
(Debris filter)
SHA/14/M/---C05/MM/001
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Rev. A
DESCRIPTION
PERIO
D
entire differential
pressure
measuring
system
isolation valves
(Differential
pressure
measuring
system)
isolation valves
(Differential
pressure
measuring
system)
isolation valves
(Differential
pressure
measuring
system)
flushing valves
with flushing
rings (Differential
pressure
measuring
system)
flushing valves
with flushing
rings (Differential
pressure
measuring
system)
flushing valves
with flushing
rings (Differential
pressure
measuring
system)
proper function, cleaning of

differential pressure measuring
system, tightness
SHA/14/M/---C05/MM/001

SHA/14/M/---C05/MM/001
SHA/14/M/---C05/MM/001
SHA/14/M/---C05/MM/001
external damage, signs of corrosion
SHA/14/M/---C05/MM/001
SHA/14/M/---C05/MM/001
tightness of flange connections and

screwed-in connections
SHA/14/M/---C05/MM/001
ITEM No.
PARTICIPANT
UNIT
SYSTEM
COMPONENT
SEQUENCE
FUNCTION
NUMBER
TAPROGGE
12/13/14 PAB41/42
CP
010
TAPROGGE
12/13/14 PAB41/42
CP
010
TAPROGGE
12/13/14 PAB41/42
CP
010
TAPROGGE
12/13/14 PAB41/42
CP
010
TAPROGGE
12/13/14 PAB41/42
CP
010
TAPROGGE
12/13/14 PAB41/42
CP
010
TAPROGGE
12/13/14 PAB41/42
CP
010
ACTION
SPARES
REQUIREMENT
Originator
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REFERENCE PROCEDURE
Rev. A
DESCRIPTION
PERIO
D
remote seals
with capillary
tubes
(Differential
pressure
measuring
system)
electric motor
(Gear motor for
backwash rotor)
fastening, tightness
SHA/14/M/---C05/MM/001
coating, cleanliness, external

damage, signs of corrosion,
operability and movability: proper
cable connection + quiet running,
compare setting current of manual
motor starter with nominal current of
motor
setting of the motor controller for soft
starting
SHA/14/M/---C05/MM/001
cleanliness, quiet running, tightness,

coating
SHA/14/M/---C05/MM/001
circumferential backlash, torque of

slip clutch
SHA/14/M/---C05/MM/001
3Y
wear of worm gear
SHA/14/M/---C05/MM/001
function test
SHA/14/M/---C05/MM/001
function test
SHA/14/M/---C05/MM/001

SHA/14/M/---C05/MM/001
movability of actuation, tightness of

flange connections
SHA/14/M/---C05/MM/001
ITEM No.
PARTICIPANT
UNIT
SYSTEM
COMPONENT
SEQUENCE
FUNCTION
NUMBER
TAPROGGE
12/13/14 PAB41/42
CP
010
TAPROGGE
12/13/14 PAB41/42
AT
010
TAPROGGE
12/13/14 PAB41/42
AT
010
TAPROGGE
12/13/14 PAB41/42
AT
010
TAPROGGE
12/13/14 PAB41/42
AT
010
TAPROGGE
12/13/14 PAB41/42
AT
010
TAPROGGE
12/13/14 PAB41/42
AT
010
TAPROGGE
12/13/14 PAB41/42
AT
010
TAPROGGE
12/13/14 PAB41/42
AA
015
TAPROGGE
12/13/14 PAB41/42
AA
015
electric motor
(Gear motor for
backwash rotor)
gear (Gear
motor for
backwash rotor)
gear (Gear
motor for
backwash rotor)
gear (Gear
motor for
backwash rotor)
rotation
monitoring
switch (Gear
motor for
backwash rotor)
manual
emergency
actuation (Gear
motor for
backwash rotor)
shut-off flap
(Discharge
valve)
shut-off flap
(Discharge
valve)
ACTION
SPARES
REQUIREMENT
Originator
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REFERENCE PROCEDURE
SHA/14/M/---C05/MM/001
Rev. A
DESCRIPTION
ITEM No.
PARTICIPANT
UNIT
SYSTEM
COMPONENT
SEQUENCE
FUNCTION
NUMBER
TAPROGGE
12/13/14 PAB41/42
AA
015
TAPROGGE
12/13/14 PAB41/42
AA
015
TAPROGGE
12/13/14 PAB41/42
AA
015
TAPROGGE
12/13/14 PAB41/42
GH
TAPROGGE
12/13/14 PAB41/42
TAPROGGE
12/13/14 PAB41/42
PERIO
D
ACTION
SPARES
REQUIREMENT
REFERENCE PROCEDURE
pneumatic
actuator
(Discharge
valve)
pneumatic
actuator
(Discharge
valve)
coating, external damage, tightness,

cleanliness
SHA/14/M/---C05/MM/001
SHA/14/M/---C05/MM/001
001
Switching and
signalling device
(Discharge
valve)
control panel
operability, tightening of pneumatic

and electrical connection, tightening
of fastening screws between actuator
and valve, adjustments: final positions
+ limit switches + mechanical position
indicator
operability
SHA/14/M/---C05/MM/001
GH
001
control panel
GH
001
control panel
2Y
lamp for common alarm (by the

function key on control panel door)
external damage, cleanliness,
terminal connections, check
adjustable times, proper function of
control (in the operating mode
AUTOMATIC)
replace battery of PLC (if existing),
replace battery of OP (if existing)
Originator
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SHA/14/M/---C05/MM/001
SHA/14/M/---C05/MM/001
SHA/14/M/---C05/MM/001
Rev. A
3.1.3.
PARTICIPANT
LUBRICATION INSTRUCTIONS AND SCHEDULE

EQUIPMENT
ITEM No.
UNIT
Taprogge
Filter system
SYSTEM
12/13/14 PAB41/42
PARTS TO BE
LUBRICATED
COMPONENT
FUNCTION
SEQUENCE
NUMBER
AT
010
PERIO
D
NUMBER OF
LUBRICATION
LUBRICANT
POINTS
REF 1
REF 2
REF 3
ARAL Degol
GS220
BP Enersyn
SG-XP220
Mobil
Glygoyle
HE460
Worm gear of gear

motor (hexagon
head screw plug)
Originator
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QUANTITY
DRAIN
FREQUENCY
1025 ccm
3Y (exchange)
Rev. A
3.1.4.
SPECIAL TOOLING AND HANDLING DEVICES
Tools for Maintenance
Part name
Material
crank handle 160-B14-D
*)
GGG
shaft crown
*)
1.4301
socket wrench for shaft nut WSS 160
*)
steel
see also section 4, Gear motor for backwash rotor, drawing 1/20/0143-0286
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Rev. A
3.1.5.
STORAGE INSTRUCTIONS
Storage of parts
Caution:
The packing is prepared for a life of 6 or 24 months.
A storage below 5 C (41 F), in particular of rubberlined parts, is not admissible.
The packing is not suitable for outdoor storage.
Parts which cannot be immediately installed shall be stored in dry and lockable rooms.
Delivery
covered with foil in

boxes or on pallets
Inspection
packing
Frequency of
inspections
every 3 months
provide packing (not

splash-proof) with waterrepellent covering
close or repair damaged
packing
(maximum storage 6
months)
in sealed vinyl cover in
boxes
Remarks
packing
every 6 months
(maximum storage 24
months)

in case of open packing:
reseal cover
moisture indicator
(if applicable)
every 6 months
desiccant
every 6 months
check moisture indicator
renew desiccant
Note:
Parts which are not sealed in vinyl cover shall be removed from packing and stored in
dry rooms. If parts cannot be stored as indicated please inform the TAPROGGE Service
Department.
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Rev. A
Disposal of packing material
Note:
Our products are protected for the transport ex works by environmentally friendly
materials (wood, cardboard, paper and PE foil) which can easily be separated and
recycled according to local regulations.
3.1.6.
PRESERVATION INSTRUCTIONS
See sections 1.3.6 and 1.3.7.
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Rev. A
3.2. CORRECTIVE MAINTENANCE INSTRUCTIONS
Wear part
3.2.1.
Drawing no.
Position
Replacement frequency
Debris filter
(12/13/14PAB41AT010 / 12/13/14PAB42AT010)
Backwash rotor
head piece
K2009/20/1367-0503
5.4
every 3 years
Backwash pipe
flange
bearing housing
6.2
K2009/20/1367-0503
6.4
o-ring
every 3 years
6.5
Rotor actuation
washer
cardan joint
7.18
K2009/20/1367-0503
7.22/7.23
bush
7.25
spring pin
7.28
washer
7.29
7.32
corrosion protection
7.38
surface seal
7.43
every 3 years
Inspection hole
gasket
K2009/20/1367-0503
8.3
8.4
with every opening, after 3 years

latest
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Rev. A
Wear part
Drawing no.
Position
K2009/20/1367-0503
11.3
Bearing
groove ball bearing
needle bearing
11.8
wiper
11.6
11.9
11.10
11.11
o-rings
every 3 years, after 5000 rotor

operation hours latest (see
running time meter at the control
panel)
every 3 years or in case of
leakages at the indicator hoses
(11.19, 11.20), after 5000 rotor
operation hours latest (see
running time meter at the control
panel). In order to check sealing
of bearing see section 3.1.1.1.5!
V-Seal
11.14
wearing ring
11.21
every 3 years or if shortened by

approximately 0.5 0.8 mm due
to wear
special-purpose grease
11.26
every 3 years, or after every

disassembly
11.28
sealing adhesive
11.29
sealing tape
11.32
adhesive
11.33
surface seal
11.12
3.2.2.
(12/13/14PAB41CP010 / 12/13/14PAB42CP010)
none
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Rev. A
Wear part
3.2.3.
Drawing no.
Position
Gear motor for backwash rotor 1)
Worm wheel
Set of wear parts V1:
K2009/20/13670503
worm wheel rim
(see section 4)
every 3 years
20
worm shaft
38
groove ball bearing
53, 91
oil
K2009/20/13670503
worm wheel hub
(see section 4)
every 3 years
22
thrust ring
23
parallel key
95

shaft seal
1)
K2009/20/13670503
(see section 4)
every 3 years
61,97,157
During replacing wear parts of the gear motor or spare part electric motor please note the
indication of the running time meter and the reverse operation counter of backwash rotor as
additional information (see operating record section 1.3.9)
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Rev. A
Wear part
3.2.4.
Drawing no.
Position
Valves
(12/13/14PAB41AA015 / 12/13/14PAB42AA015)
Shut-off flap
none
Diaphragm valve
diaphragm
see section 4
443
every 5 years
Note:
See disassembled material to a sound disposal or to separate recycling according to
materials. Observe the national regulations for waste disposal.
After the end of the service life, old rubberlined system parts can be recycled easily via
valuable metal recycling companies (smelting).
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Rev. A
4.
ACCESSORIES
KKS
MATERIAL / TYPE
SUPPLIER
12/13/14PAB41CP010
12/13/14PAB42CP010
Differential pressure transmitter / 1151 DP 4 S
Emerson
12/13/14PAB41CP010
12/13/14PAB42CP010
Remote seal / 1199
Emerson
12/13/14PAB41AT010
12/13/14PAB42AT010
Gear motor for backwash rotor (incl. slip clutch and rotation monitoring
switch) / 80.1
Rhein-Getriebe
12/13/14PAB41AA015
12/13/14PAB42AA015
Pneumatic actuator of discharge valve / EB12-DW
Ebro
12/13/14PAB41AA301
12/13/14PAB41AA302
12/13/14PAB42AA301
12/13/14PAB42AA302
Diaphragm valve / SISTO KB
KSB
12/13/14PAB41AA015
12/13/14PAB42AA015
Shut-off flap / F012-A
Ebro
12/13/14PAB41GH001
Programmable logic controller /
Allen Bradley
12/13/14PAB41GH001
Operator Terminal /
Allen Bradley
12/13/14PAB41GH001
Analogue data repeater /
Turck
12/13/14PAB41GH001
Isolating switching amplifier /
Turck
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Rev. A
5. DRAWING AND PART LISTS

ALSTOM Index no.
SHA/14/M/---C05/FD/001
SHA/14/M/---C05/GA/001
SHA/14/M/---C05/DD/001
Taprogge Index no.

K2009/20/1367-0001
K2009/20/1367-0505
K2009/20/1367-0503
K2009/20/1367-0060
K2009/20/1367-0020
K2009/20/1367-0501
K2009/20/1367-0502
SHA/14/M/---C05/WD/001
SHA/14/M/---C05/DS/001
K2009/20/1367-1000
SHA/14/M/---C05/DS/002
SHA/14/M/---C05/DS/003
SHA/14/M/---C05/DS/004
SHA/14/M/---C05/DS/005
Title
Flow Diagram
Assembly debris filter
Filter section
Inspection hole
Discharge valve
Electrical documentation of control
panel
Data sheet Condenser Debris filter
Data sheet LV Motor Condenser
Debris filter
Data sheet Valves Condenser Debris
filter
Data sheet Pr. Transmitter Condenser
Debris filter
Data sheet Actuator Condenser Debris
filter
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MM/001
19.10.2009
en
87/87

16.09.2009
Schmidlin
Gller
Neugebauer
First issue
FUS
REV
DATE
PREPARED
CHECKED
APPROVED
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
DD
Title :
Sectional drawing of Condenser

Debris Filter with parts list
Language
:E
abcd
No of
sheet : 8
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DD/001
Stand/Status: 11.12.2007
Erstellt/prepared: 16.09.2009/Bo
Blatt/Sheet: 1/4
TL2009201367.xls
TEILELISTE / PARTS LIST

FILTER PR-BW 800
Dokumenten-Nr. / Document No.
entstanden aus / originating from:
zugehrige Zeichnung / relevant drawing:
Pos.
Pos.
Part name
Benennung
Stk
No
QA2008/20/1367-0030
4/20/0150-0109
K2008/20/1367-0503
Sach-Nr.
Ident-No.
Bemerkungen
Remarks
FILTER
FILTER
FILTER GEHUSE
FILTER HOUSING
FILTEREINSATZ
Lagerblock
Halter
Absttzung
Absttzung
Filterelement
Sechskantschraube
Sechskantmutter
Scheibe
Dichtung
Ausgleichblech
Dichtung
Scheibe
Kleber
Schraubensicherung
Sechskantschraube
Scheibe
Sechskantmutter
Sechskantschraube
Scheibe
Scheibe
Sechskantmutter
Sechskantschraube
FILTER SECTION
Bearing block
Bracket
Support
Support
filter element
Hexagon bolt
Hexagon nut
Washer
Gasket
Adjusting sheet
Gasket
Washer
Adhesive
Securing for bolts and nuts
Hexagon bolt
Washer
Hexagon nut
Hexagon bolt
Washer
Washer
Hexagon nut
Hexagon bolt
K2009/20/1367-0060
RCKSPLROTOR
Rotorgehuse
Splstutzen
Kopfleiste
Randwinkel
Randwinkel
Blech
Zylinderstift
Zylinderstift
Sechskantschraube
Sechskantschraube
Sechskantschraube
Sechskantschraube
Sechskantmutter
Scheibe
Scheibe
Schraubensicherung
BACKWASH ROTOR
Rotor housing
Backwash nozzle
Head piece
Border angle
Border angle
Sheet
Parallel pin
Parallel pin
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon nut
Washer
Washer
1/20/0145-0052
4
4.1
4.2
4.3
4.4
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.21
4.22
4.25
4.26
4.27
4.28
4.29
1
1
12
12
12
12
12
12
12
12
12
12
12
1
1
24
120
84
12
48
24
12
60
5
5.1
5.2
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.13
5.14
5.15
5.16
5.17
5.20
1
1
1
1
2
2
1
2
2
12
10
5
14
10
12
14
1
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R = Reserveteil/Spare part
V = Verschleiteil/Wear part
Blatt/Sheet: 2/4
TL2009201367.xls

FILTER PR-BW 800
Pos.
Pos.
Benennung
Stk
No
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
1
1
1
1
1
1
1
6
8
3
2
7
7.1
7.2
7.3
7.4
7.5
7.8
7.9
7.10
7.11
7.12
7.13
7.15
7.16
7.17
7.18
7.19
7.20
7.21
7.22
7.23
7.24
1
1
1
1
1
1
1
1
2
1
1
8
8
8
12
8
4
4
8
1
1
16
V
V
V
R
R
4 R
1 R
1
4
1 R
2
2 R
4 R
4
4 R
4
8
RCKSPLLEITUNG
Splleitung
Flansch
Lagerflansch
Lagergehuse
O-Ring
O-Ring
Sechskantschraube
Scheibe
Gewindestift
Gewindestange
Sechskantschraube
Dichtung
Schraubensicherung
Sechskantmutter
Schraubensicherung
Absttzung
Dichtung
Sechskantschraube
Scheibe
Sechskantschraube
Sechskantmutter
Scheibe
ROTORBETTIGUNG
R Planetengetriebe
Getriebegehuse
Durchfhrung
Dichtungsscheibe
Laterne
R Welle
Zwischenflansch
R O-Ring
R O-Ring
R O-Ring
R Sechskantschraube
R Stiftschraube
Sechskantmutter
R Sechskantschraube
V Scheibe
R Sechskantschraube
R Sechskantmutter
R Stiftschraube
V Wellengelenk
V Wellengelenk
Sechskantmutter
Part name
QA2008/20/1367-0030
4/20/0150-0109
K2008/20/1367-0503
Sach-Nr.
Ident-No.
Bemerkungen
Remarks
BACKWASH PIPE
Backwash pipe
Flange
Bearing flange
Bearing housing
O-ring
O-ring
Hexagon bolt
Washer
Slotted set screw
Threaded rod
Hexagon bolt
Gasket
Hexagon nut
Support
Gasket
Hexagon bolt
Washer
Hexagon bolt
Hexagon nut
Washer
1/20/0144-0063
ROTOR ACTUATION
planetary reduction gear
Gear housing
Pipe channel
Seal washer
Lantern
Shaft
Intermediate flange
O-ring
O-ring
O-ring
Hexagon bolt
Stud
Hexagon nut
Hexagon bolt
Washer
Hexagon bolt
Hexagon nut
Stud
Cardan joint
Cardan joint
Hexagon nut
1/20/0143-0236
Blatt/Sheet: 3/4
TL2009201367.xls

FILTER PR-BW 800
Pos.
Pos.
7.25
7.26
7.27
7.28
7.29
7.30
7.31
7.32
7.33
7.38
7.39
7.40
7.42
7.43
7.46
7.47
7.48
7.49
7.51
7.52
7.53
7.54
7.55
8
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.8
8.10
8.11
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
Benennung
Stk
No
1
16
1
2
1
4
2
1
1
1
1
1
2
1
1
1
2
4
4
4
4
2
4
V
R
V
V
R
R
V
V
R
R
R
V
R
R
4/20/0150-0109
K2008/20/1367-0503
Sach-Nr.
Ident-No.
Bemerkungen
Remarks
Buchse
Scheibe
Dichtung
Schwerspannstift
Scheibe
Schwerspannstift
Zylinderstift
Schraubensicherung
Getriebefett
Korrosionsschutz
Schlauch, wei
Schlauch, rot
Gerader Verbinder
Flchendichtung
Schlauchmanschette
Anschlustck
Bush
Washer
Gasket
Spring pin
Washer
Spring pin
Parallel pin
Gear grease
Corrosion protection
Hose, white
Hose, red
Connector
Surface seal
Collar
Connection piece
Gerade Einschraubverschraubung Pipe union
Verschluschraube
Hexagon head screw plug
Stiftschraube
Stud
Sechskantmutter
Hexagon nut
Scheibe
Washer
Schutzschlauch
Protection hose
Schwerspannstift
Spring pin
INSPEKTIONSFFNUNG
rund
1
Flanschstutzen
1
Deckel
1 V Dichtung
1 V Dichtung
1
Bolzen
3
Scheibe
1
Splint
20
Sechskantschraube
40
Scheibe
20
Sechskantmutter
1
Schraubensicherung
1
1
1
1
1
1
1
1
1
Part name
QA2008/20/1367-0030
LAGERUNG
Rotorwelle
Distanzring
Rillenkugellager
Dichtungstrger
Gleitbuchse
V Abstreifer
Distanzring
V Nadellager
R
R
V
R
INSPECTION HOLE
round
Flange nozzle
Cover
Gasket
Gasket
Clevis pin
Washer
Split pin
Hexagon bolt
Washer
Hexagon nut
K2009/20/1367-0020
BEARING
Rotor shaft
Distance ring
Groove ball bearing
Seal housing
Slide bush
Wiper
Distance ring
Needle bearing
1/20/0142-0091
Blatt/Sheet: 4/4
TL2009201367.xls

FILTER PR-BW 800
Pos.
Pos.
11.9
11.10
11.11
11.12
11.13
11.14
11.15
11.16
11.17
11.18
11.19
11.20
11.21
11.22
11.23
11.24
11.25
11.26
11.27
11.28
11.29
11.30
11.31
11.32
11.33
11.34
Benennung
Stk
No
3
2
1
1
1
1
3
2
3
2
1
1
1
1
12
9
6
1
1
1
V
V
V
V
R
V
R
Part name
4/20/0150-0109
K2008/20/1367-0503
Sach-Nr.
Ident-No.
Bemerkungen
Remarks
O-Ring
O-Ring
O-Ring
Flchendichtung
Wellenmutter
V-Seal
Sechskantschraube
Zylinderstift
R Sechskantschraube
R
R
V
R
R
R
R
V
V
1 V
1
3 R
1 V
1 V
3 R
O-ring
O-ring
O-ring
Surface seal
Slotted round nut
V-Seal
Hexagon bolt
Parallel pin
Hexagon bolt
Gerade Einschraubverschraubung Pipe union
Schlauch, wei
Hose, white
Schlauch, rot
Hose, red
Verschleiring
Wearing ring
Verschluschraube
Hexagon socket screw plug
Zylinderschraube
Hexagon socket head cap screw
Sechskantmutter
Hexagon nut
Scheibe
Washer
Spezialfett
Special-purpose grease
Mehrzweckfett
Multi-purpose grease
Schraubensicherung
Dichtkleber
Sealing adhesive
Lagertrger
Bearing housing
Zylinderschraube
Dichtungsband
Sealing tape
Kleber
Adhesive
Sechskantschraube
Hexagon bolt
QA2008/20/1367-0030
Kopfhhe der Schraube auf k=4 mm

verkrzen (abplanen) / Shorten
(plane) screwhead down to k=4 mm
11.35
11.36
11.39
11.40
11.41
1R
3R
2R
2
3
Sicherungsring
Stiftschraube
Gerader Verbinder
Schutzschlauch
Dichtung
Retaining ring
Stud
Connector
Protection hose
Gasket
Blatt/Sheet: 1/1
TL2009201367.xls

