Instruction Manual: Flow Pad Size12 Fabric: Nomex

Flow Pad Size12 Name Date
Issued: TD/Willmer 28.04.1998

Fabric: Nomex
Checked: TD/Scholle 28.04.1998
Instruction Manual
Approved: TD/Scholle 28.04.1998
Revision: 0
Instruction Manual
Chapter Title
Order No: ...................................................40550/734

Keyword: ..................... EPS – TE-KO “Kostolac B”
This document contains 20 pages.
Page 1 71201204_en
Fabric: Nomex
Instruction Manual
Revision: 0
Preface
This Manual contains information and safety instructions which are essential for correct operation,
maintenance and servicing of the flow pad.
Chapter Title
Before taking the flow pad into operation carefully read the operating instructions and observe the
advice given. This will ensure trouble-free operation and a long service life.
If necessary also inform yourself on the documentation concerning the installed assemblies of other
manufacturers.
Ensure that all documentation is permanently available to the personnel and that the instructions
contained therein are observed.
Only our original spare parts guarantee the quality, safety, exchangeability and function of the flow
pad. FLSmidth MÖLLER GmbH does not assume any responsibility for damage resulting from the use
of other parts.
Unauthorized modifications to the flow pad without the approval of FLSmidth MÖLLER GmbH lead to
the forfeiture of all guarantee claims and claims for damages.
Any adjustment, repair and maintenance work may only be carried out by qualified personnel.
For spare parts orders please refer to the spare parts lists.
If you need further information on the flow pad valve please contact our Service Department.
FLSmidth MÖLLER GmbH

Service Department
Haderslebener Str. 7
D-25 421 Pinneberg
Tel.: +49 (0)4101 788-0 (Reception)

+49 (0)4101 788-159 (Spare parts)
+49 (0)4101 788-164 (Request for Installation Supervision)
Fax: +49 (0)4101 788-140 (Reception)

+49 (0)4101 788-108 (Spare parts)
In case of any questions please state the type and production number (identification plate).
The Management
Page 2 71201204_en
Fabric: Nomex
Instruction Manual
Revision: 0
Table of Contents
Chapter Title
Flow Pad 712 ..................................................................................................................... 6
A Safety Instructions ........................................................................................... 6

A.1 Warnings and symbols ....................................................................................... 6
A.2 Basic operation; designated use ........................................................................ 6
A.3 Organizational measures ................................................................................... 6
A.4 Selection and qualification of personnel - Basic responsibilities ........................ 7
A.5 Safety instructions governing specific operational phases ................................. 7
A.5.1 Standard operation ............................................................................................. 7
A.5.2 Special work in conjunction with utilization of the flow pad and maintenance and
repairs during operation; disposal of parts and consumables ............................ 7
A.6 Warning of special dangers ................................................................................ 8
A.6.2 Gas, dust, steam, smoke .................................................................................... 8
A.6.3 Pneumatic equipment......................................................................................... 8
Flow Pad 712 ..................................................................................................................... 9
B Technical Data .................................................................................................. 9

B.1 Description ......................................................................................................... 9
B.2 Dimensions......................................................................................................... 9
B.3 Materials ........................................................................................................... 10
B.4 Temperatures ................................................................................................... 10
B.5 Place and position of installation ...................................................................... 10
Flow Pad 712 ................................................................................................................... 11
C Transport Instructions ................................................................................... 11

C.1 Safety Instructions ............................................................................................ 11
C.2 Delivery ............................................................................................................ 11
C.3 Packing ............................................................................................................ 11
C.4 Storage ............................................................................................................. 11
C.5 Lifting gear........................................................................................................ 11
C.6 Fastening.......................................................................................................... 11
C.7 Transport at the site ......................................................................................... 11
Page 3 71201204_en
Fabric: Nomex
Instruction Manual
Revision: 0
Chapter Title
Flow Pad 712 ................................................................................................................... 12
D Assembly and Disassembly .......................................................................... 12

D.1 Safety Instructions ............................................................................................ 12
D.2 Provision........................................................................................................... 12
D.3 Preparation for installation ................................................................................ 12
D.4 Assembly .......................................................................................................... 12
D.5 Disassembly ..................................................................................................... 12
Flow Pad 712 ................................................................................................................... 13
E Operating Instructions ................................................................................... 13

E.1 Safety Instructions ............................................................................................ 13
E.2 Description ...................................................................................................... 13
E.3 Checking correct installation ............................................................................ 13
E.5 Functional test .................................................................................................. 14
E.6 First start-up ..................................................................................................... 14
E.7 Start-up after short standstill ............................................................................ 14
E.8 Start-up after longer standstill .......................................................................... 14
E.9 Normal operation .............................................................................................. 14
E.10 Emergency operation ....................................................................................... 14
E.11 Normal shut-down ............................................................................................ 14
E.12 Emergency Off ................................................................................................. 15
E.13 Malfunctions and how to remove them ............................................................. 15
Flow Pad 712 ................................................................................................................... 16
F Maintenance Instructions .............................................................................. 16