DIFFERENZDRUCK-MESYSTEM /
DIFFERENTIAL PRESSURE MEASURING SYSTEM
QA2008/20/1367-0031
4/00/0983-0926

K2008/20/1367-0501
1/15/0005-0285
Pos.
Pos.
Part name
Benennung
Stk
No
DIFFERENZDRUCKMESYSTEM
Emerson-MD03
Bemerkungen
Remarks
DIFFERENTIAL PRESSURE
MEASURING SYSTEM
Emerson-MD03
1 R Differenzdrucktransmitter
Typ Rosemount 1151 DP4

type Rosemount 1151 DP4
Druckmittler
Remote seal
Druckmittler
Remote seal
Kapillarrohr
Capillary tube
2 R Membranschieber
1 V Membrane
Diaphragm valve
Diaphragm
2 R Dichtung
Gasket
Sechskantschraube
Hexagon bolt
Sechskantmutter
Hexagon nut
16
Scheibe
Washer
Sach-Nr.
Ident-No.
eingestellter Mebereich /
adjusted measuring range
- 10 - + 360 mbar
in Pos. 5 enthalten/included in pos. 5
16.09.2009
Schmidlin
Gller
08.09.2009
Schmidlin
Gller
19.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
Neugebauer
APPROVED
Updated
FUS
Updated
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
IO
Title :
Language
:E
Signal Exchange List
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/IO/001
signals
s - Instrument
Instrumentation
List for iinput/output
nput/output signal
ation Setpoint - Debris Filters 12/13/14PAB41AT010 & 12/13/14PAB42AT010
R
e
v
Sensor / Signal number
Service description
Typical
connection
diagram
I/O
information
for the DCS
Measurement
range
(mbar)
Min.
12 PAB41
EA101
DF1 ALARM
BI
yes
12 PAB41
EA102
DF1 FLUSHING
BI
yes
12 PAB41
EA103
DF1 ON
BI
12 PAB41
EA104
DF1 OFF
13 PAB41
EA101
DF2 ALARM
13 PAB41
EA102
DF2 FLUSHING
BI
yes
13 PAB41
EA103
DF2 ON
BI
13 PAB41
EA104
DF2 OFF
BI
14 PAB41
EA101
DF3 ALARM
BI
yes
14 PAB41
EA102
DF3 FLUSHING
BI
yes
14 PAB41
EA103
DF3 ON
BI
14 PAB41
EA104
DF3 OFF
12 PAB42
EA101
12 PAB42
12 PAB42
Set
point
(mbar)
Process
unit
Event &
Alarm
coding
Signal
user
specif
Max.
EC1
C05
EC0
C05
yes
EC0
C05
BI
yes
EC0
C05
BI
yes
EC1
C05
EC0
C05
yes
EC0
C05
yes
EC0
C05
EC1
C05
EC0
C05
yes
EC0
C05
BI
yes
EC0
C05
DF4 ALARM
BI
yes
EC1
C05
EA102
DF4 FLUSHING
BI
yes
EC0
C05
EA103
DF4 ON
BI
yes
EC0
C05
12 PAB42
EA104
DF4 OFF
BI
yes
EC0
C05
13 PAB42
EA101
DF5 ALARM
BI
yes
EC1
C05
13 PAB42
EA102
DF5 FLUSHING
BI
yes
EC0
C05
13 PAB42
EA103
DF5 ON
BI
yes
EC0
C05
13 PAB42
EA104
DF5 OFF
BI
yes
EC0
C05
14 PAB42
EA101
DF6 ALARM
BI
yes
EC1
C05
14 PAB42
EA102
DF6 FLUSHING
BI
yes
EC0
C05
14 PAB42
EA103
DF6 ON
BI
yes
EC0
C05
14 PAB42
EA104
DF6 OFF
BI
yes
EC0
C05
-10
-10
-10
-10
-10
-10
360
360
360
360
360
360
90
90
90
90
90
90
Comment
08.09.2009
Schmidlin
Gller
26.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
APPROVED
Updated
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Title :
Language
:E
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
LC
Cable Schedule
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/LC/001
SHA/14/M/---C05/ LC/001
27.07.2009
Schmidlin
Gller
10.07.2009
Schmidlin
Gller
03.07.2009
Schmidlin
Gller
06.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
Neugebauer
Neugebauer
Revised according to customer comments
FUS
FUS
FUS
First issue
FUS
APPROVED
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
EL
Title :
Language
:E
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/EL/001
SHA/14/M/---C05/ EL/001
ELECTRICAL LOAD LIST - C05

R
E
V
Functional number
of the electrical
auxiliary
Unit
System
Equipment
Designation
of the driven machine
or of the electrical auxiliary
Load
type
Rated
volt.
V
Voltage
Consumer
type
Nature
Red
und
ancy
(Y/N)
Std
Inter
face
(Y/N)
Rated
Rated
power
factor
power
Rated
eff.
SC
/
FLC
Star
ting
time
(s)
kW/
kVA
Load
conn
diag
Local
Fuse
(A)
Loc.
Load
Term
panel
D
u
t
y
(1)
Feeding
Cubicle
Mechanical absorbed power

During
Stop of
the Unit
At Startup of the
Unit
During
normal
running
D
I
E
S
E
L
U
P
S
SIGNAL EXCHG WITH

DCS FOR INDICATION /
Supplied internally via
control panel
control panel
IFU
D
12/13/14PAB41AT010
12/13/14 PAB41
AT010
12/13/14PAB41AA015
12/13/14 PAB41
AA015
MN CW DEBRIS FILTER 1 MOTOR

MN CW DEBRIS FILTER 1 DISCHARGE
VALVE
12/13/14PAB41GH001
12/13/14 PAB41
GH001
CONTROL PANEL
12/13/14PAB41GH001B
12/13/14 PAB41
GH001B
CONTROL PANEL UPS
12/13/14PAB41GH001C
12/13/14 PAB41
GH001C
CONTROL PANEL UPS
460 AC TRI 60 Hz
IFU
IFU
IFU
IFU
3 kw
B63/400
14PAB41GS100
0,01 kw
B63/400
14PAB41GS100
8 kw
B63/400
14PAB41GS100
120 AC MONO 60 Hz L
0,25 kw
B63/400
14PAB41GS100
120 AC MONO 60 Hz L
0,25 kw
B63/400
14PAB41GS100
24 DC
460 AC TRI 60 Hz
IFU
D
12/13/14PAB42AT010
12/13/14 PAB42
AT010
12/13/14PAB42AA015
12/13/14 PAB42
AA015
MN CW DEBRIS FILTER 2 MOTOR

MN CW DEBRIS FILTER 2 DISCHARGE
VALVE
460 AC TRI 60 Hz
IFU
24 DC
3 kw
0,01 kw
B63/400
14PAB41GS100
B63/400
14PAB41GS100
Comments
To be supplied by client
X
SIGNAL EXCHG WITH
control panel
control panel
Scope
Package
no.
C05
C05
C05
C05
C05
C05
C05
AT010
22.06.2010
Schmidlin
Gller
01.06.2010
Schmidlin
Gller
19.02.2010
Schmidlin
Gller
30.11.2009
Schmidlin
Gller
28.08.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
Neugebauer
Neugebauer
Neugebauer
Integration of clients comments
FUS
FUS
FUS
FUS
First issue
FUS
APPROVED
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
WD
Title :
Electrical and Control Cabinet /
Language
:E
Wiring Diagram
abcd
for Condenser Debris Filter

No of
sheet : 45
Power Systems
Sheet :
Plants
1/45
SHA/14/M/---C05/WD/001
SHA/14/M/---C05/ WD/001
02.07.
Schmidlin
Gller
12.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
APPROVED
First issue
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
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IS
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Doc Type :
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Title :
Language
:E
System Description
abcd
No of
sheet : 17
Power Systems
Sheet :
Plants
1
SHA/14/M/---C05/DM/001
Table of Content
1.
TASK AND FUNCTION DESCRIPTION OF THE TAPROGGE FILTER SYSTEM ........................................................3

Task of the TAPROGGE filter system .........................................................................................................................3
Function description of the TAPROGGE filter system ................................................................................................4
2.
DESCRIPTION OF THE FILTER SYSTEM .......................................................................................................................8
2.1.
Assembly Debris Filter ..................................................................................................................................................8
2.1.1.
Debris Filter PR-BW 800 ..........................................................................................................................................8
2.1.2.
Differential pressure measuring system ............................................................................................................... 10
2.1.3.
Gear motor ............................................................................................................................................................. 13
2.2.
Discharge valve .......................................................................................................................................................... 14
2.3.
Control......................................................................................................................................................................... 15
1.1.
1.2.
2
1. TASK AND FUNCTION DESCRIPTION OF THE TAPROGGE FILTER SYSTEM
1.1.

A TAPROGGE debris filter is installed to prevent clogging of cooling tubes and all related problems.
Fig. 2-1: Schematic Arrangement

1
Filter
2
Discharge valve
3
Discharge pipe
4
For scope of supply please refer flow diagram SHA/14/M/---C05/FD/001.
3
1.2.
Fig. 2-2: Debris filter type PR-BW 800

1
2
3
4
Filter PR-BW 800

Gear motor
Discharge valve
4
The cooling water to be filtered enters the debris filter's 1 "dirty side" A through the filter section. The
filtered water leaves the debris filter at side B. The debris is retained on the filter section. The
differential pressure increases.
discharge pipe to a zone of lower pressure (e.g. open discharge channel, cooling water discharge
line downstream of the condenser / heat exchanger), a strong reverse flow is created in that area
of the filter section which is covered by the backwash rotor. The entire filter section is effectively
cleaned by the rotation of the backwash rotor.
The debris is either carried directly into the discharge channel or reintroduced to the cooling water
discharge line downstream of the condenser / heat exchanger.
Due to the pressure drop across the discharge pipe, the water quantity required for backwashing
the debris filter is only 3 - 8 % of the cooling water to be filtered.
5
water.
Since the area of the filter section covered by the backwash rotor is completely isolated from the
differential pressure of the cooling water during backwashing, the debris filter is fully operational
even if it is loaded with high amount of debris.
If extremely large debris like twigs or pieces of wood block the backwash rotor, the control system
initiates the
automatic reverse of the backwash rotor
Should the backwash rotor drive against an obstacle which impedes the rotor's path, the direction
of rotor revolution is reversed automatically! The automatic reverse feature functions in each
operating mode. This results in the extraordinary operational reliability of the debris filter.
6

FILTRATION
water flow
fibres are retained

filter section
the filter section
PRESSURE-RELIEF

backwash rotor
FILTER BACKWASH

Fig. 2-3: Backwash process
7
2. DESCRIPTION OF THE FILTER SYSTEM

The filter system contains all components and subassemblies required to efficiently filter the cooling
water, to backwash the debris filter and to ensure trouble-free operation of the system.
2.1.
2.1.1.

1
2
3
4
5
6
Filter housing
Filter section
Backwash rotor
Backwash pipe
Rotor actuation
Bearing
8
Filter section
consists of a bearing block with radially arranged support sheets.

The bearing block houses the bearing 6. Filter elements are fixed
between the support sheets thus forming the individual filter
segments.
The filter elements are made of perforated stainless steel sheets
with a semiconical design to ensure proper stiffness.
Backwash rotor
is connected to the backwash pipe 4. During the backwash

procedure, the backwash rotor successively covers each filter
segment.
Backwash pipe
Considering the pressure ratio, the diameter of the backwash

pipe is designed for the proper water discharge required for filter
backwash.
Rotor actuation
consists of the gear box flanged to the bearing block (housing of

bearing 6), a cardan shaft and the gear motor. The rotor
actuation is isolated from the cooling water.
Bearing
The bearing of the backwash rotor is equipped with multiple

seals to protect the bearing against penetration of water and
debris particles. This protection results in enhanced product life.
By the arrangement of the seals at the bearing, two chambers
are formed which are connected to the atmosphere by means of
two coloured indicator hoses. The indicator hoses - one white and
one red hose - lead to the outside of the debris filter. The proper
sealing of the bearing can be checked by means of these
indicator hoses even during the filter operation.
9
2.1.2.
Fig. 2-5: Differential pressure measuring system

1
2
3
6
7
9

Remote seal PLUS
Isolation valves
Measuring nozzles
Operator panel
10
The differential pressure measuring system (p system) monitors the amount of debris on the filter
by constantly measuring the differential pressure (p).
The differential pressure is electronically converted to a signal.
Operator panel 9
indicates:


initiates:

limit value 1:
(test function)
The proper functioning of the measuring system is electrically
monitored constantly. In the event of a fault, the differential
pressure falls below limit value IN-SERVICE MONITORING and
an alarm message will be signalled by the control system.
limit value 2:
(service function)
FILTER BACKWASH
If debris accumulates on the filter section, the differential
pressure increases. If the limit value FILTER BACKWASH is
reached, the automatic control system initiates filter
backwash, until the differential pressure falls below the pre-set
limit value.
limit value 3:
(security function)
p EXCESSIVE HIGH
If the differential pressure continues to increase in spite of the
existent backwash and reaches the limit value p EXCESSIVE
HIGH, the automatic control system continues filter backwash.
Simultaneously, a signal and an alarm message are indicated.
The customer can connect the potential free alarm from the
control panel to the control room.
11
Isolation valves 6
The differential pressure measuring system can be isolated

from the cooling water flow for maintenance purposes by
means of the isolation valves.
12
2.1.3.
Gear motor
The backwash rotor is operated by a special gear motor designed for 100 % continuous operation.
It is equipped with a slip clutch, which protects the backwash rotor, the actuation and the gear
motor against overload by power interruption, if a pre-set torque is exceeded.
The automatic reverse of the backwash rotor is initiated when the rotation monitoring switch has
tripped. The rotation monitoring switch is coupled to the gear motor of the backwash rotor.
13
2.2.
Discharge valve
The discharge valve in this filter system is a shut-off flap operated by a specially designed part-turn
actuator (electric or pneumatic) with short running time. In the open position, the valve allows an
unrestricted flow of the debris laden water.
The part-turn actuator is equipped with limit switches signalling the end positions to the control
panel. It is also equipped with torque limit switches protecting the valve as well as the actuator
against overload.
14
2.3.
Control
operation (programmes) are stored in a single programme (Flashcard).
By means of a selector switch at the control panel the operating mode AUTOMATIC or MANUAL is
selected.
All further operations are effected via function keys at the operator panel.
cases:
function key FILTER CONTINUOUS BACKWASH
malfunction differential pressure measuring system (intermittent backwash every 3 minutes)
function key p SYSTEM FLUSH
Backwash
The part-turn actuator opens the discharge valve

discharge pipe.
control system
If p < limit value FILTER BACKWASH, the backwash rotor stops and the discharge valve
closes
15
Note:
The operating mode MANUAL is not permitted for routine filter operation and
may be selected for commissioning and in case of trouble in the operating
mode AUTOMATIC only!
panel.
Backwash


discharge pipe.

16
Control panel

...
...
...

main switch
operator panel for

indication:
operation:
individual alarms
reverse operation counter of the backwash rotor
timers of control
alternative language
setting of timers
selection of language
The control panel contains potential-free contacts which should be connected to the control room
by the customer.
17
13.10.2009
Schmidlin
Gller
Neugebauer
First issue
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Doc Type :
MD
Handling drawings
Language
:E
for Debris Filters
abcd
No of
sheet : 3
Power Systems
Sheet :
Plants
SHA/14/M/---C05/MD/003

SHA/14/M/---C05/MD/003
Rev.A
Handling instructions for Condenser Debris Filter BW 800
Lifting points
Lifting device
Weight 5900 kg
Remark: observe the maximal load of the chains and check if the chains are correctly fastened. The length of
chains must allow having an angle smaller than 60.
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MD/003
13.10.2009
EN
2/3
Rev.A
Handling instructions for CCW Exchanger Debris Filter BW 100
Lifting points
Lifting device
Gear motor
Weight 1100 kg
Remark: according to the length of chains, its necessary to demount the gear motor in order to avoid the
deteriorations during the handling of debris filter.
Remark: observe the maximal load of the chains and check if the chains are correctly fastened. The length of
chains must allow having an angle smaller than 60.
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/MD/003
13.10.2009
EN
3/3
28.05.2009
Schmidlin
Gller
Neugebauer
First issue
FUS
REV
DATE
PREPARED
CHECKED
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CONTRACTOR
abcd
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IS
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Title :
Debris Filters
Language
:E
abcd
No of
sheet : 3
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DS/100
SHA/14/M/---C05/ DS/100
PARTICIPANT
EQUIPMENT
ITEM No.
UNIT
Taprogge
Filter system for

Condenser
SYSTEM
12/13/14 PAB41/42
PARTS TO BE
LUBRICATED
COMPONENT
FUNCTION
SEQUENC
E NUMBER
AT
010
Worm gear of
gear motor
(hexagon head
screw plug)
PERIOD
NUMBER OF
LUBRICATION
LUBRICANT
POINTS
REF 1
REF 2
REF 3
ARAL Degol
GS220
BP Enersyn
SG-XP220
Mobil
Glygoyle
HE460
QUANTITY
DRAIN FREQUENCY
1025 ccm
3Y (exchange)
PARTICIPANT
EQUIPMENT
ITEM No.
UNIT
SYSTEM
PARTS TO BE
LUBRICATED
COMPONENT
FUNCTION
SEQUENC
E NUMBER
PERIOD
NUMBER OF
LUBRICATION
LUBRICANT
POINTS
REF 1
REF 2
REF 3
QUANTITY
DRAIN FREQUENCY
Taprogge
Filter system for

CCW Exchanger
12/13/14 PCB15/16
AT
010
bearing of
backwash
rotor, worm
wheel of
reduction gear
(worm wheel
shaft/ worm
shaft )
ARAL Aralub
HLP 2
BP
Energrease
LS-EP 2
ESSO
Beacon EP 2
500 g
3Y
Taprogge
Filter system for

CCW Exchanger
12/13/14 PCB15/16
AT
010
bearing of
backwash
rotor, rolling
bearing
120/180 x 28
(cage)
ARAL Aralub
HLP 2
BP
Energrease
LS-EP 2
ESSO
Beacon EP 2
250 g
3Y (exchange)
Taprogge
Filter system for

CCW Exchanger
12/13/14 PCB15/16
001
Gear motor for

backwash rotor
(gear housing)
ARAL
Getriebel
EP 85 W-90
ARAL Degol
BG 150 / BG
220
BP Energol
GR-XP 150 /
220
700 ccm
3Y (exchange)
Taprogge
Filter system for

CCW Exchanger
12/13/14 PCB15/16
002
gear of partturn actuator of

discharge
valve (worm
wheel / worm
shaft / manual
drive worm /
planetary
gearing)
ARAL Aralub
FDP 00
CLS Grease
DEA
Glissando
6833 EP00
300 g
3Y (exchange)
Taprogge
Filter system for

CCW Exchanger
12/13/14 PCB15/16
002
switching and
signalling
device of partturn actuator
(cover of gear
housing)
ARAL Aralub
FDP 00
CLS Grease
DEA
Glissando
6833 EP00
5g
3Y (top up)
10.09.2009
Schmidlin
Gller
07.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
APPROVED
Updated
FUS
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CONTRACTOR
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Ta p r o g g e
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IS
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Doc Type :
DS
Title :
DATA SHEET Condenser Debris

Filter
Language
:E
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DS/001
DATA SHEET
ENERGY
Pow er Pl ants
CONDENSER DEBRIS FILTERS ND 84
Project : SHOAIBA III

1
2
CLIENT
NUMBER
3
4
5
6
TYPE
Conveyed fluid
Max operation temperature
Rated flow
Unit : 12/13/14
SAUDI ELECTRICITY COMPANY

SIX
FUNCTIONAL CODE
12/13/14PAB41AT010 /
12/13/14PAB42AT010
Mfr's REFERENCE
K2009/20/1367
MANUFACTURER
TAPROGGE GmbH
OPERATING CHARACTERISTICS
Seawater
50C
30010 m/h
10
Design pressure
11
Mesh aperture
7 bar gauge / Vacuum
12
Washing water consumption
13
Head loss clean
14
Inlet/outlet apertures - ND (1)
15
Drilling through flanges
16
Washing water discharge aperture - ND (1)
17
Electric power supplies
18
Motor power
19
Rotation speed of washing system
20
Capacity of the reducing gear oil casing
n.a.
21
Oil type
n.a.
22
Installation level
5 mm dia. with pitch 6 mm / 60

min. 900 m/h
0.73 mWG
2100 mm
AWWA C207 Cl D
DN 350 ANSI B16.5, 150 lbs
460 V / 60 Hz
3 Kw
6.rpm
n.a.
l
m
23
CONSTRUCTION
24
Type
25
Material
Grade
Standard
Mild steel
S235JR / rubberlined
EN 10025
26
27
Housing
28
Filter Element
Duplex Stainless Steel
1.4462
DIN EN
10088
29
Washing system
1.4462
DIN EN
10088
30
Lower bearings
31
Internal bolts and nuts
32
External bolts and nuts
33
Gaskets
PA 6 G for seawater
1.4462
A193B7 / A194Gr2M
equivalent A4-70 / A4
Asbestos free
34
WEIGHTS AND OVERALL DIMENSIONS
35
36
WEIGHT
37
In operating order
38
Empty
39
OVERALL DIMENSIONS
40
Length
See drawing SHA/14/M/---C05/GA/001
41
Width
42
Height
13,7 t
4t
43
44
45
46
OUTLINE AND LAYOUT DIAGRAM
47
(supporting and lifting included)
48
49
50
51
REMARKS
(1) nominal diameter
Rubber
DIN EN
10088
29.07.2009
Schmidlin
Gller
27.07.2009
Schmidlin
Gller
17.07.2009
Schmidlin
Gller
15.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
Neugebauer
Neugebauer
APPROVED
Updated
FUS
Updated
FUS
Updated
FUS
First issue
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CLIENT
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CONSULTANT
CONTRACTOR
abcd
Power Systems
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Format :
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Ta p r o g g e
58292 Wetter
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IS
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KKS
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Doc Type :
DS
Title :
LV Motor DATA SHEET
Language
:E
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DS/002
Rev. D
1
2
CLIENT
QUANTITY
3
4
MOTOR DESIGNATION RA 500/280

DRIVEN MACHINE Debris Filter (Condenser)
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
POWER SUPPLY NETWORK

Type
: alternating
Voltage between phases / variation
:460V +10-15%
Frequency / variation
:
60Hz +6-5%
Neutral
:
grounded
ENVIRONMENT
Installation area : non explosive explosive
Nature of service ambient conditions
:
Atmosphere
:
clean
Max - min - normal air temperature
:
55/9/30
Relative maximum humidity
: 100 %
Altitude
:6m
Particular risks
:
Seismicity
: UBC Zone 2A
MOTOR CHARACTERISTICS
Motor type
Location
Arrangement
Rated voltage
Rated frequency
Rated output
Synchronous speed
Slip (4/4 load)
Rated current
Starting current Id/In
Rated torque
Starting torque Cd/Cn
Max. torque Cmax/Cn
No load current
FUNCTIONAL CODE
12/13/14PAB41AT010 /
12/13/14PAB42AT010
Alstom
2 per unit
: asynchronous
:
inside
:
horizontal
: 460V
: 60Hz
: 3 kW
: 1800 rpm
: 82%
: 4,7 A
: 5,6
: 15 Nm
: 2,5
:3
: 6,2 A
2/4
3/4
4/4
MANUFACTURER
Rheingetriebe
CONSTRUCTION
Rotor
Stator winding
- class of insulation
- winding impregnation
- temperature rise
Type construction
Frame
dry
Coupling type
Bearings
- on shaft ends sides
- on opposite side or thrust
- lubrication type
Mfr's REFERENCE
K2009/20/1367
: class F
: varnish
:B
:
B
:
: F7
: roller bearing
: roller bearing
:
grease or oil flow or quantity per bearing : -l/mn

grease or oil viscosity
:
oil inlet/outlet temperature
:
-/
grease or oil change every
:-
Cooling
- type
- ventilating air flow
- cooling water pressure
- cooling water flow
- water inlet/outlet temp rise
- water inlet/outlet head losses
PAINTING
kg
-cSt
C
TEFC
:
:
:
:
:
:
/
/
m/h
bar abs.
m/h
C
Mwg
RAL 7037
MATERIALS
Stator winding
:
Stator bars
:
Efficiency
%
Frame
:
82,5
82
Power factor
Shaft
:
0,82
Cyclic duration factor
: n.a.
Insulation
:
Impregnation
:
Motor inertia
: 0,0047 kgm
Terminal box
:
Starting time
: < 6sec.
Rotor laminations
:
Number of successive startings
:3
:
Stator laminations
Max. permissible amplitudes of vibrations < 1 mm
Noise level 1 m from the motor surface :
<70 dB(A) (A)
WEIGTHS AND OVERALL DIMENSIONS
Protection class
: IP56
Rotation viewed from coupling end
Axis height
:
clockwise
Height
:
Stator winding coupling
:
star
Length
:
Width
:
Applicable standards
Shaft end diameter
:
- design
: IEC 60034
Net weight
:
- construction
: IEC 60034
- tests
: IEC 60034
Standard
VDE
VDE
VDE
VDE
n.a.
n.a.
VDE
VDE
VDE
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/DS/002
29.07.2009
en
2/2
steel
cast +Al
steel
n.a.
n.a.
Al
steel
steel
85 mm
196 mm
372 mm
258 mm
20 mm
24 kg
Originator
Grade
copper
14.09.2009
Schmidlin
Gller
20.07.2009
Schmidlin
Gller
18.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
Neugebauer
APPROVED
Updated
FUS
Updated
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
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CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
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IS
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Doc Type :
DS
Title :
Valves DATA SHEET
Language
:E
abcd
No of
sheet : 3
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DS/003
Rev. C
DATA SHEET
VALVES
ENERGY
Pow er Pl ants
Project : SHOAIBA Unit : 12/13/14

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
DESIGNATION
12/13/14PAB41AA015
12/13/14PAB42AA015
IDENTIFIER
SUPPLIER
Mfr's REFERENCE
ND =
14 (DN350)
14 (DN350)
TAPROGGE
K2009/20/1367
ISO-PN ANSI B16.5 150lbs
/ SERIES =
CONSTRUCTION - CODES - STANDARDS
ANSI B 16-34
DIN
NFE
General constructive arrangements
Butterfly valve
- Body
ISO 5752
Cast
Forged
Fabricated
Die-worked
- Obturator
DIN 3202
- Body / bonnet junction
feather key
Bolted
Autoclave
Screwed & welded
- Weld end connection
Not applicable
Materials :
- housing
Cast iron with EPDM Sleeve
- disc
1.4469
- valve shaft
1.4462
- housing seat
NBR
- bolts
A4-70, DIN ISO 8992
OPTIONS
Body :
Straight
Angle
Inclined
3-way
- Pipe connection :
O D x inlet / outlet thickness
DN14 (DN350) ANSI B16.5, Class 150 lbs, R.F.
- Neck : Material :
inlet / outlet diameter
DN14 (DN350)
Control : Manual
Yes
No
Motor-driven : emerg. man. contr.
with withou without reducer
*
t
electric
pneumatic
hydraulic
- By-pass ND
n.a.
- Decompression ND
n.a.
- Over-pressure valve (>= 2500 Lbs)
*
n.a.
Stuffing-box :
Standard gasket
Gasket for vacuum
Water seal
Limit-switch on positions :
Open
Closed
Intermediate
Position Transmitter
No
Driving column Stem lengthening piece
No
Accesory for check valve
not applicable
Counter weight
Damper
Seat bore
-integral
Yes
-seat
350
Replacement Ring
Yes
Lining: Body/Obturator
NBR/no lining
Water seal
NBR
SERVO-MOTOR
pneumatic
Nature of fluide
Maximum pressure
6 bar abs. for motor
Temperature
Flow
50
C
1000
m3/h
Breakdown torque
*
520 Nm
Operation time
/ Rpm of stem
n.a.
s
/
Particular conditions :
Differential pressure allowing operation
6 bar
Torque required for operation
*
520 Nm
Setting of torque limiter
*
n.a.
Seat / obturator tightness : class / standard
Installation - orientation : by-pass / servo-motor
Drawing No
Weight of valve with fittings
*
123 kg
Fluid :seawater
Max. pressure : 10
bar G.
Max. temp. : 60
C
REMARKS : The lines marked with * will be completed by the supplier. The others must obligatorily be filled in by ALSTOM
if needed, completed by the supplier.
Originator
Rev.
Date
Lang.
Sheet
ALSTOM
TAPROGGE
SHA/14/M/---C05/DS/003
14.09.2009
en
2/3

Rev. C
DATA SHEET
VALVES
ENERGY
Pow er Pl ants

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
DESIGNATION
12/13/14PAB41AA201
12/13/14PAB42AA201
IDENTIFIER
SUPPLIER
Mfr's REFERENCE
ND =
2 (DN50)
2 (DN50)
TAPROGGE
K2009/20/1367
/ SERIES =
ANSI B 16-34
DIN
NFE
Drain valve
- Body
ISO 5752
Cast
Forged
Fabricated
Die-worked
- Obturator
DIN 3202
feather key
Bolted
Autoclave
Screwed & welded
Not applicable
Materials :
- housing
EN-JL-1040, DIN EN 1561
- diaphragm
EPDM
- switching shaft
1.4104, DIN EN 10088-1
- seal rings / gaskets
n.a.
- bolts
5.6, DIN ISO 8992
OPTIONS
Body :
Straight
Angle
Inclined
3-way
- Pipe connection :
DN50 ANSI B16.5, Class 150 lbs, R.F.
- Neck : Material :
DN50
Control : Manual
Yes
No
*
t
electric
pneumatic
hydraulic
- By-pass ND
n.a.
- Decompression ND
n.a.
*
n.a.
Stuffing-box :
Standard gasket
Gasket for vacuum
Water seal
Closed
Intermediate
Open
No
No
not applicable
Counter weight
Damper
Seat bore
-integral
Yes
-seat
350
Replacement Ring
Yes
NBR/no lining
Water seal
NBR
SERVO-MOTOR
pneumatic
Nature of fluide
Maximum pressure
Temperature
Flow
50
C
1000
m3/h
Breakdown torque
*
520 Nm
Operation time
/ Rpm of stem
n.a.
s
/
10 bar
*
Manually operated
*
n.a.
Drawing No
*
10,3 kg
Fluid :seawater
Max. pressure : 10
bar G.
Max. temp. : 60
C
if needed, completed by the supplier.
Originator
Rev.
Date
Lang.
Sheet
ALSTOM
TAPROGGE
SHA/14/M/---C05/DS/003
14.09.2009
en
3/3

18.05.2009
Schmidlin
Gller
Neugebauer
First issue
FUS
REV
DATE
PREPARED
CHECKED
APPROVED
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
DS
Title :
Pressure Transmitter DATA SHEET
Language
:E
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DS/004
SHA/14/M/---C05/ DS/004
ENERGY
Pow er Pl ants
DATA SHEET
PRESSURE TRANSMITTER
Unit : 14,13,12
1
2
3
4
5
6
CLIENT
SAOUDI ELECTRICITY COMPANY
Quantity
Functional code (s)
14/13/12 PCB41CP010
14/13/12 PCB42CP010
Destination
Debris filter
Debris filter
MAKE
ROSEMOUNT-EMERSON
ROSEMOUNT-EMERSON
Type
1151 DP4
1151 DP4
MANUFACTURER
TAPROGGE GmbH
FUNCTIONAL CODE
14/13/12 PAB41/42CP010
Mfr's REFERENCE
K2009/20/1367
8
9
10
11
12
13
14
15
16
17
18
Nature of fluid
19
Nominal/maximum pressure
water
20
Nominal/maximum temperature
21
Density
22
water
bar abs.
5,5/16
50/70
5,5/16
50/70
appr. 1000kg/m
appr. 1000kg/m
370mbar
INSTRUMENT
23
Scale
bar abs.
370mbar
24
Measuring scale
bar abs.
-10 to 360 mbar
-10 to 360 mbar
25
Accuracy
0,1% of SPAN
0,1% of SPAN
26
Transmitter
Yes
Yes
27
Action
28
Signal/power supply characteristics
%
DIRECT / INDIRECT
29
4-20mA HART / 24V DC
(SMART TYPE)
(SMART TYPE)
CONSTRUCTION
30
31
Box
32
Protection class IP
33
Instrument connections
34
Coupling - dimensions
35
Location - standards
36
Connection
Yes / No
37
Expansion loop
38
Manifold
39
Drain trap
IP65
IP65
mm
DN3 Remote seal
DN3 Remote seal
mm
DN 3 Remote seal
DN 3 Remote seal
Yes / No
No
No
Yes / No
No
No
Yes / No
No
No
Electrical/process
40
41
MATERIALS
42
Gear chamber
1.4401/1.4404
1.4401/1.4404
43
Box
Aluminium
Aluminium
44
Equipment
2.4819
2.4819
45
Nut & bolts
SS316
SS316
DRAWINGS - NOTICES
K2009/20/1367-0501
K2009/20/1367-0501
46
47
48
49
50
51
52
53
REMARKS Local Indicator LCD Type = 0-100%

Label AISI 316
Transmitters with capillaries: capillary length 3 m, Flange ANSI RF, liquid fill with silicon oil
Issue
Date
Author
Checked by
Approved by
A
18.05.2009
Schmidlin
Gller
Neugebauer
N SHA/14/M/---/C05/DS/004
04.08.2009
Schmidlin
Gller
18.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
APPROVED
Updated
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
DS
Title :
Actuator DATA SHEET
Language
:E
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DS/005
Rev. B
Actuator
Series/Size
EBRO / EB12-DW
Spring Range
n.a.
Supply Pressure
3-8 bar
Action
0,7 s
Air failure
n.a.
Hand Wheel
n.a.
Pn.tubing Size/Mtl.
L-connection for air tube
Shut-off Pressure
6 bar
IBR
IBR for Pressure Parts
n.a.
Air Filter Regulator with Gauge
Make/Model
n.a.
Qty
Filter Size
Valve Positioner
Make/Model
local positioner by Ebro
Input Signal/Action
Certification
Cable Entry
Cable Gland
Limit Switch
Qty
n.a.
Specifications
Solenoid Valve
Qty
1
Supplier/type
Festo / NVF3
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/DS/005
04.08.2009
en
2/2

02.06.2010
Schmidlin
Gller
22.10.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
APPROVED
Revised acc. to clients comments
FUS
First issue / Preliminary
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
MP
Title :
Language
:E
for
abcd
CCW Exhanger Debris Filter

No of
sheet : 89
Power Systems
Sheet :
Plants
SHA/14/M/---C05/MM/002
SHA/14/M/---C05/ MM/002
Rev. A
Maintenance manual number :
SHA/14/M/---C05/MM/002
Equipment component code :
See equipment schedule
Equipment description :
Filter System
Subcontractor name :
Taprogge
Subcontractor document N. :
K2009/20/1368
List of contents
1.
EQUIPMENT DESCRIPTION & OPERATING INSTRUCTIONS ..............................................................5

1.1. Task and function description of the TAPROGGE filter system ............................................................... 5
1.1.1.
Task of the TAPROGGE filter system ..........................................................................................................5
1.1.2.
Function description of the TAPROGGE filter system ................................................................................6
1.2. Description of the filter system .................................................................................................................. 10
1.2.1.
Assembly Debris Filter ................................................................................................................................10
1.2.1.1.
Debris Filter PR-BW 100 .......................................................................................................................10
1.2.1.2.
1.2.1.3.
Gear motor..............................................................................................................................................14
1.2.2.
Discharge valve ...........................................................................................................................................15
1.2.3.
Control ..........................................................................................................................................................16
1.3. Operating instructions................................................................................................................................ 19
1.3.1.
General .........................................................................................................................................................19
1.3.1.1.
Definition of basic position .....................................................................................................................20
1.3.2.
Description of operating modes ..................................................................................................................21
1.3.2.1.
Operating mode AUTOMATIC LOCAL .................................................................................................21
1.3.2.2.
Operating mode MANUAL .....................................................................................................................22
1.3.3.
Pre-commissioning settings and checks....................................................................................................23
1.3.3.1.
Testing and setting of the control panel ................................................................................................24
1.3.3.2.
Dry function test......................................................................................................................................26
1.3.3.3.
Commissioning of the actuators ............................................................................................................27
1.3.3.3.1. Part-turn actuator of discharge valve ...............................................................................................27
1.3.3.3.2. Gear motor for backwash rotor .........................................................................................................28
1.3.4.
Commissioning of the differential pressure measuring system ................................................................29
1.3.4.1.
Functional test of the control and setting of the limit values at the diff. press. measuring system ...30
1.3.4.2.
Filter system start-up..............................................................................................................................32
1.3.5.
Operation of the filter system ......................................................................................................................33
1.3.5.1.
Routine filter operation (AUTOMATIC): ................................................................................................33
1.3.5.2.
Filter backwash in the operating mode Automatic ...............................................................................34
1.3.5.2.1. Programme "filter backwash"............................................................................................................35
1.3.5.2.2. Programme "filter extended backwash" ...........................................................................................36
1.3.5.3.
Filter backwash in the operating mode MANUAL ................................................................................37
1.3.5.4.
Emergency operation (voltage breakdown) ..........................................................................................38
1.3.6.
Filter system shut-down ..............................................................................................................................39
1.3.7.
Measures to prevent corrosion due to stagnation .....................................................................................40
1.3.8.
Filter system restart after shut-down ..........................................................................................................41
1.3.9.
Operating Record ........................................................................................................................................42
1.3.10.
"Indication" and Operation"; Operator terminal screens ...........................................................................44
1.3.11.
Operational trouble-shooting.......................................................................................................................45
1.3.11.1. Backwash rotor fault...............................................................................................................................46
Originator
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22.10.2009
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Rev. A
1.3.11.2. Fault of actuator of discharge valve ......................................................................................................47
1.3.11.3. Fault of differential pressure measuring system ..................................................................................49
1.3.11.4. p EXCESSIVE HIGH ...........................................................................................................................50
1.3.11.5. Voltage breakdown.................................................................................................................................51
1.3.11.6. PLC fault .................................................................................................................................................52
1.3.11.7. Battery low ..............................................................................................................................................53
2.
ENVIRONMENTAL, HEALTH AND SAFETY ............................................................................................54
3.
MAINTENANCE ...........................................................................................................................................55
3.1. Preventive maintenance ............................................................................................................................ 55
3.1.1.
PREVENTIVE MAINTENANCE INSTRUCTIONS ....................................................................................55
3.1.1.1.
Debris filter ..............................................................................................................................................56
3.1.1.1.1. Bearing assembly ..............................................................................................................................56
3.1.1.1.2. Backwash rotor ..................................................................................................................................65
3.1.1.2.
3.1.1.3.
Gear motor for backwash rotor .............................................................................................................71
3.1.1.4.
Part-turn actuator of the discharge valve ..............................................................................................72
3.1.1.5.
Valves......................................................................................................................................................74
3.1.1.5.1. Ball valve of discharge valve .............................................................................................................74
3.1.1.5.2. Isolation valves of differential pressure measuring system ............................................................75
3.1.1.5.3. Filter drain valve.................................................................................................................................76
3.1.1.6.
Control panel ..........................................................................................................................................77
3.1.2.
PREVENTIVE MAINTENANCE SCHEDULE ............................................................................................78
3.1.3.
LUBRICATION INSTRUCTIONS AND SCHEDULE .................................................................................81
3.1.4.
SPECIAL TOOLING AND HANDLING DEVICES .....................................................................................82
3.1.5.
STORAGE INSTRUCTIONS ......................................................................................................................83
3.1.6.
PRESERVATION INSTRUCTIONS ...........................................................................................................84
3.2. CORRECTIVE MAINTENANCE INSTRUCTIONS.................................................................................. 85
3.2.1.
Debris filter ...................................................................................................................................................85
3.2.2.
Differential pressure measuring system .....................................................................................................86
3.2.3.
Gear motor for backwash rotor ...................................................................................................................86
3.2.4.
Valves ...........................................................................................................................................................87
4.
ACCESSORIES ...........................................................................................................................................88
5.
DRAWING AND PART LISTS ....................................................................................................................89
Originator
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Sheet
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22.10.2009
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Rev. A
EQUIPMENT SCHEDULE
KKS No.
DESCRIPTION
REFERENCE PROCEDURE
EQUIPMENT
TYPE
PARTICIPANT
UNIT
SYSTEM
COMPONENT
FUNCTION
SEQUENCE
NUMBER
TAPROGGE
12/13/14
PCB15
AT
001
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB16
AT
001
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15
CP
010
Diff. press. measuring system
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB16
CP
010
Diff. press. measuring system
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15
AA
016
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB16
AA
016
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15
GH
001
Control panel
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB16
GH
001
Control panel
SHA/14/M/---C05/MM/002
Originator
Rev.
Date
Lang.
Sheet
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22.10.2009
en
4/89

Rev. A
1.
EQUIPMENT DESCRIPTION & OPERATING INSTRUCTIONS
1.1.
Task and function description of the TAPROGGE filter system
1.1.1.

1
Filter
2
Discharge valve
3
Discharge pipe
4
For scope of supply please see flow diagram SHA/14/M/---C05/FD/002.
Originator
Rev.
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Sheet
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Rev. A
1.1.2.

1
2
3
4
Filter PR-BW 100

Gear motor
Discharge valve
Originator
Rev.
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Sheet
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Rev. A
The cooling water to be filtered enters the debris filter's 1 "dirty side" A through the filter section.
The filtered water leaves the debris filter at side B. The debris is retained on the filter section.
The differential pressure increases.
discharge pipe to a zone of lower pressure (e.g. open discharge channel, cooling water
discharge line downstream of the condenser / heat exchanger), a strong reverse flow is created
in that area of the filter section which is covered by the backwash rotor. The entire filter section
is effectively cleaned by the rotation of the backwash rotor.
The debris is either carried directly into the discharge channel or reintroduced to the cooling
water discharge line downstream of the condenser / heat exchanger.
Due to the pressure drop across the discharge pipe, the water quantity required for
backwashing the debris filter is only 3 - 8 % of the cooling water to be filtered.
Originator
Rev.
Date
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Rev. A
water.
Since the area of the filter section covered by the backwash rotor is completely isolated from
the differential pressure of the cooling water during backwashing, the debris filter is fully
operational even if it is loaded with high amount of debris.
Originator
Rev.
Date
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Sheet
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Rev. A

FILTRATION
water flow
fibres are retained

filter section
the filter section
PRESSURE-RELIEF

backwash rotor
FILTER BACKWASH

Backwash process
Originator
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9/89

Rev. A
1.2.
Description of the filter system
The filter system contains all components and subassemblies required to efficiently filter the
water, to backwash the debris filter and to ensure trouble-free operation of the system.
1.2.1.
1.2.1.1.