F.1 Safety Instructions ............................................................................................ 16
F.2 Description ....................................................................................................... 16
F.3 Maintenance ..................................................................................................... 16
F.3 Maintenance interval ........................................................................................ 18
F.4 Proposals for spare parts depot ....................................................................... 18
Flow Pad 712 ................................................................................................................... 19
H Spare parts...................................................................................................... 19
H.1 Spare parts drawing ......................................................................................... 19
H.2 Spare parts list ................................................................................................. 19
Page 4 71201204_en
Fabric: Nomex
Instruction Manual
Revision: 0
Chapter Title
Fabric 273.289 ................................................................................................................. 20
H Spare parts...................................................................................................... 20
H.1 Spare parts drawing ......................................................................................... 20
H.2 Spare parts list ................................................................................................. 20
Page 5 71201204_en
Flow pad Name Date
Checked: MK/Friedrichs 20.02.2004
Safety Instructions
Revision: 0 Approved: TL/Duwe 20.02.2004
A Safety Instructions
A.1 Warnings and symbols
The following designations and signs are used in the Instruction Manual to refer to instructions of
particular importance:
Important
Refers to special information on how to use the flow pad most effi-
ciently.
Attention
Refers to special information and/or orders and prohibitions di-
rected towards preventing damage.
Danger
Refers to orders and prohibitions designed to prevent injury or
extensive damage.
A.2 Basic operation; designated use
The flow pad has been built in accordance with state-of-the-art standards and the recognized safety
rules. Nevertheless its use may constitute a risk to life and limb of the user or third parties, or cause
damage to the flow pad and to other material property.
The flow pad must only be used in technically perfect condition in accordance with its designated
use and the instructions set out in the Instruction Manual, and only by safety-conscious persons who
are fully aware of the risks involved in operating the flow pad. Any functional disorders, especially
those affecting safety, should therefore be rectified immediately!
The flow pad is a discharge aid for powdered bulk materials from containers. Using the injector for
purposes other than that mentioned above is considered contrary to its designated use. Möller Mate-
rials Handling cannot be held liable for any damage resulting from such use. The risk of such misuse
lies entirely with the user.
Operating the injector within the limits of its designated use also involves observing the operating
instructions and complying with the inspection and maintenance directives.
A.3 Organizational measures
The operating instructions must always be kept at hand at the place of use of the flow pad!
In addition to the operating instructions, observe and instruct the user in all other generally applica-
ble legal and other mandatory regulations relevant to accident prevention and environmental protec-
tion!
These compulsory regulations may also deal with the handling of hazardous substances, issuing and/
or wearing of personal protective equipment, or traffic regulations.
The operating instructions must be supplemented by instructions covering the duties involved in
supervising and notifying special organizational features, such as job organization, working se-
quences, or the personnel entrusted with the work.
Page 6 712A
Flow pad Name Date
Safety Instructions
Personnel entrusted with work on the plant must have read the operating instructions and in particu-
lar the chapter on safety before beginning work. Reading the instructions after work has begun is too
late. This applies especially to persons working only occasionally on the plant e. g. during setting up
or maintenance.
Check – at least from time to time – whether the personnel is carrying out the work in compliance
with the operating instructions and paying attention to risks and safety factors.
Never make any modifications, additions or conversions to the flow pad which might affect safety
without the supplier's approval. This also applies to the installation and adjustment of safety devices
and valves as well as to welding work on load-bearing elements.
Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts
from original equipment manufacturers can be relied to do so.
Adhere to prescribed intervals or those specified in the Instruction Manual for routine checks and
inspections.
For the execution of maintenance work, tools and workshop equipment adapted to the task on hand
are absolutely indispensable.
A.4 Selection and qualification of personnel - Basic responsibilities
Any work on the flow pad must be executed by reliable personnel only. Statutory minimum age limits
must be observed.
Employ only trained or instructed personnel and set out clearly the individual responsibilities of the
personnel for operation, set-up, maintenance and repair.
A.5 Safety instructions governing specific operational phases
A.5.1 Standard operation
Avoid any operational mode that might be prejudicial to safety.
Take the necessary precautions to ensure that the flow pad is used only in a safe and reliable state!
Operate the flow pad only if all protective and safety-oriented devices such as removable safety
devices, emergency shut-off equipment, sound-proofing elements and exhausters are in place and
fully functional!
Check the flow pad at least once per working shift for damage and defects! Report any changes
(including changes in the working behaviour) to the competent authority/person immediately. If nec-
essary, stop the plant immediately and lock it.
In the event of malfunctions, stop the plant immediately and lock it. Have any defects rectified imme-
diately.
A.5.2 Special work in conjunction with utilization of the flow pad and
maintenance and repairs during operation; disposal of parts and
consumables
Observe the adjusting, maintenance and inspection activities and intervals set out in the instruction
manual, including information on the replacement of parts and equipment.
Page 7 712A
Flow pad Name Date
Safety Instructions
Brief operating personnel before beginning special operations and maintenance work, and appoint a
person to supervise the activities.
If the conveying plant must be completely shut down for maintenance and repair work, it must be
secured against inadvertent starting by:
- locking the main command devices and removing the key and/or
- attaching a warning sign to the main switch.
To avoid the risk of accidents, individual parts and large assemblies being moved for replacement
purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically
perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under
suspended loads.
The fastening of loads and the instructing of crane operators should be entrusted to experienced
persons only. The marshaller giving the instructions must be within sight or sound of the operator.
For carrying out overhead assembly work always use specially designed or otherwise safety-ori-
ented ladders and working platforms. Never use machine parts as a climbing aid. Wear a safety
harness when carrying out maintenance work at greater heights.
Clean the flow pad before carrying out maintenance/repair. Never use aggressive detergents. Use
lint-free cleaning rags.
After cleaning, examine all air connections for leaks, loose connections, chafe marks and damage.
Any defects found must be rectified without delay.
Always tighten any screwed connections that have been loosened during maintenance and repair.
A.6 Warning of special dangers
A.6.2 Gas, dust, steam, smoke
Carry out welding, flame cutting and grinding work on the flow pad only if this has been expressly
authorized, as there may be a risk of explosion and fire. It is essential that the fabric is covered
(danger of combustion)!
Before carrying out welding, flame cutting and grinding operations, clean the flow pad and its sur-
roundings from dust and other inflammable substances and make sure that the premises are ad-
equately ventilated (risk of explosion)!
A.6.3 Pneumatic equipment
Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair
damage immediately.
Depressurize all system sections and pressure pipes (compressed-air system) to be removed in
accordance with the specific instructions for the unit concerned before carrying out any repair work.
Compressed-air lines must be laid and fitted properly. Ensure that no connections are interchanged.
The fittings, lengths and quality of the hoses must comply with the technical requirements.
Page 8 712A
Flow Pad Size 12 Name Date
Technical Data
Revision: 0 Approved: TD/Scholle 28.04.1998
B Technical Data
B.1 Description
By means of a flow pad it is possible to discharge dry, non-sticking, free-flowing bulk materials from
containers with conical bottom.
By the application of air (0.03 bar min. to 0.6 bar max.) the material above the fabric is fluidized and
thus made flowable. Then the material is discharged from the container by means of a suitable dis-
charge system.
The illustration below shows the construction of the flow pad.
1 Pad trough 9 Fabric