1/2
3
4
5
6
Filter housing
Bearing assembly
Backwash rotor
Filter section with wiper
Inspection hole
Originator
Rev.
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Rev. A
The filter housing 1 / 2
consists of two hemispheres, one carrying the cooling water inlet, the
other carrying the cooling water outlet flange. The hemisphere with
the cooling water inlet flange is further equipped with an inspection
hole. In case of horizontal installation, the hemisphere with the
cooling water outlet flange includes a drain nozzle.
The nozzle (C) with blind flange can be used for inspection of
hemisphere 2.
The two hemispheres are bolted together by a pair of flanges positioned
at an angle of 45 to the cooling water inlet / outlet axis. This
configuration allows an installation of the debris filter either in a straight
pipe or as a substitute for a 90-elbow without any modifications or
additional assemblies.
Bearing assembly
consists of a rotating hollow shaft with worm gear. The water is

discharged through the hollow shaft. The backwash rotor is actuated by
the gear motor which is mounted to the worm gear. The discharge valve
is fixed to the outlet flange of the bearing assembly.
The backwash rotor 4
consists of a funnel-shaped arm with rubber lips. This arm is connected

to the bearing assembly by a flange connection.
Filter section
weldless design; standard perforations typically start from 2 mm

(special designs for smaller perforations available). A wiper is mounted
to the filter section. All debris particles that cling to the rubber lip of the
backwash rotor are reliably detached and discharged with the next
backwash rotor rotation.
Originator
Rev.
Date
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Rev. A
1.2.1.2.

1
2
3
6
7
9

Remote seal PLUS
Isolation valves
Measuring nozzles
Operator terminal
Originator
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Rev. A
The differential pressure measuring system (p system) monitors the amount of debris on the
filter by constantly measuring the differential pressure (p).
The differential pressure is electronically converted to a

signal.
Operator terminal 9
indicates:
initiates:
limit value 1:
(test function)


The proper functioning of the measuring system is
electrically monitored constantly. In the event of a fault,
the differential pressure falls below limit value INSERVICE MONITORING and an alarm message will be
signalled by the control system.
limit value 2:
(service function)
FILTER BACKWASH
If debris accumulates on the filter section, the
differential pressure increases. If the limit value FILTER
BACKWASH is reached, the automatic control system
initiates filter backwash, until the differential pressure
falls below the pre-set limit value.
limit value 3:
(security function)
p EXCESSIVE HIGH
If the differential pressure continues to increase in spite
of the existent backwash and reaches the limit value p
EXCESSIVE HIGH, the automatic control system
continues filter backwash. Simultaneously, a signal and
an alarm message are indicated. The customer can
connect the potential free alarm from the control panel
to the control room.
Isolation valves 6
The differential pressure measuring system can be

isolated from the cooling water flow for maintenance
purposes by means of the isolation valves.
Originator
Rev.
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Rev. A
1.2.1.3.
Gear motor
The backwash rotor is operated by a special gear motor designed for 100 % continuous
operation.
Originator
Rev.
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Rev. A
1.2.2.
Discharge valve
The discharge valve in this filter system is a ball valve operated by a specially designed partturn actuator with short running time. In the open position, the valve allows an unrestricted flow
of the debris laden water.
against overload.
Originator
Rev.
Date
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Rev. A
1.2.3.
Control
operation (programmes) are stored in a single programme (EEPROM).
By means of a selector switch at the control panel the operating mode AUTOMATIC or
MANUAL is selected.
All further operations are effected via function keys at the operator terminal.
cases:
function key FILTER EXTENDED BACKWASH
malfunction differential pressure measuring system (intermittent backwash every 3

minutes)
Backwash

discharge pipe.
control system
If p < limit value FILTER BACKWASH, the backwash rotor stops and the discharge
valve closes
Originator
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Rev. A
Note:
The operating mode MANUAL is not permitted for routine filter operation and may be
selected for commissioning and in case of trouble in the operating mode AUTOMATIC
only!
terminal.
Backwash


discharge pipe.

Originator
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Rev. A
Control panel

...
...
...

main switch
operator terminal for

indication:
operation:
individual alarms
timers of control
setting of timers
The control panel contains potential-free contacts which should be connected to the
control room by the customer.
Originator
Rev.
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Rev. A
1.3.
Operating instructions
1.3.1.
General
The filter system is automatically operated. The differential pressure measuring system
monitors debris accumulation on the filter section. When the differential pressure reaches the
pre-set limit value FILTER BACKWASH, the automatic control initiates the filter backwash.
If the automatic control failed, backwashing must be manually initiated upon reaching the limit
value FILTER BACKWASH.
Caution:
Operation of the cooling water circuit without the control panel switched on will lead to
mechanical damage of the filter.
Originator
Rev.
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Rev. A
1.3.1.1.
Definition of basic position
Operation starts from the basic position, which is defined as follows:
KKS *)
Component / subassembly
Status
12/13/14 PCB15 GH001 Control panel

12/13/14 PCB16 GH001
selector switch MANUAL /

AUTOMATIC
in position AUTOMATIC
main switch Q01 in position I
12/13/14 PCB15 AT001 Gear motor for backwash rotor

12/13/14 PCB16 AT001
OFF
12/13/14 PCB15 AA016 Discharge valve

12/13/14 PCB16 AA016
CLOSE
12/13/14 PCB15 AA301 Isolation valves of differential

12/13/14 PCB16 AA302 pressure measuring system
OPEN
*) see flow diagram SHA/14/M/---C05/FD/002
The filter system leaves the basic position under one of the following conditions:
p reaches the limit value FILTER BACKWASH
function key FILTER BACKWASH is pressed at the operator terminal
function key FILTER EXTENDED BACKWASH is pressed at the operator terminal
control command filter backwash is sent from the control room
filter backwash is initiated by timer
alarm message p SYSTEM DEFECT
Alarm messages are indicated at the control panel and at the control room
Originator
Rev.
Date
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Sheet
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22.10.2009
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Rev. A
1.3.2.
Description of operating modes
1.3.2.1.
Operating mode AUTOMATIC LOCAL
In the operating mode AUTOMATIC LOCAL, all motor-operated components are actuated via
the control programmes. The isolation valves of the differential pressure measuring system
must be manually actuated. The operator terminal indicates the actual operating status of the
motor-operated components.
The accumulation of debris on the filter section causes an increasing differential pressure which
is constantly monitored by the differential pressure measuring system. During routine filter
operation the filter system is monitored by the differential pressure measuring system.
As a standard the debris filter must be backwashed once a day, unless operational experiences
require other backwash sequences. The debris filter can be backwashed by the function key
FILTER BACKWASH.
When the alarm p SYSTEM DEFECT is activated, a filter backwash cycle is initiated for a
pre-set duration (intermittent backwash).
Originator
Rev.
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22.10.2009
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Rev. A
1.3.2.2.
In the operating mode MANUAL, all motor-operated components are individually actuated via
the appropriate function keys at the operator terminal. The actual operating status of the motoroperated components is indicated at the operator terminal.
The operating mode MANUAL is selected :
for commissioning
in the event of problems in the operating mode AUTOMATIC
Note:
The operating mode MANUAL is not permitted for routine filter operation!
In the operating mode MANUAL the differential pressure on the filter section is indicated.
However, the debris filter is not automatically backwashed upon reaching the limit value
FILTER BACKWASH.
Upon reaching the limit value FILTER BACKWASH, filter backwash must be manually initiated.
Upon reaching the limit value p EXCESSIVE HIGH, an alarm message is indicated at the
control panel and at the control room. The debris filter must be backwashed in the operating
mode MANUAL (for details see section 1.3.5.3). In operating mode MANUAL the filter
backwash programme will not be automatically initiated.
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
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22.10.2009
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Rev. A
1.3.3.
Conditions:
All components are installed
All electrical connections have been made and checked to be in accordance with the
specified circuit diagram, operating voltage and frequency. For more information see
electrical documentation in section 5.
Verify rotating magnetic field of three-phase connection for clockwise rotation.
Cooling water line is not flooded
Originator
Rev.
Date
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22.10.2009
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Rev. A
1.3.3.1.
Testing and setting of the control panel
Check the actual operating voltage; change transformer connection(s), if necessary
All manual motor starters in the position I
Connection of terminals checked
All fuses in working order
Insert main fuse F 01.

position MANUAL
Main switch Q01 in position
All miniature circuit breakers in the position ON
Connect voltage supply (green LED POWER lights up)
CPU must be in position RUN (green LED indicates RUN mode); green LED COMM 0
lights up.
Connect voltage supply (green LED POWER lights up)
CPU must be in position RUN (green LED indicates RUN mode)
Check lamp for proper functioning by push-button LAMP TEST
Preliminary programming of limit values at the operator terminal (see section 9), as
follows:

p = 156 mbar
p = 200 mbar
Set the timers to the following values; after commissioning, record timer settings and
send one copy to TAPROGGE
Originator
Rev.
Date
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Sheet
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22.10.2009
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24/89

Rev. A
Time Table
Timer
(adjustable
by function
key)
Denomination
Factory set
value
time filter backwash
30 sec.
time filter backwash after start filter backwash

from the control room
300 sec.
start filter backwash, if differential pressure

measuring system is defective
180 sec.
start filter backwash
Value after
commissioning
24 h
execution time check: running time of discharge

valve
30 sec.
time filter extended backwash
900 sec.
The following internal timers are already factory pre-set, alterations are not permitted:
Timer
Denomination
Value
iT
execution time check: test contact of differential pressure

measuring system
5 sec.
iT
delay time limit value filter backwash
5 sec.
iT
delay time limit value "p excessive high"
10 sec.
Originator
Rev.
Date
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Sheet
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22.10.2009
en
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Rev. A
1.3.3.2.
Dry function test
Before flooding the filter system, the function of the backwash rotor and the discharge valve
must be checked.
Conditions:
the check must be performed without water in the filter system
selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in position

MANUAL
main switch Q01 in position I = ON
Discharge valve
The running times for the pneumatic actuator can be adjusted at the exhaust regulator with
sound absorber.
Backwash rotor
Warning:
During the following functional test do not reach into the filter housing.
Otherwise severe injury will result due to rotating parts!
Start the backwash rotor by the function key backwash rotor ON at the operator
terminal. The backwash rotor should now rotate. The proper rotation should be visually
checked through the inspection hole.
Close the inspection hole and tighten bolts.
Turn the backwash rotor off by pressing the function key backwash rotor OFF at the
operator terminal.
Originator
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Rev. A
1.3.3.3.
Commissioning of the actuators
selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the position

MANUAL
1.3.3.3.1.
Part-turn actuator of discharge valve
Check the moving direction of the part-turn actuator of ball valve:
Use the handwheel of the part-turn actuator in order to turn the ball valve into a position
between the final positions OPEN and CLOSE
Press the function key discharge valve CLOSE
Before reaching the final position CLOSE: stop the part-turn actuator by pressing the
function key STOP
If the ball valve does not move into the direction CLOSE (note mechanical position
indicator at the part-turn actuator), correct the wiring by changing two of three phases at
the terminal strip of the part-turn actuator.
Setting the limit switches of the part-turn actuator of ball valve
The torque limit switches have already been factory pre-set.
The travel limit switches must be set according to the manufacturers instructions (see
section 4 Part-turn actuator of discharge valve).
Originator
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Rev. A
The assignment of limit switches to the moving direction of the ball valve into the final positions
OPEN / CLOSE depends on the rotation direction of the part-turn actuator:
Rotation direction of
part-turn actuator
Moving direction of
ball valve
Assignment of limit switches
CLOSE
torque limit switch and

travel limit switch
closing
counterclockwise
OPEN

travel limit switch
opening
clockwise
OPEN

travel limit switch
closing
CLOSE

travel limit switch
opening
clockwise
counterclockwise
Final positions CLOSE and OPEN

Turn the handwheel of the part-turn actuator into the final position CLOSE.
Set the travel limit switch for the position CLOSE.
Turn the handwheel of the part-turn actuator into the final position OPEN.
Set the travel limit switch for the position OPEN.
Press the function key discharge valve CLOSE.

Upon reaching the final position CLOSE, the part-turn actuator is shut off by the travel
limit switch. The final position is signalled to the operator panel by the same travel limit
switch.
Press the function key discharge valve OPEN.

Upon reaching the final position OPEN, the part-turn actuator is shut off by the travel
limit switch. The final position is signalled to the operator panel by the same travel limit
switch.
Note:
The torque limit switches serve as an overload protection. If they are tripping,
an alarm message will be indicated (see section 5).
1.3.3.3.2.
The gear motor has already been factory pre-adjusted.
Originator
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Rev. A
1.3.4.
Commissioning of the differential pressure measuring system
Conditions :

minimum

normal

maximum admissible
389 kg/s
499 kg/s
528 kg/s
Isolation valves of differential pressure measuring system are open
Setting of the differential pressure transmitter and programming at the operator

terminal:
Zero point and measuring range of the differential pressure transmitter have already been set.
The limit values shall be programmed at the operator terminal by selecting the screen "Setting"
(see section 1.3.10).
Determination of pclean:
Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in position

AUTOMATIC LOCAL
Main switch Q01 at the control panel in the position I
Backwash the filter repeatedly by means of the function key FILTER BACKWASH.
Read the differential pressure directly after each filter backwash. The mean value is
determined as the differential pressure of the clean filter (pclean).

p = pclean + 80 mbar (preliminary value)
p = pclean + 160 mbar (preliminary value)
Originator
Rev.
Date
Lang.
Sheet
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22.10.2009
en
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Rev. A
1.3.4.1.
Functional test of the control and setting of the limit values at the diff. press.
measuring system
Conditions :

minimum

normal

maximum admissible
389 kg/s
499 kg/s
528 kg/s

Main switch Q01 at the control panel in position I
Check limit value FILTER BACKWASH

Programming of limit value FILTER BACKWASH at the operator terminal to a value <
pclean.
The programme "Filter backwash is initiated according to section 1.3.5.2.
Programming of limit value FILTER BACKWASH to the preliminary value (see section
1.3.4.3)
After the backwash procedure the differential pressure of the clean filter (pclean) will be
indicated (see section 1.3.4.3).
Check limit value p EXCESSIVE HIGH in the operating mode MANUAL


position MANUAL
pclean.
The following alarm messages are indicated:
individual alarm
common alarm
at the control room
p EXCESSIVE HIGH
p EXCESSIVE HIGH
ALARM
common alarm
1.3.4.3)
Originator
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22.10.2009
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Rev. A
Check limit value p EXCESSIVE HIGH in the operating mode AUTOMATIC


pclean.
The control initiates filter backwash according to section 1.3.5.2. Moreover, the following
alarm messages are indicated:
individual alarm
common alarm
at the control room
p EXCESSIVE HIGH
p EXCESSIVE HIGH
ALARM
common alarm
1.3.4.3)

p = pclean + 80 mbar
p = pclean + 160 mbar
Originator
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Rev. A
1.3.4.2.

minimum

normal

maximum admissible
389 kg/s
499 kg/s
528 kg/s

Main switch at the control panel in position I
The filter system is in the basic position (see section 1.3.1.1).
Filter backwash by the function key FILTER BACKWASH

Filter backwash according to section 1.3.5.2
The filter system is now ready for operation.
Originator
Rev.
Date
Lang.
Sheet
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22.10.2009
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Rev. A
1.3.5.
Operation of the filter system
1.3.5.1.
Routine filter operation (AUTOMATIC):
In the basic position the debris filter separates debris from the cooling water
KKS*)
Component to be
operated
filter system
*)
Position
basic
position
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
control panel
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
gear motor for

backwash rotor
OFF
12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
discharge valve
CLOSE
12/13/14
PCB15
AA301
12/13/14
PCB16
AA302
isolation valves of
measuring system
OPEN
Action
Indication
selector switch MANUAL / AUTOMATIC LOCAL /

AUTOMATIC REMOTE in the position
AUTOMATIC LOCAL
backwash rotor OFF
Originator
Rev.
Date
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22.10.2009
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Rev. A
1.3.5.2.
Filter backwash in the operating mode Automatic
Under the following operating conditions, the debris filter must be backwashed several
times as a precautionary measure:
during start of the cooling water pump
before start of another condenser / heat exchanger
before start of another cooling water pump
during or after cleaning work at the cooling water pipe or at the cooling water pump
sump
when high tide
Backwash of the debris filter can be accomplished as follows:

in the operating mode AUTOMATIC LOCAL:
repeatedly press the function key

FILTER EXTENDED BACKWASH at
the operator terminal
Before shutdown of the filter system the debris filter must be backwashed several times as
a precautionary measure:
in the operating mode AUTOMATIC LOCAL:
or
repeatedly press the function key

FILTER BACKWASH at the operator
terminal
by means of repeating the control
commands filter backwash from the
control room in AUTOMATIC
REMOTE
Originator
Rev.
Date
Lang.
Sheet
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22.10.2009
en
34/89

Rev. A
1.3.5.2.1.
KKS*)
Programme "filter backwash"
Component to be
operated
Position
Action
Indication
initiated by one of the following conditions:
12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
discharge valve
OPEN
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
gear motor for

backwash rotor
ON
p-indication reaches the limit value

FILTER BACKWASH

FILTER BACKWASH
timer (recommended setting 24 h)
FILTER BACKWASH
FILTER BACKWASH
backwash rotor ON
*)
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
gear motor for

backwash rotor
OFF
12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
discharge valve
CLOSE

backwash rotor OFF
Even after the pre-set backwash period has elapsed, the filter will automatically continue backwashing until the
differential pressure measured across the filter section falls below the limit value FILTER BACKWASH. The
backwash rotor then stops and the discharge valve closes.
Originator
Rev.
Date
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Rev. A
1.3.5.2.2.
KKS*)
Programme "filter extended backwash"
Component to be
operated
Position
12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
discharge valve
OPEN
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
gear motor for

backwash rotor
ON
Action
Indication
initiated by
- function key FILTER CONTINUOUS

BACKWASH
- p reaches limit value p excessive high

backwash rotor ON
after the pre-set time (filter extended backwash):
*)
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
gear motor for

backwash rotor
OFF
12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
discharge valve
CLOSE

backwash rotor OFF
Originator
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Rev. A
1.3.5.3.
KKS*)
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
Component to be
operated
Position
control panel
Action
Indication

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
discharge valve
OPEN
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
gear motor for

backwash rotor
ON
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
*)
Filter backwash in the operating mode MANUAL
gear motor for

backwash rotor
OFF
12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
discharge valve
CLOSE
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
control panel
p-indication reaches the limit value FILTER

BACKWASH
function key discharge valve OPEN
function key backwash rotor ON
backwash rotor ON
after approximately 1 minute of backwash rotor

operation, check:
function key backwash rotor OFF
backwash rotor OFF
function key discharge valve CLOSE

AUTOMATIC LOCAL
Note:
The operating mode MANUAL is not permitted for routine filter operation. It is only intended for
commissioning and in case of trouble in the operating mode AUTOMATIC!
Originator
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Rev. A
1.3.5.4.
Emergency operation (voltage breakdown)
Caution:
If voltage does not return immediately, the following measures must be taken in order to avoid
damage of the filter.
KKS*)
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
Component to be
operated
Position
control panel
discharge valve
Action
Indication
main switch Q01 in the position 0
OPEN
actuation by the part-turn actuator handwheel
mechanical position indicator at partturn indicator in the position OPEN
After removing the cover at the worm gear, attach

the handwheel (included in the scope of supply)
to the free shaft end and move the backwash
rotor by turning the handwheel. One backwash
rotor cycle corresponds to approximately 80 turns
of the handwheel in the indicated direction
gear motor for

backwash rotor
verify return of voltage

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
discharge valve
gear motor for

backwash rotor
CLOSE
actuation by the part-turn actuator handwheel
mechanical position indicator at partturn indicator in the position CLOSE
remove the handwheel

reinstall the worm gear cover
control panel
control panel
push-button LAMP TEST
control panel
Filter backwash:
lamp at the control panel lights while

pressing the push-button
selector switch MANUAL / AUTOMATIC

in the position AUTOMATIC
check:
filter system
*)
continue routine filter operation according to

section 1.3.5.1
Originator
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Rev. A
1.3.6.
Filter system shut-down
KKS*)
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
Component to be
operated
Position

AUTOMATIC LOCAL
control panel

or
control command FILTER BACKWASH
(from the control room)
discharge valve
OPEN
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
gear motor for

backwash rotor
ON
12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
Indication
Filter backwash:
12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
Action
FILTER BACKWASH
backwash rotor ON

gear motor for
backwash rotor
OFF
discharge valve
CLOSE

backwash rotor OFF
check:
filter system
basic
position
after filter backwash:

cooling water pump
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
*)
control panel
OFF
The filter system is now out of operation
Originator
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Rev. A
1.3.7.
Measures to prevent corrosion due to stagnation
During prolonged shut-down periods the following must be strictly observed:
The corrosion resistance of stainless steel in aggressive water can be affected by the conditions
prevailing during shut-downs.
During shut-down periods, stagnant water, as well as evaporation of remaining water (e.g. drops),
is to be avoided.
The following measures are necessary to prevent corrosion damage :
Shut-downs up to 3 days:
Run the cooling water pump for a few minutes each day to circulate the cooling water and
to rinse deposits away.
If a high amount of debris is expected during operation of the cooling water pump turn the
main switch Q01 in the position I and backwash the debris filter according to section
1.3.5.3.
Shut-downs over 3 days require a dry conservation

Drain the TAPROGGE components
Clean the internals of the filter system with fresh water
Dry by natural aeration
Originator
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Rev. A
1.3.8.
Filter system restart after shut-down
For shut-downs up to 3 days or maintenance of the debris filter

(with water in the filter system):
Functional test of control and

setting of the limit values at the
differential pressure measuring system
Resume routine filter operation
For shut-downs over 3 days or after maintenance of

the drained debris filter
Resume of routine filter operation
Originator
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Rev. A
1.3.9.
Operating Record
For documentation of the debris filter operation please use the attached form.
The documentation of the operational parameters of the TAPROGGE filter system on a regular
basis is helpful to evaluate special operational conditions, to optimize settings of the differential
pressure measuring system and timers and to trace the cause of damages.
We recommend recording the indicated differential pressure of the clean debris filter every 2
weeks and after each alarm p EXCESSIVE HIGH (potential-free contact)
We kindly ask you to have one completed copy of the form ready for information of the
TAPROGGE service department.
Originator
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Rev. A
Operating Record
Date
Differential pressure
after the last filter
backwash (pclean)
Backwash rotor
operation hours
Remarks
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Rev. A
1.3.10. "Indication" and Operation"; Operator terminal screens
Originator
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Rev. A
1.3.11. Operational trouble-shooting
Note:
Alarm messages are indicated at the operator terminal of the control panel and at the control room
(common alarm) and can be reset in operating mode MANUAL* / AUTOMATIC* by means of the
push-button ALARM RESET. If operational trouble cannot be solved by following the procedures
described herein, or if alarm messages continue, kindly inform the TAPROGGE Service
Department. After trouble shooting, continue filter operation according to section 1.3.5.1.
Originator
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Rev. A
1.3.11.1.
Backwash rotor fault
Indication at
operator terminal
tripped
Potential-free
contact to
control room
common alarm
Probable cause
Remedy

tripped
Reclose the manual motor starter. If the manual motor

the gear motor for backwash rotor according to section
4 "Gear motor for backwash rotor
Originator
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Rev. A
1.3.11.2.
Fault of actuator of discharge valve
Indication at
operator terminal
Potential-free
contact to
control room
Probable cause
Remedy
motor starter tripped
common alarm
motor current
too high
Reclose the manual motor starter, if the manual motor

the part-turn actuator of the discharge valve according
to section 4 "Part-turn actuator of discharge valve".
Check motor current
Check setting of manual motor starter
motor temperature
too high
motor short or earthcircuit

malfunction both travel
limit switches actuated
not adjusted
defective cabling
running time exceeded
OPEN
CLOSE
Check cooling of motor

Check temperature of the part-turn actuator according
to section 4 "Part-turn actuator discharge valve"
documentation in section 5"
Check setting travel limit switches according to section
4 "Part-turn actuator of discharge valve"
Check whether the discharge valve is difficult to move
or blocked by means of the actuator handwheel
Check the travel limit switches according to section 4
"Part-turn actuator of discharge valve"
Check the torque limit switch according to section 4
Check running time of discharge valve according to
the time table, section 1.3.3.1
Check contacts of contactor
Originator
Rev.
Date
Lang.
Sheet
TAPROGGE
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22.10.2009
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Rev. A
Indication at
operator terminal
Potential-free
contact to
control room
torque limit switches

tripped
OPEN
CLOSE
Probable cause
Remedy
Check whether the discharge valve is difficult to move

or blocked by means of the actuator handwheel
Check the travel limit switches according to section 4
Check the torque limit switch according to section 4
cabling

Caution:
If the discharge valve has not opened completely due to a defect of the part-turn actuator, the
discharge valve must be turned to the position OPEN by means of the part-turn actuator
handwheel.
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Rev. A
1.3.11.3.
Fault of differential pressure measuring system
The filter is running in "intermittent backwash", i.e. the filter is backwashing every 180
seconds.
Indication at
operator terminal
Potential-free
contact to
control room
p SYSTEM DEFECT
common alarm
Probable cause
no signal from
transmitter
measuring range fault
p below limit value

IN-SERVICEMONITORING for
more than 5 sec.
current loop of transmitter interrupted
Remedy
Check the calibration of the differential pressure

transmitter according to section 4 "Differential
pressure transmitter"
Check the differential pressure transmitter according

to section 4 "Differential pressure transmitter".
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Rev. A
1.3.11.4.
p EXCESSIVE HIGH
Indication at
operator terminal
Potential-free
contact to
control room
Probable cause
Remedy
p excessive high
common alarm

1.3.4.4
p excessive high
extraordinary amount
of debris
Check the pre-screening system
cooling water flow

increased

1.3.4.4
change in load and

type of debris:
deviation from design
data
discharge flow fallen

below the design data
Verify that the

- discharge valve is fully opened
- backwash pipe is not clogged
cooling water flow rate
is less than the design
data (insufficient
backwash)
sense of rotation
backwash rotor
Check the rotation direction: the plate indicating turning direction must correspond with the worm shaft
rotation (worm shaft rotation can be observed after
dismantling the cap located at the free end of bearing
housing)
Complete the operating record after each alarm p EXCESSIVE HIGH
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Rev. A
1.3.11.5.
Voltage breakdown
Note:
In the event of voltage breakdown, run the filter system in emergency operation (see section
1.3.5.4).
Indication/Signal
at control panel
Potential-free
contact
to control room
no indication
common alarm
Probable cause
Remedy
no supply voltage to
the control panel
Check the main supply voltage

no control voltage
Check the manual motor starter of the control

voltage transformer

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Rev. A
1.3.11.6.
PLC fault
Indication at
operator terminal
and CPU
Potential-free
contact to
control room
no indication
LED at CPU:
FLT
Probable cause
Remedy
common alarm
Replace fuse, check wiring according to the electrical

documentation in section 5 and section 4
"Programmable controller"
common alarm
CPU fault

documentation in section 5
to
the
electrical
data bus fault

documentation section 5
to
the
electrical
at operator terminal:
no active nodes found
on network
Compare error number, section 4, "Operator Terminal"
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Rev. A
1.3.11.7.
Battery low
Indication at
operator terminal
and CPU
Potential-free
contact to
control room
battery low
common alarm
Probable cause
Remedy
battery of PLC has run Replace / add the battery of the CPU as soon as
out
possible
(see
also
manufacturer's
manual
"programmable logic controller")
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Rev. A
2.
ENVIRONMENTAL, HEALTH AND SAFETY
The operating instructions contain basic information on erection, operation and maintenance. For
this reason it is essential that the operating instructions are carefully read before erection and
commissioning by both the installation personnel as well as those responsible for operation and
maintenance. The operation manual must always be available.
In order to prevent personal injury or property damage particular note must be taken of the
following:
the technical data and information as described in the operating instructions
accident prevention regulations
safety regulations of plant operator
electric protective measures acc. to local safety regulations
technical information on manufacturing plates
warning plates at components
regulations concerning environmental protection
all work on or near the system is to be done by qualified personnel
Moreover, the operating instructions contain safety notes which, if ignored, may cause
damage to persons, machinery or environment and which can be identified by the
following symbols:
Warning:
means that danger to life may result if corresponding measures are

not taken or ignored.
Caution:
means that personal injury or considerable material damage may

result if corresponding measures are not taken or ignored.
Note:
points out important information to which the readers specific

attention is drawn.
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Rev. A
3.
MAINTENANCE
3.1. Preventive maintenance
3.1.1.
PREVENTIVE MAINTENANCE INSTRUCTIONS
In general the following must be observed during maintenance work:
Lightly grease metal parts before assembly.
In order to avoid crevice corrosion, the non-rubberlined sealing surfaces are to be

cleaned and completely covered with a permanently flexible sealing material during
maintenance work.
Only lubricate and grease o-rings with a silicone-based valve grease free of
hydrocarbons (see lubrication list)
Avoid excessive force, especially in case of rubberlined components
Pipes shall be connected stress-free. Take care of fixing points and expansion joints
to avoid unexpected forces at the components.
Restart the filter system according to section 1.3.8. after the maintenance work has been
completed.
If maintenance work cannot be performed according to the procedures described herein

kindly inform the TAPROGGE Service Department.
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Rev. A
3.1.1.1.
3.1.1.1.1.
Debris filter
Bearing assembly
(see drawing K2009/20/1368-0503)
To replace wear parts the subassembly must be completely disassembled. We recommend to

have this work done by the TAPROGGE Service Department.
Warning:
danger due to an inrush of water into the filter during maintenance work.
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Rev. A
o-rings
1.3.37
1.3.66
1.3.74
1.3.75
gaskets
1.3.71
1.3.79
wipers
1.3.72
1.3.80
o-rings
1.3.81
The replacement of
1.3.82
wiper
1.3.26
o-ring
1.3.37
guide ring
1.3.38
wiper
1.3.16
o-ring
1.3.77
tab washer
1.3.78
is described in section 3.1.1.1.2

lubricant for
1.3.64
worm wheel and bearings
For assembly, you will need securing for bolts and nuts (Loctite 242) 1.3.62, securing for bolts
and nuts (Loctite 270) 1.3.63 and permanently elastic sealing material 1.3.69.
Worn-out internal sealing (1.3.71, 1.3.74, 1.3.75, 1.3.79, 1.3.81, 1.3.82) can be immediately
detected by leaks from the open bottom drain hole in seal supports 1.3.3 and 1.3.70 or 1.3.4
and 1.3.73.
The bearing assembly is protected towards the worm wheel shaft by additional sealings,
permitting a temporary continuation of filter operation. However, the sets of wear parts V1, V2
and V4 (see also section 3.2.1) must be replaced by the next opportunity.
Dismantling
Disconnect the discharge pipe.
Loosen hexagon socket head cap screws 1.3.43 and remove the seal support 12 1.3.4
with all assembled components.
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Rev. A
Loosen the hexagon socket head cap screw 1.3.58, remove the o-ring 1.3.66 and seal
support 9 1.3.73.
Replace o-rings 1.3.66, 1.3.74 and 1.3.75 as well as gaskets 1.3.79 and wipers 1.3.80
(Note: insert wear parts after greasing with silicone grease GX 1).
Install the seal support 9 1.3.73 with assembled o-rings 1.3.74 / 1.3.75 as well as gasket
1.3.79 and wiper 1.3.80 into the seal support 12 1.3.4 with the o-ring 1.3.66 and
hexagon socket head cap screw 1.3.58.
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Rev. A
Replace the wiper 1.3.26.
Loosen hexagon nut 1.3.46 and carefully support the hollow shaft 1.3.1 with the
backwash rotor in the filter housing. The corrosion protection of the filter housing
(rubberlining, coating) must not be damaged.
Note:
If the upper half of the filter housing has been disassembled (see section
3.1.1.1.2 Replacement of wear parts of backwash rotor) the hollow shaft 1.3.1
must be prevented from sliding out.
Screw the bow of the safety device for mounting (special tool is provided within the
scope of supply) to nut 1.3.9 by means of hexagon bolts.
Loosen slotted round nut 1.3.32 by means of hook wrench (special tool within scope of
supply) and remove together with distance ring 1.3.15 and tab washer 1.3.33.
Pull off the housing 1.3.2 complete with the worm gear and gear motor.
Remove the parallel keys 1.3.25, guide rings 1.3.38 and loosen hexagon socket head
cap screws 1.3.36.
Carefully remove the seal support 11 1.3.3 with o-ring 1.3.37.
Dismantle the seal support 10 1.3.70 with o-rings 1.3.81, 1.3.82, gasket 1.3.71 and
wiper 1.3.72.
Dismantle bush 1.3.8 with guide rings 1.3.38.
Replace gaskets 1.3.71 and wiper 1.3.72 as well as o-rings 1.3.81, 1.3.82 and guide
rings 1.3.38.
Replace the o-ring 1.3.37; grease the new o-ring with silicone grease GX 1 before
installation.
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Rev. A
Assembly
Apply the permanently elastic sealing material 1.3.69 to the medium touched contact
surfaces of positions 1.3.1, 1.3.8, 1.3.58.
Mount bush 1.3.8 with guide rings 1.3.38.
Slip mounting device (enclosed in the set of special tools) onto the hollow shaft 1.3.1
and completely install the seal support 11 1.3.3 with seal support 10 1.3.70 and o-ring
1.3.37; carefully avoid any skewing!
Note:
The bores of the housing 1.3.2 and the seal supports 1.3.3 / 1.3.70 and 1.3.4 /
1.3.73 must be mounted in true alignment. The bottom drain holes must be
open.
Tighten the hexagon socket head cap screws 1.3.36.
Remove the mounting device and insert parallel keys 1.3.25.
Mount the housing 1.3.2 with the complete worm gear and fix with hexagon nuts 1.3.46.
Install the distance ring 1.3.15, tighten the slotted round nut 1.3.32 and secure with tab
washer 1.3.33.
Remove bow of the safety device for mounting.
Carefully position the fully assembled seal support 12 1.3.4.
Flange-mount the discharge pipe; ensure that the wiper 1.3.26 is fitted correctly !
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Rev. A
Replacement of:
worm wheel shaft

worm shaft
groove ball bearing
angular ball bearing
1.3.6
1.3.7
1.3.28/1.3.29
1.3.54
For assembly, you will need securing for bolts and nuts (Loctite 242) 1.3.62.
The parts above mentioned are not wear parts. If replacement becomes necessary,
please proceed as follows:
Please ensure the following:
heat the bearings with suitable heaters before assembly

maximum temperatures
position 1.3.28 approximately 80 C (176 F)
position 1.3.29 approximately 70 C (158 F)
do not damage the seal contact surfaces on the hollow shaft
the bottom drain holes must be open
Dismantling
Disconnect the discharge pipe.
Loosen hexagon socket head cap screws 1.3.43 and remove seal support 12 1.3.4 with
all assembled components.
Loosen hexagon nut 1.3.46 and carefully support the hollow shaft 1.3.1 with the
backwash rotor in the filter housing. The corrosion protection of the filter housing
(rubberlining, coating) must not be damaged.
Note:
If the upper half of the filter housing has been disassembled (see section
3.1.1.1.2 "Replacement of wear parts of backwash rotor") the hollow shaft
1.3.1 must be prevented from sliding out.
Screw the bow of the safety device for mounting (special tool is provided within the
scope of supply) to nut 1.3.9 by means of hexagon bolts.
Loosen slotted round nut 1.3.32 by means of hook wrench (special tool within scope of
supply) and remove together with distance ring 1.3.15 and tab washer 1.3.33.
Pull off the housing 1.3.2 complete with the worm gear and gear motor.
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Rev. A
At the motor-actuated side:

Loosen hexagon nut 1.3.50 of the threaded pin 1.3.56.
Remove the gear motor.
Remove the lantern 1.3.18 and the coupling.
At the non-actuated side:

Loosen the hexagon bolt 1.3.23 and remove the cap 1.3.24.
Loosen the hexagon nut 1.3.50.
Remove the bearing support 4 1.3.20 by means of jacking screws.
Remove the retaining ring 1.3.40 and the supporting ring 1.3.22 and remove the groove
ball bearing 1.3.29 (free bearing side).
Loosen the hexagon nut 1.3.50 on the fixed bearing side and remove the stud 1.3.49
and threaded pin 1.3.56.
Remove the worm shaft 1.3.7 with the bearing support 3 1.3.19 by tipping and turning
(fixed bearing side).
Loosen hexagon socket head cap screw 1.3.21 and remove the cover 1.3.5.
Remove the worm shaft 1.3.7 with the angular ball bearing 1.3.54 from the bearing
support 3 1.3.19.
Loosen the tab washer 1.3.48 and the slotted round nut 1.3.41 by using the hook wrench
(special tool provided within the scope of supply) and remove the ring 1.3.14 and the
Nilos ring 1.3.55.
Remove the angular ball bearing 1.3.54, remove the Nilos ring 1.3.55 (note: only use
new Nilos rings for assembly).
Remove the retaining rings 1.3.34, 1.3.35 and the shim ring 1.3.60.
Push the worm wheel shaft 1.3.6 with the groove ball bearing 1.3.28, the supporting ring
1.3.13 and the shim ring 1.3.61 out of the housing 1.3.2 towards the fixed bearing side.
Remove the groove ball bearing 1.3.28 (free bearing) from the housing.
Remove the groove ball bearing 1.3.28 (fixed bearing), shim ring 1.3.61 and the
supporting ring 1.3.13.
Check the bearing and bearing seating.
Check the worm wheel shaft 1.3.6 and the worm shaft 1.3.7 for wear and replace, if
necessary.
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Rev. A
Assembly
Note:
Secure positions 1.3.21, 1.3.49, 1.3.50 and 1.3.56 (except counter nuts) with
securing for bolts and nuts 1.3.62.
Fit the supporting ring 1.3.13 and the shim ring 1.3.61 to the worm wheel shaft 1.3.6.
Fix the groove ball bearing 1.3.28 at the fixed bearing side; adjust with shim rings 1.3.60
and secure with the retaining ring 1.3.35.
Mount the worm wheel shaft 1.3.6 with the fully assembled groove ball bearing 1.3.28
into the housing 1.3.2.
Insert the retaining ring 1.3.34.
Add grease G 7 (1.3.64) - approximately 400 g.
Mount the groove ball bearing 1.3.28 to the free bearing side.
Mount the Nilos ring 1.3.55 and the angular ball bearing 1.3.54 (fixed bearing side) to
the worm shaft 1.3.7; apply the Nilos ring 1.3.55, ring 1.3.14 and tab washer 1.3.48,
tighten and secure with the slotted round nut 1.3.41.
Mount the bearing support 3 1.3.19 and fix the cover 1.3.5 with the hexagon socket head
cap screws 1.3.21.
Spread grease G 7 (approximately 100 g) on the worm shaft.
Insert the worm shaft 1.3.7 with the fully assembled angular ball bearing 1.3.54 by
tipping and turning into the housing 1.3.2.
According to position of the gear motor the bearing support 3 1.3.19 is mounted to the
housing 1.3.2 with studs 1.3.49, threaded pin 1.3.56 and hexagon nuts 1.3.50 or with
studs 1.3.49 and hexagon nuts 1.3.50.
Mount the groove ball bearing 1.3.29 and fix it with the supporting ring 1.3.22 and
retaining ring 1.3.40.
Mount the bearing support 4 1.3.20 with stud 1.3.49 and hexagon nut 1.3.50 or with
stud 1.3.49, threaded pin 1.3.56 and hexagon nut 1.3.50.
Set the flank clearance by positioning the bearing supports 3 1.3.19 and 4 1.3.20.
Tighten the hexagon nuts 1.3.50 with the required tightening torque.
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Rev. A
At the non-actuated side:

Fix the cap 1.3.24 with hexagon bolt 1.3.23.
At the motor-actuated side:

Install and secure the coupling.
Install the lantern 1.3.18 and the gear motor.
Mount the housing 1.3.2 with the complete worm gear and fix with hexagon nuts 1.3.46.
Install the distance ring 1.3.15, tighten the slotted round nut 1.3.32 and secure with tab
washer 1.3.33.
Remove bow of the safety device for mounting.
Carefully position the fully assembled seal support 12 1.3.4 (bottom drain hole must be
open)
Flange-mount the discharge pipe; ensure that the wiper 1.3.26 is fitted correctly!
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Rev. A
3.1.1.1.2.
Backwash rotor
(see drawing K2009/20/1368-0503)
Warning:
To begin work, the main cooling water flow must be shut off and locked and the filter has
been drained. It is absolutely necessary to ensure that people are not exposed to danger
due to an inrush of water into the filter during maintenance work.
The filter housing must be removed for the replacement of wear parts. We recommend this
work to be performed by the TAPROGGE Service Department.
Wear parts of bearing:
wiper
o-rings
tab washer
1.3.16
1.3.77
1.3.78
Loosen the tab washers 1.3.78 and hexagon nuts 1.3.50 and remove together with
washers 1.3.51
Remove the shim rings 1.3.10 (if any), o-ring support 1.3.76, wiper 1.3.16, spacer 1.3.17
and o-rings 1.3.77 and lay the backwash rotor down in the filter section
Replace the wiper 1.3.16, tab washer 1.3.78 and o-rings 1.3.77
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Rev. A
rubber lip 1
1.4.1.2
rubber lip 2
1.4.1.3
domed cap nut
1.4.1.7
slide washer
rubber lip 3
1.4.16
rubber lip 4
1.4.17
rubber lip 5
1.4.18
rubber lip 6
1.4.19
o-ring
1.4.20
o-ring
1.4.21
o-ring
1.4.22
1.4.9
For assembly of the backwash rotor, you will need securing for bolts and nuts 1.4.1.9 and
1.4.33 (Loctite 242).
(see drawing K2009/20/1368-0503)
Loosen and remove the domed cap nut 1.4.1.7 with washers 1.4.1.6 and hexagon bolt
1.4.29, replace the domed cap nuts
Take out the sheets 1.4.1.4, 1.4.1.5, 1.4.14, 1.4.15 and the rubber lips 1.4.1.2, 1.4.1.3,
1.4.16, 1.4.17, 1.4.18 and 1.4.19, replace the rubber lips
Loosely screw the rubber lips and sheets with the domed cap nuts 1.4.1.7 and hexagon
bolts 1.4.29
Note:
In the rotation direction the rubber lip 1.4.1.3 on the leading edge gives a
clearance of a few millimetres to the filter section. The rubber lip 1.4.1.2 on the
trailing edge, as well as rubber lips 1.4.16, 1.4.17, 1.4.18 and 1.4.19, must sit
close to the filter section!
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Rev. A
Replacement of the o-rings 1.4.20, 1.4.21, 1.4.22 and the slide washer 1.4.9:

loosen the hexagon bolts 1.4.23 and remove with washers 1.4.30, 1.4.11,
rotor 1.4.4, shim rings 1.4.10 and parallel key 1.4.13
loosen the hexagon bolts 1.4.24, 1.4.25 and remove the washer 1.4.12
remove the arm 1.4.1.1 of the backwash rotor
loosen the hexagon bolts 1.4.26 at the rotor support 1.4.2
remove the rotor support 1.4.2
remove the pusher shaft 1.4.3, o-ring 1.4.20 and 1.4.21 and gasket 1.4.8
remove the slide washer 1.4.9 and bush 1.4.5
remove the o-ring 1.4.22 from the shielding 1.4.6
replace the o-rings 1.4.20, 1.4.21, 1.4.22 and slide washer 1.4.9
Secure the screws with securing for bolts and nuts 1.4.1.9 while reassembling in reverse
order
Mount the component parts of the bearing, fix with the hexagon nuts 1.3.50 and the tab
washers 1.3.78 and secure with securing for bolts and nuts 1.3.63
Apply the sealing material 1.3.69 to the medium touched contact surfaces of the
positions 1.3.9, 1.3.10, 1.3.17 and 1.3.27
Adjust the rubber lips, tighten the domed cap nuts 1.4.1.7 and hexagon bolts 1.4.29 and
secure with securing for bolts and nuts 1.4.1.9.
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Rev. A
3.1.1.2.
(see drawing K2009/20/1368-0501)
Caution:
As long as the differential pressure measuring system is out of order the debris
accumulated on the filter section cannot be monitored.
Therefore the filter shall be backwashed continuously while performing the following
work in the operating mode MANUAL (see section 1.3.5.3).
After the work has been completed, resume the operating mode AUTOMATIC.
Check tightness of the differential pressure measuring system as follows:

Simultaneously close the isolation valves of the differential pressure measuring system.
The p indication must remain at the present value, otherwise the leakage must be traced and
eliminated.
If the p indication decreases:

check PLUS side of the differential pressure measuring system for leakage and repair it
accordingly.
If the p indication increases:

check MINUS side of the differential pressure measuring system for leakage and repair
it accordingly.
If it may become necessary to replace parts or the complete isolation, see section
3.1.1.5.2 as well as section 4.
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Rev. A
Cleaning of the differential pressure measuring system
Caution:
must be drained.
tube. Take care, that the measuring diaphragm will not be damaged.
Caution:
sharp objects.
Clean the isolation valves of the differential pressure measuring system and the
diaphragm of the differential pressure transmitter.
Clean the sealing between remote seal and isolating valve
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Rev. A
Calibration of the differential pressure measuring system
Caution:
must be drained.
tube. Take care, that the diaphragm will not be damaged.
Caution:
sharp objects.
Calibration according to manufacturer's instructions "Differential pressure transmitter",

section 4.
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Rev. A
3.1.1.3.
Caution:
make it safe. Ensure that the voltage supply to the electric consumers has been
must be drained because the debris accumulation at the filter section cannot be
monitored or discharged.
After the work is completed, restart the filter system according to section 1.3.8 of
these operating instructions.
Repairs according to the manufacturers instructions (see section 4: Gear motor for backwash
rotor).
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Rev. A
3.1.1.4.
Part-turn actuator of the discharge valve
(see drawing K2009/20/1368-0502)

The part-turn actuator has no wear parts and should be completely replaced in case of defect.
Caution:
As long as the discharge valve is closed the debris accumulated cannot be removed.
Therefore the filter shall be backwashed in the operating mode MANUAL before
starting maintenance work. During replacement of actuator the differential pressure
must not reach the limit value p EXCESSIVE HIGH.
Replacement of the part-turn actuator with built-in ball valve
Backwash the filter according to section 1.3.5.3 in the operating mode MANUAL,
actuate the discharge valve by the handwheel of the defective part-turn actuator
Check the position CLOSE of the ball valve; final position is indicated at the control
panel
Interrupt the voltage supply to the filter system; put the main switch Q01 in the position
OFF
Unplug part-turn actuator
Loosen the screw connection and remove the part-turn actuator together with the
coupling from the lantern of the ball valve.
Turn the spare part-turn actuator to the position CLOSE by means of the handwheel.
Verify 90 movement of pointer at the window of the mechanical position indicator,
indicating the proper function of the travel limit switches of the part-turn actuator
Verify that the ball valve is in the position CLOSE (marking at stem vertical to flow
direction)
Put the spare part-turn actuator (in position CLOSE) with the built-in coupling onto the
lantern of ball valve
Mount the part-turn actuator to the lantern of ball valve by means of the screw
connection following the manufacturers instructions
Set the mechanical position indicator at the part-turn actuator to the position CLOSE
Plug in part-turn actuator
Connect voltage supply to filter system: put the main switch Q01 in the position ON
Originator
Rev.
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Rev. A
Check of limit switches at the part-turn actuator of discharge valve

After replacing the part-turn actuator, the setting of the limit switches (travel limit switches and
torque limit switches) must be checked and corrected according to the rating plate on the partturn actuator, if necessary (see section 4 Part-turn actuator of discharge valve).
Put the selector switch MANUAL / AUTOMATIC at the control panel in the position
MANUAL
Move the part-turn actuator by means of the handwheel

Upon reaching the final position OPEN or CLOSE the part-turn actuator shuts off via the
corresponding travel limit switch. The final positions are signalled to the control panel by
these travel limit switches.
Note:
The torque limit switches serve as overload protection. In case of tripping,
see section 1.3.11.
Check the moving direction of the part-turn actuator

Put the selector switch MANUAL / AUTOMATIC at the control panel in the position
MANUAL
Use the handwheel of the part-turn actuator to turn the discharge valve into a position
between the final positions OPEN and CLOSE
Press the function key discharge valve CLOSE to move the part-turn actuator
Before reaching the final position CLOSE, stop the part-turn actuator by pressing the
function key discharge valve STOP
Check the moving direction (towards CLOSE) by means of the mechanical position
indicator on the part-turn actuator.
The mechanical position indicator on the part-turn actuator must correspond with the
selected moving direction. Otherwise the moving direction of the part-turn actuator must
be corrected according to section 4 Part-turn actuator of discharge valve.
Put the selector switch MANUAL / AUTOMATIC at the control panel in the operating
mode AUTOMATIC
Initiate a filter backwash by pressing the function key FILTER BACKWASH
Originator
Rev.
Date
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Sheet
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22.10.2009
en
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Rev. A
3.1.1.5.
3.1.1.5.1.
Valves
Ball valve of discharge valve
(see drawing K2009/20/1368-0502)
Warning:
danger due to an inrush of water during maintenance work.
To replace wear parts or make repairs on the valves, please proceed as follows:
Remove the part-turn actuator
Drain the discharge pipe
Remove the valve from the discharge pipe
Replace the wear parts (section 3.2.4) or perform repairs according to section 4 Ball
valve
Originator
Rev.
Date
Lang.
Sheet
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22.10.2009
en
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Rev. A
3.1.1.5.2.
Isolation valves of differential pressure measuring system
(see drawing K2009/20/1368-0501)
Caution:
must be drained.
valve
Originator
Rev.
Date
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Sheet
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Rev. A
3.1.1.5.3.
Filter drain valve
Warning:
Before starting work, shut down the filter system (see section 4.6), isolate it and make
has been drained.
After the work is completed, restart the filter system according to section 4.8 of these
Replace the wear parts or perform repairs according to manufacturers instructions, section 9
"Ball valve"
Originator
Rev.
Date
Lang.
Sheet
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22.10.2009
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Rev. A
3.1.1.6.
Control panel
Caution:
To begin work, the filter must run in emergency actuation according to section 1.3.5.4.
The control panel contains no wear parts. Signal lamps are spare parts and are included in the
control panel.
For repairs of the electrotechnical components see the electrical documentation, section 5 and
the manufacturers' instructions, section 4.
Originator
Rev.
Date
Lang.
Sheet
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en
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Rev. A
3.1.2.
PREVENTIVE MAINTENANCE SCHEDULE
DESCRIPTION
ITEM No.
PARTICIPANT
UNIT
SYSTEM
COMPONENT
SEQUENCE
FUNCTION
NUMBER
PERIO
D
ACTION
SPARES
REQUIREMENT
REFERENCE PROCEDURE
TAPROGGE
12/13/14
PCB15/1
6
AT
001
filter housing
(Debris filter)
coating of housing, external damage,

signs of corrosion
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15/1
6
AT
001
sealings (Debris
filter)
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15/1
6
AT
001
bearing
assembly
(Debris filter)
tightness of bearing assembly

(check by means of drain hole at
bearing housing), tightening of screw
connections, quiet running of worm
gear
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15/1
6
AT
001
backwash rotor
(Debris filter)
movability : filter backwash in the

operating mode MANUAL (section
1.3.5.3) differential pressure must
drop
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15/1
6
AT
001
backwash rotor
(Debris filter)
movability : check direction of rotation

of backwash rotor
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15/1
6
AT
001
backwash rotor
and filter section
(Debris filter)
3Y
cleanliness, fastening of internals,

condition of rubber lips, rubberlining
of internal filter housing
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15/1
6
AT
001
drain valve
(Debris filter)
Movability of actuation
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15/1
6
AT
001
drain valve
(Debris filter)
tightening of flange connections
SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15/1
6
AT
001
drain valve
(Debris filter)

SHA/14/M/---C05/MM/002
TAPROGGE
12/13/14
PCB15/1
6
CP
010
entire differential
pressure
measuring
system
proper function, tightness
SHA/14/M/---C05/MM/002
Originator
Rev.
Date
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Sheet
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22.10.2009
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Rev. A
DESCRIPTION
PERIO
D
entire differential
pressure
measuring
system
entire differential
pressure
measuring
system
isolation valves
(Differential
pressure
measuring
system)
isolation valves
(Differential
pressure
measuring
system)
isolation valves
(Differential
pressure
measuring
system)
remote seals /
remote seals
with capillary
tubes
(Differential
pressure
measuring
system)
electric motor
(Gear motor for
backwash rotor)
6M
electric motor
(Gear motor for
backwash rotor)
ITEM No.
PARTICIPANT
UNIT
SYSTEM
COMPONENT
SEQUENCE
FUNCTION
NUMBER
TAPROGGE
12/13/14
PCB15/1
6
CP
010
TAPROGGE
12/13/14
PCB15/1
6
CP
010
TAPROGGE
12/13/14
PCB15/1
6
CP
010
TAPROGGE
12/13/14
PCB15/1
6
CP
010
TAPROGGE
12/13/14
PCB15/1
6
CP
010
TAPROGGE
12/13/14
PCB15/1
6
CP
010
TAPROGGE
12/13/14
PCB15/1
6
AT
001
TAPROGGE
12/13/14
PCB15/1
6
AT
001
ACTION
SPARES
REQUIREMENT
REFERENCE PROCEDURE
cleaning of differential pressure

measuring system
SHA/14/M/---C05/MM/002
calibration of differential pressure

measuring system
SHA/14/M/---C05/MM/002

SHA/14/M/---C05/MM/002
SHA/14/M/---C05/MM/002
SHA/14/M/---C05/MM/002
fastening, tightness
SHA/14/M/---C05/MM/002
coating, cleanliness, external

damage, quiet running, compare
setting current of manual motor
starter with nominal current of motor
proper cable connection
SHA/14/M/---C05/MM/002
Originator
Rev.
Date
Lang.
Sheet
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22.10.2009
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SHA/14/M/---C05/MM/002
Rev. A
DESCRIPTION
PERIO
D
spur gear (Gear

motor for
backwash rotor)
ball valve
(Discharge
valve)
ball valve
(Discharge
valve)
part-turn
actuator
(Discharge
valve)
part-turn
actuator
(Discharge
valve)
cleanliness, quiet running, tightness,

coating
SHA/14/M/---C05/MM/002

SHA/14/M/---C05/MM/002
movability of actuation, tightness of

flange connections
SHA/14/M/---C05/MM/002
coating, external damage, tightness,

cleanliness
SHA/14/M/---C05/MM/002
SHA/14/M/---C05/MM/002
3Y
operability and movability (by

handwheel), proper cable connection,
tightening of fastening screws
between actuator and valve,
adjustments: limit stops + limit
switches + mechanical position
indicator
wear of worm gear and planetary
gearing
ITEM No.
PARTICIPANT
UNIT
SYSTEM
COMPONENT
SEQUENCE
FUNCTION
NUMBER
TAPROGGE
12/13/14
PCB15/1
6
AT
001
TAPROGGE
12/13/14
PCB15/1
6
AA
016
TAPROGGE
12/13/14
PCB15/1
6
AA
016
TAPROGGE
12/13/14
PCB15/1
6
AA
016
TAPROGGE
12/13/14
PCB15/1
6
AA
016
TAPROGGE
12/13/14
PCB15/1
6
AA
016
TAPROGGE
12/13/14
PCB15/1
6
AA
016
TAPROGGE
12/13/14
GH
001
TAPROGGE
12/13/14
PCB15/1
6
PCB15/1
6
part-turn
actuator
(Discharge
valve)
switching and
signalling device
(Discharge
valve)
control panel
GH
001
control panel
TAPROGGE
12/13/14
GH
001
control panel
2Y
TAPROGGE
12/13/14
PCB15/1
6
PCB15/1
6
GH
001
control panel
7Y
ACTION
SPARES
REQUIREMENT
operability
lamp for common alarm (by the

function key on control panel door)
external damage, cleanliness,
terminal connections, check
adjustable times, proper function of
control (in the operating mode
AUTOMATIC)
replace / add battery of PLC
REFERENCE PROCEDURE
SHA/14/M/---C05/MM/002
SHA/14/M/---C05/MM/002
replace battery of the Operator

Terminal / real-time clock module
Originator
Rev.
Date
Lang.
Sheet
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22.10.2009
en
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SHA/14/M/---C05/MM/002
SHA/14/M/---C05/MM/002
SHA/14/M/---C05/MM/002
SHA/14/M/---C05/MM/002
Rev. A
3.1.3.
PARTICIPANT
LUBRICATION INSTRUCTIONS AND SCHEDULE

EQUIPMENT
ITEM No.
UNIT
Taprogge
Taprogge
Taprogge
SYSTEM
worm wheel of 12/13/14 PCB15/16

reduction gear
(bearing of
backwash rotor)
rolling bearing 12/13/14 PCB15/16
120/180 x 28
(bearing of
backwash rotor)
Gear motor for 12/13/14 PCB15/16
backwash rotor
PARTS TO BE
LUBRICATED
COMPONENT
FUNCTION
SEQUENCE
NUMBER
AT
010
AT
AT
PERIO
D
NUMBER OF
LUBRICATION
LUBRICANT
QUANTITY
DRAIN
FREQUENCY
POINTS
REF 1
REF 2
REF 3
worm wheel shaft/

worm shaft
ARAL Degol
GS220
BP Enersyn
SG-XP220
Mobil
Glygoyle
HE460
500 g
3Y
010
cage
ARAL Degol
GS220
BP Enersyn
SG-XP220
Mobil
Glygoyle
HE460
250 g
3Y (exchange)
010
gear housing
ARAL Degol
GS220
BP Enersyn
SG-XP220
Mobil
Glygoyle
HE460
700 ccm
3Y (exchange)
Originator
Rev.
Date
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Sheet
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22.10.2009
en
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Rev. A
3.1.4.
SPECIAL TOOLING AND HANDLING DEVICES
Tools for Maintenance
Part name
Material
handwheel AL-315-K28-D
Al
mounting device
steel
hook wrench HN 18
steel
hook wrench NN 7
steel
safety device for mounting
1.4541
Originator
Rev.
Date
Lang.
Sheet
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Rev. A
3.1.5.
STORAGE INSTRUCTIONS
Storage of parts
Caution:
The packing is prepared for a life of 6 or 24 months.
A storage below 5 C (41 F), in particular of rubberlined parts, is not admissible.
The packing is not suitable for outdoor storage.
Parts which cannot be immediately installed shall be stored in dry and lockable rooms.
Delivery
covered with foil in

boxes or on pallets
Inspection
packing
Frequency of
inspections
every 3 months

close or repair damaged
packing
(maximum storage 6
months)
in sealed vinyl cover in
boxes
Remarks
packing
every 6 months
(maximum storage 24
months)

in case of open packing:
reseal cover
moisture indicator
(if applicable)
every 6 months
desiccant
every 6 months
check moisture indicator
renew desiccant
Note:
Parts which are not sealed in vinyl cover shall be removed from packing and stored in
dry rooms. If parts cannot be stored as indicated please inform the TAPROGGE Service
Department.
Originator
Rev.
Date
Lang.
Sheet
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22.10.2009
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Rev. A
Disposal of packing material
Note:
Our products are protected for the transport ex works by environmentally friendly
materials (wood, cardboard, paper and PE foil) which can easily be separated and
recycled according to local regulations.
3.1.6.
PRESERVATION INSTRUCTIONS
See sections 1.3.6 and 1.3.7.
Originator
Rev.
Date
Lang.
Sheet
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Rev. A
3.2. CORRECTIVE MAINTENANCE INSTRUCTIONS
Wear part
3.2.1.
Drawing no.
Position
Debris filter
(12/13/14PCB15AT010 / 12/13/14PCB16AT010)
Bearing assembly 2.3

o-ring
o-ring
gasket
wiper
o-ring
o-ring
gasket
wiper
o-ring
o-ring
wiper
wiper
o-ring
guide ring
o-ring
tab washer
lubricant for worm wheel and
bearings
K2009/20/1368-0503
1.3.37
1.3.66
1.3.71
1.3.72
1.3.74
1.3.75
1.3.79
1.3.80
1.3.81
1.3.82
every 3 years or in case of

leakages from the drain hole.
In order to check sealing of
bearing assembly see section
3.1.1.1.1
1.3.16
1.3.26
1.3.37
1.3.38
1.3.77
1.3.78
1.3.64
Backwash rotor
rubber lip 1
rubber lip 2
domed cap nut
slide washer
rubber lip 3
rubber lip 4
rubber lip 5
rubber lip 6
o-ring
o-ring
o-ring
*
K2009/20/1368-0503
1.4.1.2
1.4.1.3
1.4.1.7
1.4.9
1.4.16
1.4.17
1.4.18
1.4.19
1.4.20
1.4.21
1.4.22
every 3 years
During replacing wear parts of filter please record the reading of the running time meter of
backwash rotor as an additional information (see operating record section 1.3.9)
Originator
Rev.
Date
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Sheet
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Rev. A
Wear part
3.2.2.
Drawing no.
Position
(12/13/14PCB15CP010 / 12/13/14PCB16CP010)
none
3.2.3.
(12/13/14PCB15AT001 / 12/13/14PCB16AT001)
none
Originator
Rev.
Date
Lang.
Sheet
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en
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Rev. A
Wear part
3.2.4.
Drawing no.
Position
Valves
(12/13/14PCB15AA016 / 12/13/14PCB16AA016)
Ball valve
see manufacturer's instructions
(12/13/14PCB15AA301/302 & 12/13/14PCB16AA301/302)

Diaphragm valve
diaphragm
see section 4
443
every 5 years
Note:
See disassembled material to a sound disposal or to separate recycling according to
materials. Observe the national regulations for waste disposal.
After the end of the service life, old rubberlined system parts can be recycled easily via
valuable metal recycling companies (smelting).
Originator
Rev.
Date
Lang.
Sheet
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en
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Rev. A
4.
ACCESSORIES
KKS
MATERIAL / TYPE
SUPPLIER
12/13/14PCB15CP010
12/13/14PCB16CP010
Differential pressure transmitter / 1151 DP 4 S
Emerson
12/13/14PCB15CP010
12/13/14PCB16CP010
Remote seal / 1199
Emerson
12/13/14PCB15AT001
12/13/14PCB16AT001
Gear motor for backwash rotor / SK 02
Getriebebau Nord
12/13/14PCB15AA016
12/13/14PCB16AA016
Part turn actuator of discharge valve / SG 07.1
AUMA
12/13/14PCB15AA016
12/13/14PCB16AA016
Ball valve
Brooksbank
12/13/14PCB15AA301/302
12/13/14PCB16AA301/302
Diaphragm valve / SISTO KB
KSB
12/13/14PCB15/16GH001
Programmable logic controller / FlexxLogix 5434
Allen Bradley
12/13/14PCB15/16GH001
Operator Terminal / PV 600
Allen Bradley
12/13/14PCB15/16GH001
Analogue data repeater / IM31-12Ex-I
Turck
12/13/14PCB15/16GH001
Isolating switching amplifier / IM1-12Ex-R
Turck
Originator
Rev.
Date
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Sheet
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Rev. A
5. DRAWING AND PART LISTS

ALSTOM Index no.
SHA/14/M/---C05/FD/002
SHA/14/M/---C05/GA/002
SHA/14/M/---C05/DD/002
Taprogge Index no.

K2009/20/1368-0001
K2009/20/1368-0505
K2009/20/1368-0503
1/20/0111-0016
1/20/0112-0005
K2009/20/1368-0501
K2009/20/1368-0502
SHA/14/M/---C05/WD/002
K2009/20/1368-1000
SHA/14/M/---C05/DS/011
SHA/14/M/---C05/DS/012
SHA/14/M/---C05/DS/013
SHA/14/M/---C05/DS/014
SHA/14/M/---C05/DS/015
Title
Flow Diagram
Assembly debris filter
Filter section
Inspection hole
Discharge valve
Electrical documentation of control
panel
Data sheet CCW Exchanger Debris
filter
Data sheet LV Motor CCW Exchanger
Debris filter
Data sheet Valves CCW Exchanger
Debris filter
Data sheet Pr. Transmitter CCW
Exchanger Debris filter
Data sheet Actuator CCW Exchanger
Debris filter
Originator
Rev.
Date
Lang.
Sheet
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16.09.2009
Schmidlin
Gller
Neugebauer
First issue
FUS
REV
DATE
PREPARED
CHECKED
APPROVED
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
DD
Title :
Sectional drawing of CCW Exchanger

Debris Filter with parts list
Language
:E
abcd
No of
sheet : 8
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DD/002
Erstellt/prepared: 16.09.2009/w
Blatt/Sheet: 1/4
TL2009201368.xls

FILTER PR-BW 100
Typ 2.3 (762, 1046; 1416)

Pos.
Pos.
Part name
Benennung
Stk
No
QA2009/20/1368-0020
4/20/0150-0112
K2009/20/1368-0503
1/20/0150-0005
Sach-Nr.
Ident-No.
Bemerkungen
Remarks
FILTER
FILTER
V1-V4 = Verschleiteil-Stze
1.1
FILTERGEHUSE 1
FILTER HOUSING 1
R1-R6 = Reserveteil-Stze
1.2
FILTERGEHUSE 2
FILTER HOUSING 2
LAGERUNG
Hohlwelle
Gehuse
Dichtungstrger 11
Dichtungstrger 12
Deckel
Schneckenradwelle
Schneckenwelle
Buchse
Mutter
Pascheibe
Sttzscheibe
Ring
Distanzring
Abstreifer
Distanzscheibe
Laterne
Lagertrger 3
Lagertrger 4
Zylinderschraube
Sttzscheibe
Sechskantschraube
Haube
Pafeder
Abstreifer
BEARING ASSEMBLY
Hollow shaft
Housing
Seal support 11
Seal support 12
Cover
Worm wheel shaft
Worm shaft
Bush
Nut
Adjusting washer
Supporting ring
Ring
Distance ring
Wiper
Spacer
Lantern
Bearing support 3
Bearing support 4
= Sets of wear parts
= Sets of spare parts
1.3
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.3.6
1.3.7
1.3.8
1.3.9
1.3.10
1.3.13
1.3.14
1.3.15
1.3.16
1.3.17
1.3.18
1.3.19
1.3.20
1.3.21
1.3.22
1.3.23
1.3.24
1.3.25
1.3.26
1.3.27
1.3.28
1.3.29
1.3.32
1.3.33
1.3.34
1.3.35
1.3.36
1.3.37
1
1
1
1
1
1
1 R1
1 R1
1
1
1
1 R2
1
1
1 V2
1
1
1
1
4
1 R3
2
1
2 R1
1 V2
1 Satz/
set
2 R2
1 R3
1 R2
1 R2
1 R2
1 R2
2
1 V1
Pascheibe
Rillenkugellager
Rillenkugellager
Wellenmutter
Sicherungsblech
Sicherungsring
Sicherungsring
Zylinderschraube
O-Ring
Supporting ring
Hexagon bolt
Cap
Parallel key
Wiper
Adjusting washer
Groove ball bearing
Groove ball bearing
Slotted round nut
Tab washer
Retaining ring
Retaining ring
O-ring
V2
1.3.38
1.3.39
1.3.40
1.3.41
1.3.42
1.3.43
1.3.44
1.3.45
2 V2 Fhrungsring
8
Stiftschraube
1 R3 Sicherungsring
1 R3 Wellenmutter
2
Pafeder
16
Zylinderschraube
16
Scheibe
16
Scheibe
Guide ring
Stud
Retaining ring
Slotted round nut
Parallel key
Washer
Washer
Blatt/Sheet: 2/4
TL2009201368.xls

FILTER PR-BW 100
Typ 2.3 (762, 1046; 1416)

Pos.
Pos.
1.3.46
1.3.47
1.3.48
1.3.49
1.3.50
1.3.51
1.3.52
1.3.53
1.3.54
1.3.55
1.3.56
1.3.58
1.3.60
1.3.61
1.3.62
1.3.63
1.3.64
Benennung
Stk
No
16
16
1
10
36
26
2
14
2
2
4
8
5
5
R3
R3
R3
R2
R2
Sechskantmutter
Stiftschraube
Sicherungsblech
Stiftschraube
Sechskantmutter
Scheibe
Scheibe
Gewindestift
Schrgkugellager
NILOS-Ring
Gewindebolzen
Zylinderschraube
Pascheibe
Pascheibe
Schraubensicherung
Schraubensicherung
RCKSPLROTOR
Rcksplrotor
Arm
Gummilippe 1
Gummilippe 2
Blech 1
Blech 2
Scheibe
Hutmutter
Sttzblech
BACKWASH ROTOR
Backwash rotor
Arm
Rubber lip 1
Rubber lip 2
Sheet 1
Sheet 2
Washer
Domed cap nut
Supporting plate
radsatz und Lager

1 V1 O-Ring
1
Drehrichtungsanzeige,
1.3.68
1.3.69
1.3.70
1.3.71
1.3.72
1.3.73
1.3.74
1.3.75
1.3.76
1.3.77
1.3.78
1.3.79
1.3.80
1.3.81
1.3.82
1
1
1
1
1
1
1
2
4
1
1
1
2
1.4
1.4.1
1.4.1.1
1.4.1.2
1.4.1.3
1.4.1.4
1.4.1.5
1.4.1.6
1.4.1.7
1.4.1.8
1
1
1
1
1
2
2
38
14
1
V1
V1
V2
V2
V1
V1
V1
V1
V3
V3
V3
rechts
Drehrichtungsanzeige,
links
Dichtungsmasse
Dichtungstrger 10
Dichtung
Abstreifer
Dichtungstrger 9
O-Ring
O-Ring
O-Ringtrger
O-Ring
Sicherungsblech
Dichtung
Abstreifer
O-Ring
O-Ring
1.3.66
1.3.67
V1
Hexagon nut
Stud
Tab washer
Stud
Hexagon nut
Washer
Washer
Hexagon socket set screw
Angular ball bearing
NILOS ring
Threaded pin
Shim ring
Shim ring
Lubricant for worm wheel
and bearings
O-ring
Indication turning direction,
right
Indication turning direction,
left
Sealing material
Seal support 10
Gasket
Wiper
Seal support 9
O-ring
O-ring
O-ring support
O-ring
Tab washer
Gasket
Wiper
O-ring
O-ring
V4 Schmiermittel fr Schnecken-
V1
Part name
QA2009/20/1368-0020
4/20/0150-0112
K2009/20/1368-0503
1/20/0150-0005
Sach-Nr.
Ident-No.
Bemerkungen
Remarks
Blatt/Sheet: 3/4
TL2009201368.xls

FILTER PR-BW 100
Typ 2.3 (762, 1046; 1416)

Pos.
Pos.
1.4.1.9
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
1.4.7
1.4.8
1.4.9
1.4.10
1.4.11
1.4.12
1.4.13
1.4.14
1.4.15
1.4.16
1.4.17
1.4.18
1.4.19
1.4.20
1.4.21
1.4.22
1.4.23
1.4.24
1.4.25
1.4.26
1.4.27
1.4.28
1.4.29
1.4.30
1.4.31
1.4.32
1.4.33
Part name
Benennung
Stk
No
1
1
1
1
1
1
1
1
1
5
1
1
1
2
2
1
1
1
1
1
1
1
1
1
4
14
3
3
28
6
1
14
1
V3
V3
V3
V3
V3
V3
V3
V3
Schraubensicherung
Rotorsttze
Mitnehmerwelle
Rotor
Buchse
Abdeckung
Scheibe
Dichtung
Gleitscheibe
Pascheibe
Scheibe
Scheibe
Pafeder
Blech 6
Blech 7
Gummilippe 3
Gummilippe 4
Gummilippe 5
Gummilippe 6
O-Ring
O-Ring
O-Ring
Sechskantschraube
Sechskantschraube
Sechskantschraube
Sechskantschraube
Sechskantschraube
Sechskantmutter
Sechskantschraube
Scheibe
Scheibe
Scheibe
Schraubensicherung

Rotor support
Pusher shaft
Rotor
Bush
Shielding
Washer
Gasket
Slide washer
Shim ring
Washer
Washer
Parallel key
Sheet 6
Sheet 7
Rubber lip 3
Rubber lip 4
Rubber lip 5
Rubber lip 6
O-Ring
O-Ring
O-Ring
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon nut
Hexagon bolt
Washer
Washer
Washer
FILTER SECTION
Filter element C
Wiper
1.5
1.5.1
1.5.2
1.5.3
1.5.4
1
1
1
4
1
FILTEREINSATZ
Filterelement C
Abstreifer
Senkschraube
Schraubensicherung
1.6
INSPEKTIONSFFNUNG
INSPECTION HOLE
1.7
SCHILDER
PLATES
1.8
1.9
1.10
1.16
28
24
52
1
Sechskantschraube
Sechskantmutter
Scheibe
Blindflansch
Hexagon bolt
Hexagon nut
Washer
Blind flange
Slotted countersunk flat head screw
QA2009/20/1368-0020
4/20/0150-0112
K2009/20/1368-0503
1/20/0150-0005
Sach-Nr.
Ident-No.
Bemerkungen
Remarks
Blatt/Sheet: 4/4
TL2009201368.xls

FILTER PR-BW 100
Typ 2.3 (762, 1046; 1416)

Pos.
Pos.
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.26
1.27
1.28
1.29
Part name
Benennung
Stk
No
4
Sechskantschraube
4
Sechskantmutter
4
Scheibe
1 R4 Dichtung
12
Stiftschraube
12
Sechskantmutter
12
Scheibe
1
Dichtung
2 R4 Dichtung
4
Ringmutter
1
Warnschild
1.30
Sttzring
3.
1 R6 GETRIEBEMOTOR FR
RCKSPLROTOR
QA2009/20/1368-0020
4/20/0150-0112
K2009/20/1368-0503
1/20/0150-0005
Sach-Nr.
Ident-No.
Bemerkungen
Remarks
Hexagon bolt
Hexagon nut
Washer
Gasket
Stud
Hexagon nut
Washer
Gasket
Gasket
Lifting eye nut
Warning plate
Supporting ring
GEAR MOTOR FOR
BACKWASH ROTOR
5.
1 R5 KUPPLUNG
COUPLING
6.
2 R5 Gewindestift
Hexagon socket set screw
7.
Stiftschraube
Stud
8.
Sechskantmutter
Hexagon nut
9.
Scheibe
Washer
fr DIN/BS/JIS/AFNOR
Stutzen DN 3 = DN 80
TL2009201368.xls
Blatt/Sheet: 1/1

DIFFERENZDRUCK-MESYSTEM /
DIFFERENTIAL PRESSURE MEASURING SYSTEM
QA2009/20/1368-0021
4/00/0983-0926

K2008/20/1368-0501
1/15/0005-0285
Pos.
Pos.
Benennung
Stk
Sach-Nr.
Ident-No.
DIFFERENZDRUCKMESYSTEM
Emerson-MD03
1
Part name
No
Bemerkungen
Remarks
DIFFERENTIAL PRESSURE
MEASURING SYSTEM
Emerson-MD03
1 R Differenzdrucktransmitter
Typ Rosemount 1151 DP4

type Rosemount 1151 DP4
Druckmittler
Remote seal
Druckmittler
Remote seal
Kapillarrohr
Capillary tube
2 R Membranschieber
1 V Membrane
Diaphragm valve
Diaphragm
2 R Dichtung
Gasket
Sechskantschraube
Hexagon bolt
Sechskantmutter
Hexagon nut
16
Scheibe
Washer
eingestellter Mebereich /
adjusted measuring range
- 10 - + 360 mbar
in Pos. 5 enthalten/included in pos. 5
27.07.2009
Schmidlin
Gller
10.07.2009
Schmidlin
Gller
03.07.2009
Schmidlin
Gller
11.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
Neugebauer
Neugebauer
FUS
FUS
FUS
First issue
FUS
APPROVED
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
EL
Title :
CCW Exchanger Debris Filter
Language
:E
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/EL/002
SHA/14/M/---C05/ EL/002
ELECTRICAL LOAD LIST - C05

R
E
V
Functional number
of the electrical
auxiliary
Unit
System
Equipment
Designation
of the driven machine
or of the electrical auxiliary
Load
type
Rated
volt.
V
Voltage
Consumer
type
Nature
Red
und
ancy
(Y/N)
Std
Inter
face
(Y/N)
Rated
Rated
power
factor
power
Rated
eff.
SC
/
FLC
Star
ting
time
(s)
kW/
kVA
Load
conn
diag
Local
Fuse
(A)
Loc.
Load
Term
panel
D
u
t
y
(1)
Feeding
Cubicle
Mechanical absorbed power

During
Stop of
the Unit
At Startup of the
Unit
During
normal
running
D
I
E
S
E
L
U
P
S
SIGNAL EXCHG WITH

control panel
control panel
IFU
D
12/13/14PCB15AT010
12/13/14 PCB15
AT010
12/13/14PCB15AA016
12/13/14 PCB15
AA016
AUX CW DEBRIS FILTER 1 MOTOR

AUX CW DEBRIS FILTER 1 DISCHARGE
IFU
VALVE
12/13/14PCB15GH001
12/13/14 PCB15
GH001
CONTROL PANEL
12/13/14PCB15GH001B
12/13/14 PCB15
GH001B
CONTROL PANEL UPS
12/13/14PCB15GH001C
12/13/14 PCB15
GH001C
CONTROL PANEL UPS
IFU
IFU
IFU
460 AC TRI 60 Hz
0,75 kw
B63/400
14PCB15GS100
460 AC TRI 60 Hz
0,16 kw
B63/400
14PCB15GS100
460 AC TRI 60 Hz
2 kw
B63/400
14PCB15GS100
120 AC MONO 60 Hz L
0,25 kw
B63/400
14PCB15GS100
120 AC MONO 60 Hz L
0,25 kw
B63/400
14PCB15GS100
X
SIGNAL EXCHG WITH
control panel
control panel
IFU
D
12/13/14PCB16AT010
12/13/14 PCB16
AT010
12/13/14PCB16AA016
12/13/14 PCB16
AA016
AUX CW DEBRIS FILTER 2 MOTOR

AUX CW DEBRIS FILTER 2 DISCHARGE
IFU
VALVE
12/13/14PCB16GH001
12/13/14 PCB16
GH001
CONTROL PANEL
12/13/14PCB16GH001B
12/13/14 PCB16
GH001B
CONTROL PANEL UPS
12/13/14PCB16GH001C
12/13/14 PCB16
GH001C
CONTROL PANEL UPS
IFU
IFU
IFU
460 AC TRI 60 Hz
0,75 kw
B63/400
14PCB16GS100
460 AC TRI 60 Hz
0,16 kw
B63/400
14PCB16GS100
460 AC TRI 60 Hz
2 kw
B63/400
14PCB16GS100
120 AC MONO 60 Hz L
0,25 kw
B63/400
14PCB16GS100
120 AC MONO 60 Hz L
0,25 kw
B63/400
14PCB16GS100
Comments
X
Scope
Package
no.
C05
C05
C05
C05
C05
C05
C05
C05
C05
C05
010
010
010
010
16.09.2009
Schmidlin
Gller
08.09.2009
Schmidlin
Gller
19.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
Neugebauer
APPROVED
Updated
FUS
Updated
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
IO
Title :
Language
:E
Signal Exchange List
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/IO/002
signals
s - Instrumentation Setpoint - Debris Filters 12/13/14PCB15AT010 & 12/13/14PCB16AT010
List for iinput/output
nput/output signal
R
e
v
Sensor / Signal number
Service description
Typical
connection
diagram
I/O
information
for the DCS
Measurement
range
(mbar)
Min.
12 PCB15
EA101
DF1 ALARM
BI
yes
12 PCB15
EA102
DF1 FLUSHING
BI
yes
12 PCB15
EA103
DF1 ON
BI
12 PCB15
EA104
DF1 OFF
13 PCB15
EA101
DF2 ALARM
13 PCB15
EA102
13 PCB15
13 PCB15
A
A
Set
point
(mbar)
Process
unit
Event &
Alarm
coding
Signal
user
specif
Max.
EC1
C05
EC0
C05
yes
EC0
C05
BI
yes
EC0
C05
BI
yes
EC1
C05
DF2 FLUSHING
BI
yes
EC0
C05
EA103
DF2 ON
BI
yes
EC0
C05
EA104
DF2 OFF
BI
yes
EC0
C05
14 PCB15
EA101
DF3 ALARM
BI
yes
EC1
C05
14 PCB15
EA102
DF3 FLUSHING
BI
yes
EC0
C05
14 PCB15
EA103
DF3 ON
BI
yes
EC0
C05
14 PCB15
EA104
DF3 OFF
BI
yes
EC0
C05
12 PCB16
EA101
DF4 ALARM
BI
yes
EC1
C05
12 PCB16
EA102
DF4 FLUSHING
BI
yes
EC0
C05
12 PCB16
EA103
DF4 ON
BI
yes
EC0
C05
12 PCB16
EA104
DF4 OFF
BI
yes
EC0
C05
13 PCB16
EA101
DF5 ALARM
BI
yes
EC1
C05
13 PCB16
EA102
DF5 FLUSHING
BI
yes
EC0
C05
13 PCB16
EA103
DF5 ON
BI
yes
EC0
C05
14 PCB16
EA104
DF5 OFF
BI
yes
EC0
C05
14 PCB16
EA101
DF6 ALARM
BI
yes
EC1
C05
14 PCB16
EA102
DF6 FLUSHING
BI
yes
EC0
C05
14 PCB16
EA103
DF6 ON
BI
yes
EC0
C05
14 PCB16
EA104
DF6 OFF
BI
yes
EC0
C05
-10
-10
-10
-10
-10
-10
360
360
360
360
360
360
120
120
120
120
120
120
Comment
08.09.2009
Schmidlin
Gller
26.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
APPROVED
Updated
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Title :
Language
:E
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
LC
Cable Schedule
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/LC/002
SHA/14/M/---C05/ LC/002
22.06.2010
Schmidlin
Gller
01.06.2010
Schmidlin
Gller
18.05.2010
Schmidlin
Gller
19.02.2010
Schmidlin
Gller
30.11.2009
Schmidlin
Gller
02.09.2009
Schmidlin
Gller
28.08.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
Neugebauer
Neugebauer
Neugebauer
Neugebauer
Neugebauer
FUS
FUS
FUS
FUS
FUS
FUS
First issue
FUS
APPROVED
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
WD
Title :
Electrical and Control Cabinet /
Language
:E
Wiring Diagram
abcd
for CCW Exchanger Debris Filter

No of
sheet : 40
Power Systems
Sheet :
Plants
1/40
SHA/14/M/---C05/WD/002
SHA/14/M/---C05/ WD/002
03.07.2009
Schmidlin
Gller
13.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
APPROVED
Second issue
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
DM
Title :
Language
:E
System Description
abcd
No of
sheet : 17
Power Systems
Sheet :
Plants
1
SHA/14/M/---C05/DM/002
Table of Contents
1.
TASK AND FUNCTION DESCRIPTION OF THE TAPROGGE FILTER SYSTEM ........................................................3

Task of the TAPROGGE filter system .........................................................................................................................3
Function description of the TAPROGGE filter system ................................................................................................4
2.
DESCRIPTION OF THE FILTER SYSTEM .......................................................................................................................8
2.1.
Assembly Debris Filter ..................................................................................................................................................8
2.1.1.
Debris Filter PR-BW 100 ..........................................................................................................................................8
2.1.2.
Differential pressure measuring system ............................................................................................................... 10
2.1.3.
Gear motor ............................................................................................................................................................. 13
2.2.
Discharge valve .......................................................................................................................................................... 14
2.3.
Control......................................................................................................................................................................... 15
1.1.
1.2.
2
1. TASK AND FUNCTION DESCRIPTION OF THE TAPROGGE FILTER SYSTEM
1.1.


1
Filter
2
Discharge valve
3
Discharge pipe
4
Heat exchanger
For scope of supply please refer flow diagram SHA/14/M/---C05/FD/002.
3
1.2.

1
2
3
4
Filter PR-BW 100

Gear motor
Discharge valve
4
The cooling water to be filtered enters the debris filter's 1 "dirty side" A through the filter section. The
filtered water leaves the debris filter at side B. The debris is retained on the filter section. The
differential pressure increases.
discharge pipe to a zone of lower pressure (e.g. open discharge channel, cooling water discharge
line downstream of the condenser / heat exchanger), a strong reverse flow is created in that area
of the filter section which is covered by the backwash rotor. The entire filter section is effectively
cleaned by the rotation of the backwash rotor.
The debris is either carried directly into the discharge channel or reintroduced to the cooling water
discharge line downstream of the condenser / heat exchanger.
Due to the pressure drop across the discharge pipe, the water quantity required for backwashing
the debris filter is only 3 - 8 % of the cooling water to be filtered.
5
water.
Since the area of the filter section covered by the backwash rotor is completely isolated from the
differential pressure of the cooling water during backwashing, the debris filter is fully operational
even if it is loaded with high amount of debris.
6

FILTRATION
water flow
fibres are retained

filter section
the filter section
PRESSURE-RELIEF

backwash rotor
FILTER BACKWASH

Fig. 2-3: Backwash process
7
2. DESCRIPTION OF THE FILTER SYSTEM

The filter system contains all components and subassemblies required to efficiently filter the water,
to backwash the debris filter and to ensure trouble-free operation of the system.
2.1.
2.1.1.

1/2
3
4
5
6
Filter housing
Bearing assembly
Backwash rotor
Filter section with wiper
Inspection hole
8
The filter housing 1 / 2
consists of two hemispheres, one carrying the cooling water inlet,

the other carrying the cooling water outlet flange. The
hemisphere with the cooling water inlet flange is further
equipped with an inspection hole. In case of horizontal
installation, the hemisphere with the cooling water outlet flange
includes a drain nozzle.
The nozzle (C) with blind flange can be used for inspection of
hemisphere 2.
The two hemispheres are bolted together by a pair of flanges
positioned at an angle of 45 to the cooling water inlet /
outlet axis. This configuration allows an installation of the debris
filter either in a straight pipe or as a substitute for a 90-elbow
without any modifications or additional assemblies.
Bearing assembly 3
consists of a rotating hollow shaft with worm gear. The

water is discharged through the hollow shaft. The backwash
rotor is actuated by the gear motor which is mounted to the worm
gear. The discharge valve is fixed to the outlet flange of the
bearing assembly
The backwash rotor 4 consists of a funnel-shaped arm with rubber lips. This arm is
connected to the bearing assembly by a flange connection.
Filter section
weldless design; standard perforations typically start from 2

mm (special designs for smaller perforations available). A wiper is
mounted to the filter section. All debris particles that cling to the
rubber lip of the backwash rotor are reliably detached and
discharged with the next backwash rotor rotation.
9
2.1.2.
Fig. 2-5: Differential pressure measuring system

1
2
3
6
7
9

Remote seal PLUS
Isolation valves
Measuring nozzles
Operator panel
10
The differential pressure measuring system (p system) monitors the amount of debris on the filter
by constantly measuring the differential pressure (p).
The differential pressure is electronically converted to a signal.
Operator panel 9
indicates:


initiates:

limit value 1:
(test function)
The proper functioning of the measuring system is electrically
monitored constantly. In the event of a fault, the differential
pressure falls below limit value IN-SERVICE MONITORING and
an alarm message will be signalled by the control system.
limit value 2:
(service function)
FILTER BACKWASH
If debris accumulates on the filter section, the differential
pressure increases. If the limit value FILTER BACKWASH is
reached, the automatic control system initiates filter
backwash, until the differential pressure falls below the pre-set
limit value.
limit value 3:
(security function)
p EXCESSIVE HIGH
If the differential pressure continues to increase in spite of the
existent backwash and reaches the limit value p EXCESSIVE
HIGH, the automatic control system continues filter backwash.
Simultaneously, a signal and an alarm message are indicated.
The customer can connect the potential free alarm from the
control panel to the control room.
11
Isolation valves 6
The differential pressure measuring system can be isolated

from the cooling water flow for maintenance purposes by
means of the isolation valves.
12
2.1.3.
Gear motor
The backwash rotor is operated by a special gear motor designed for 100 % continuous operation.
13
2.2.
Discharge valve
The discharge valve in this filter system is a ball valve operated by a specially designed part-turn
actuator with short running time. In the open position, the valve allows an unrestricted flow of the
debris laden water.
against overload.
14
2.3.
Control
operation (programmes) are stored in a single programme (Flashcard).
By means of a selector switch at the control panel the operating mode AUTOMATIC or MANUAL is
selected.
All further operations are effected via function keys at the operator panel.
cases:
function key FILTER CONTINUOUS BACKWASH
malfunction differential pressure measuring system (intermittent backwash every 3 minutes)
function key p SYSTEM FLUSH
Backwash

discharge pipe.
control system
If p < limit value FILTER BACKWASH, the backwash rotor stops and the discharge valve
closes
15
Note:
The operating mode MANUAL is not permitted for routine filter operation and
may be selected for commissioning and in case of trouble in the operating
mode AUTOMATIC only!
panel.
Backwash


discharge pipe.

16
Control panel

...
...
...

main switch
operator panel for

indication:
operation:
individual alarms
timers of control
alternative language
setting of timers
selection of language
The control panel contains potential-free contacts which should be connected to the control room
by the customer.
17
10.09.2009
Schmidlin
Gller
07.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
APPROVED
Updated
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
DS
Title :
DATA SHEET CCW Exchanger

Debris Filter
Language
:E
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DS/011
DATA SHEET
ENERGY
Pow er Pl ants
EXCHANGER DEBRIS FILTERS ND 20

1
2
CLIENT
NUMBER
3
4
5
6
TYPE
Conveyed fluid
Max operation temperature
Rated flow
Unit : 12/13/14
SAUDI ELECTRICITY COMPANY

SIX
FUNCTIONAL CODE
12/13/14PCB15AT010 /
12/13/14PCB16AT010
Mfr's REFERENCE
K2009/20/1368
MANUFACTURER
TAPROGGE GmbH
Seawater
50C
1580 m/h
10
Design pressure
11
Mesh aperture
10 bar gauge / Vacuum
12
Washing water consumption
13
Head loss clean
14
Inlet/outlet apertures - ND (1)
15
Drilling through flanges
16
Washing water discharge aperture - ND (1)
17
Electric power supplies
18
Motor power
19
Rotation speed of washing system
20
Capacity of the reducing gear oil casing
n.a.
21
Oil type
n.a.
22
Installation level
3 mm
min. 50 m/h
0.8 mWG
500 mm
ANSI B16.5
DN 150 ANSI B16.5, 150 lbs
460 V/60 Hz
0,75 Kw
2.rpm
n.a.
l
m
23
CONSTRUCTION
24
Type
25
Material
Grade
Standard
Mild steel
S235JR / rubberlined
EN 10025
DIN EN
10088
DIN EN
10088
26
27
Housing
28
Filter Element
1.4462
29
Washing system
1.4462
30
Lower bearings
31
Internal bolts and nuts
32
External bolts and nuts
33
Gaskets
PA 6 G for seawater
1.4462
A193B7 / A194Gr2M
equivalent A4-70 / A4
Asbestos free
34
WEIGHTS AND OVERALL DIMENSIONS
35
36
WEIGHT
37
In operating order
1,7 t
38
Empty
1,1 t
39
OVERALL DIMENSIONS
40
Length
41
Width
42
Height
43
44
45
46
OUTLINE AND LAYOUT DIAGRAM
47
(supporting and lifting included)
48
49
50
51
REMARKS
(1) nominal diameter
Rubber
DIN EN
10088
10.09.2009
Schmidlin
Gller
20.07.2009
Schmidlin
Gller
18.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
Neugebauer
APPROVED
Updated
FUS
Updated
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
DS
Title :
Valves DATA SHEET
Language
:E
abcd
No of
sheet : 3
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DS/013
Rev. C
DATA SHEET
VALVES
ENERGY
Pow er Pl ants

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
DESIGNATION
12/13/14PCB15AA016
12/13/14PCB16AA016
IDENTIFIER
SUPPLIER
Mfr's REFERENCE
ND =
DN150
DN150
TAPROGGE
K2009/20/1368
/ SERIES =
ANSI B 16-34
DIN
NFE
Ball valve
- Body
ISO 5752
Cast
Forged
Fabricated
Die-worked
- Obturator
ANSI B16.10
feather key
Bolted
Autoclave
Screwed & welded
Not applicable
Materials :
- housing
BS 1504 318 C17 ST.ST.
- ball
904L ST.ST.
- switching shaft
904L ST.ST.
- seat rings / gaskets
PTFE (TFM1600) / graphite
- bolts
A 193 B8M CL2 / A 194 8M
OPTIONS
Body :
Straight
Angle
Inclined
3-way
- Pipe connection :
- Neck : Material :
DN150
Control : Manual
Yes
No
*
t
electric
pneumatic
hydraulic
- By-pass ND
n.a.
- Decompression ND
n.a.
*
n.a.
Stuffing-box :
Standard gasket
Gasket for vacuum
Water seal
Open
Closed
Intermediate
No
No
not applicable
Counter weight
Damper
Seat bore
-integral
Yes
-seat
150
Replacement Ring
Yes
NBR/no lining
Water seal
NBR
SERVO-MOTOR
electric
Nature of fluide
Maximum pressure
Temperature
Flow
50
C
50
m3/h
Breakdown torque
*
135 Nm
Operation time
/ Rpm of stem
n.a.
s
/
6 bar
*
135 Nm
*
n.a.
Drawing No
*
26,5 kg
Fluid :seawater
Max. pressure : 10
bar G.
Max. temp. : 60
C
if needed, completed by the supplier. Length of the valve 151/2
Originator
Rev.
Date
Lang.
Sheet
ALSTOM
TAPROGGE
SHA/14/M/---C05/DS/013
10.09.2009
en
2/3

Rev. C
DATA SHEET
VALVES
ENERGY
Pow er Pl ants

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
DESIGNATION
12/13/14PCB15AA201
12/13/14PCB16AA201
IDENTIFIER
SUPPLIER
Mfr's REFERENCE
ND =
DN50
DN50
TAPROGGE
K2009/20/1368
/ SERIES =
ANSI B 16-34
DIN
NFE
Drain valve
- Body
ISO 5752
Cast
Forged
Fabricated
Die-worked
- Obturator
ANSI B16.10
feather key
Bolted
Autoclave
Screwed & welded
Not applicable
Materials :
- housing
BS 1504 318 C17 ST.ST.
- ball
BS 1504 318 C17 ST.ST.
- switching shaft
904L ST.ST.
- seat rings / gaskets
PTFE (TFM1600) / graphite
- bolts
A 193 B8M CL2 / A 194 8M
OPTIONS
Body :
Straight
Angle
Inclined
3-way
- Pipe connection :
- Neck : Material :
DN50
Control : Manual
Yes
No
*
t
electric
pneumatic
hydraulic
- By-pass ND
n.a.
- Decompression ND
n.a.
*
n.a.
Stuffing-box :
Standard gasket
Gasket for vacuum
Water seal
Closed
Intermediate
Open
No
No
not applicable
Counter weight
Damper
Seat bore
-integral
Yes
-seat
150
Replacement Ring
Yes
NBR/no lining
Water seal
NBR
SERVO-MOTOR
electric
Nature of fluide
Maximum pressure
Temperature
Flow
50
C
50
m3/h
Breakdown torque
*
135 Nm
Operation time
/ Rpm of stem
n.a.
s
/
15 bar
*
41 Nm
*
n.a.
Drawing No
*
11 kg
Fluid :seawater
Max. pressure : 10
bar G.
Max. temp. : 60
C
if needed, completed by the supplier. Length of the valve 7
Originator
Rev.
Date
Lang.
Sheet
ALSTOM
TAPROGGE
SHA/14/M/---C05/DS/013
10.09.2009
en
3/3

29.07.2009
Schmidlin
Gller
27.07.2009
Schmidlin
Gller
20.07.2009
Schmidlin
Gller
18.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
Neugebauer
Neugebauer
APPROVED
Updated
FUS
Updated
FUS
Updated
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
DS
Title :
LV Motor DATA SHEET
Language
:E
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DS/012
Rev. D
1
2
CLIENT
QUANTITY
3
4
MOTOR DESIGNATION SK02F-IEC-80L/4

DRIVEN MACHINE Debris Filter (Exchanger)
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53

Type
: alternating
:460V +10-15%
:
60Hz +6-5%
Neutral
:
grounded
ENVIRONMENT
:
Atmosphere
:
clean
:
55/9/30
: 100 %
Altitude
:6m
Particular risks
:
Seismicity
: UBC Zone 2A
Motor type
Location
Arrangement
Rated voltage
Rated frequency
Rated output
Synchronous speed
Slip (4/4 load)
Rated current
Rated torque
Max. torque Cmax/Cn
No load current
FUNCTIONAL CODE
12/13/14PCB15AT010 /
12/13/14PCB16AT010
Alstom
2 per unit
: asynchronous
:
inside
:
horizontal
: 460V
: 60Hz
: 0,75 kW
: 1800 rpm
: 74 %
: 1,95 A
:6
: 5,1 Nm
: 2,5
: 2,6
:5A
2/4
3/4
4/4
74
74
74
MANUFACTURER
NORD
CONSTRUCTION
Rotor
Stator winding
- temperature rise
Type construction
Frame
dry
Coupling type
Bearings
- lubrication type
Mfr's REFERENCE
K2009/20/1368
: class F
: varnish
:B
:
B
:
: F7
: roller bearing
: roller bearing
:

:
:
-/
:-
Cooling
- type
PAINTING
kg
-cSt
C
TEFC
:
:
:
:
:
:
/
/
m/h
bar abs.
m/h
C
Mwg
RAL 7037
MATERIALS
Stator winding
:
Stator bars
:
Efficiency
%
Frame
:
Power factor
Shaft
:
0,8
0,8
0,8
: n.a.
Insulation
:
Impregnation
:
Motor inertia
: 0,0053 kgm
Terminal box
:
Starting time (Un)
: < 6 sec. (460 V)
Rotor laminations
:
:3
:
Stator laminations
<70 dB(A) (A)
Protection class
: IP56
Axis height
:
clockwise
Height
:
:
star
Length
:
Width
:
Shaft end diameter
:
- design
: IEC 60034
Net weight
:
- construction
: IEC 60034
- tests
: IEC 60034
Standard
VDE
VDE
VDE
VDE
n.a.
n.a.
VDE
VDE
VDE
Rev.
Date
Lang.
Sheet
TAPROGGE
SHA/14/M/---C05/DS/012
29.07.2009
en
2/2
steel
cast +Al
steel
n.a.
n.a.
Al
steel
steel
140 mm
279 mm
318 mm
166 mm
25 mm
18 kg
Originator
Grade
copper
06.05.2009
Schmidlin
Gller
21.04.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
FUS
First issue
FUS
APPROVED
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
DS
Title :
DATA SHEET PRESSURE

TRANSMITTER
Language
:E
abcd
No of
sheet : 2
Power Systems
Sheet :
Plants
SHA/14/M/---C05/DS/014
SHA/14/M/---C05/ DS/014
ENERGY
Pow er Pl ants
DATA SHEET
PRESSURE TRANSMITTER
Unit : 14,13,12
1
2
3
4
5
6
CLIENT
SAOUDI ELECTRICITY COMPANY
Quantity
Functional code (s)
14/13/12 PCB15CP010
14/13/12 PCB16CP010
Destination
Debris filter
Debris filter
MAKE
ROSEMOUNT-EMERSON
ROSEMOUNT-EMERSON
Type
1151 DP4
1151 DP4
MANUFACTURER
TAPROGGE GmbH
FUNCTIONAL CODE
14/13/12 PCB15/16CP010
Mfr's REFERENCE
K2009/20/1368
8
9
10
11
12
13
14
15
16
17
18
Nature of fluid
19
Nominal/maximum pressure
water
20
Nominal/maximum temperature
21
Density
22
water
bar abs.
5,5/16
50/70
5,5/16
50/70
appr. 1000kg/m
appr. 1000kg/m
370mbar
INSTRUMENT
23
Scale
bar abs.
370mbar
24
Measuring scale
bar abs.
-10 to 360 mbar
-10 to 360 mbar
25
Accuracy
0,1% of SPAN
0,1% of SPAN
26
Transmitter
Yes
Yes
27
Action
28
Signal/power supply characteristics
%
DIRECT / INDIRECT
29
(SMART TYPE)
(SMART TYPE)
CONSTRUCTION
30
31
Box
32
Protection class IP
33
Instrument connections
34
Coupling - dimensions
35
Location - standards
36
Connection
Yes / No
37
Expansion loop
38
Manifold
39
Drain trap
IP65
IP65
mm
DN3 Remote seal
DN3 Remote seal
mm
DN 3 Remote seal
DN 3 Remote seal
Yes / No
No
No
Yes / No
No
No
Yes / No
No
No
Electrical/process
40
41
MATERIALS
42
Gear chamber
1.4401/1.4404
1.4401/1.4404
43
Box
Aluminium
Aluminium
44
Equipment
2.4819
2.4819
45
Nut & bolts
SS316
SS316
DRAWINGS - NOTICES
K2009/20/1367-0501
K2009/20/1367-0501
46
47
48
49
50
51
52
53
REMARKS Local Indicator LCD Type = 0-100%

Label AISI 316
Transmitters with capillaries: capillary length 3 m, Flange ANSI RF, liquid fill with silicon oil
Issue
Date
Author
Checked by
Approved by
21.04.2009
06.05.2009
Schmidlin
Schmidlin
Gller
Gller
Neugebauer
Neugebauer
N SHA/14/M/---/C05/DS/014
20.07.2009
Schmidlin
Gller
19.05.2009
Schmidlin
Gller
REV
DATE
PREPARED
CHECKED
Neugebauer
Neugebauer
APPROVED
Updated
FUS
First issue
FUS
MODIFICATIONS
STATUS
CLIENT
PROJECT

CONSULTANT
CONTRACTOR
abcd
Power Systems
Scale :
SUBCONTRACTOR
N/A
Format :
A4
Ta p r o g g e
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0
Project :
SHA
IS
N/A
KKS
N/A
Doc Type :
DS
abcd
Title :
Actuator DATA SHEET
Language
:E

No of
sheet : 2
Power Systems
Sheet :
Plants
1
SHA/14/M/---C05/DS/015
Rev. B
FUNCTIONAL CODE
12/13/14PCB15M002 /
12/13/14PCB16M002
1
2
CLIENT
QUANTITY
3
4
MOTOR DESIGNATION AUMA SG 07.1-32

DRIVEN MACHINE
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53

Type
: alternating
:460V +10-15%
:
60Hz +6-5%
Neutral
:
grounded
ENVIRONMENT
:
Atmosphere
:
clean
:
55/9/30
: 100 %
Altitude
:6m
Particular risks
:
Seismicity
: UBC Zone 2A
Motor type
Location
Arrangement
Rated voltage
Rated frequency
Rated output
Synchronous speed
Slip (4/4 load)
Rated current
Rated torque
Max. torque Cmax/Cn
No load current
: asynchronous
:
inside
:
horizontal
: 460V
: 60Hz
: 0,08 kW
: 1800 rpm
: 59 %
: 0,55 A
: 1,64
: 135 Nm
:3
: 2,1
: 3,3 A
2/4
3/4
4/4
MANUFACTURER
AUMA
CONSTRUCTION
Rotor
Stator winding
- temperature rise
Type construction
Frame
dry
Coupling type
Bearings
- lubrication type
Mfr's REFERENCE
K2009/20/1368
: class F
: varnish
:B
:
B
:
: F7
: roller bearing
: roller bearing
:

:
:
-/
:-
Cooling
- type
PAINTING
kg
-cSt
C
no cooling
:
:
:
:
:
:
m/h
bar abs.
m/h
/
C
/
Mwg
Manufacturer Standard
MATERIALS
Stator winding
:
Stator bars
:
Efficiency
%
Frame
:
59
59
Power factor
Shaft
:
60
60
: n.a.
Insulation
:
Impregnation
:
Motor inertia
: 0,005 kgm
Terminal box
:
Starting time
: < 6sec.
Rotor laminations
:
:3
:
Stator laminations
<65 dB(A) (A)
Protection class
: IP67
Axis height
:
clockwise
Height
:
:
star
Length
:
Width
:
Shaft end diameter
:
- design
: IEC 60034
Net weight
:
- construction
: IEC 60034
- tests
: IEC 60034
Standard
VDE
VDE
VDE
VDE
n.a.
n.a.
VDE
VDE
VDE
Originator
Rev.
Date
Lang.
Sheet
SHA/14/M/---C05/DS/015
20.07.2009
en
2/2
steel
cast +Al
steel
n.a.
n.a.
Al
steel
steel
50 mm
275 mm
450 mm
250 mm
40 mm
18 kg
ALSTOM
TAPROGGE
Grade
copper

Sha 14 M - C05 MM 100 A

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SHA 14 M --- C05 MM 100, Rev A. Page 1 of 361

Shoaiba Steam Power Plant

Operation & Maintenance Manual

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

001 Condensor Debris Filter- Actuator

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

001 Condensor Debris Filter- Actuator

Condensor Debris Filter System

Condensor Debris Filter System

Condensor Debris Filter System

Checked and released:

SHA 14 M --- C05 MM 100, Rev A. Page 2 of 361

Checked and released:

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

001 Condensor Debris Filter- Actuator

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

001 Condensor Debris Filter- Actuator

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

001 Condensor Debris Filter- Actuator

Condensor Debris Filter System

Condensor Debris Filter/PR-BW 800

Shoaiba Steam Power Plant

Condensor Debris Filter System

Condensor Debris Filter System

Checked and released:

SHA 14 M --- C05 MM 100, Rev A. Page 3 of 361

Checked and released:

Shoaiba Steam Power Plant

201 Condensor Debris Filter- Valves /DN 50

see 14 PAB 41AA015

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

001 Condensor Debris Filter- Actuator

Debris Filter- Condenser & CCW Exchanger

CCW Exchanger Debris Filter System

Operation & Maintenance Manual

Checked and released:

SHA 14 M --- C05 MM 100, Rev A. Page 4 of 361

Checked and released:

201 CCW Exchanger Debris Filter- Valves/DN 50

Shoaiba Steam Power Plant

Debris Filter- Condenser & CCW Exchanger

Debris Filter- Condenser & CCW Exchanger

Checked and released:

SHA 14 M --- C05 MM 100, Rev A. Page 5 of 361

Checked and released:

Shoaiba Steam Power Plant

Debris Filter- Condenser & CCW Exchanger

Debris Filter- Condenser & CCW Exchanger

See 14 PCB15 AT010

Checked and released:

SHA 14 M --- C05 MM 100, Rev A. Page 6 of 361

Checked and released:

Revised acc. clients comments

First issue / Preliminary

SHOAIBA POWER PLANT STAGE III

Operation & Maintenance Manual

Consortium Participant or Subcontractor Document No. : N/A

Condenser Debris Filter

Client Document No. :

SHA 14 M --- C05 MM 100, Rev A. Page 7 of 361

Maintenance manual number :

Equipment component code :