3, 4 Covering strips 10 Hexagon cap screw
8 Fabric support 11 Hexagonal nut
The position and size of the air connection, the length of the flow pad, the number and positions of the
fxing straps are order-related data and are specifically stated.
B.2 Dimensions
The drawing below provides a schematic survey on the positioning of the attachments.
Page 9 712B-12
Flow Pad Size 12 Name Date
Technical Data
B.3 Materials
The flow pad is made of steel. For the fabric material refer to the enclosed spare parts list for the
fabric.
B.4 Temperatures
The maximum bulk material temperature amounts to 160 °C for polyester fabric, 220 °C for Nomex
fabric and 400 °C for Dynapore.
B.5 Place and position of installation
Please refer to the plant drawings for the place of installation. The flow pads are radially arranged in
the container.
Page 10 712B-12
Flow Pad Name Date
Transport Instructions
C Transport Instructions
C.1 Safety Instructions
Attention
Use only suitable, tested and approved means of transportation for
handling the equipment.
Attention
Use only tested and approved lifting gear.
C.2 Delivery
The flow pad is delivered on a pallet. It is fixed to the pallet by fixing band.
When received by the customer the delivery should be checked for correctness, completeness and
possible transport damage.
C.3 Packing
The flow pad is delivered ready for installation. The fabric is protected by foil. Remove the foil right
before start-up.
C.4 Storage
The flow pad must be stored so that no humidity can enter. It also must be protected from contamina-
tion.
C.5 Lifting gear
Use only tested transport belts and load lifting devices of sufficient carrying capacity for transport.
C.6 Fastening
Take care that the flow pad is not damaged by the transport belts during transportation.
C.7 Transport at the site
The flow pad - lying on the pallet - is transported by lift truck to the place of installation or as near as
possible to the place of installation. Do not remove the fixing band before the place of installation has
been reached.
Should transportation by lift truck be impossible, the flow pad may be transported by crane or similar
equipment. Use transport belts of sufficient capacity to lift the flow pad.
Attention
Be careful when cutting up the fixing band. Injury may result from
rebounding fixing band ends.
Page 11 712C
Flow Pad Name Date
Assembly and Disassembly
D Assembly and Disassembly

D.1 Safety Instructions
See chapter A: Safety Instructions.
D.2 Provision
The flow pad is delivered ready for installation. The fabric is protected by foil. Remove the foil right
before start-up.
When received by the customer the delivery should be checked for correctness, completeness and
possible transport damage.
D.3 Preparation for installation
Inspect the flow pad for damage in transport and storage prior to installation. In particular the fabric
must be checked for damage. A flow pad with wet, fouled or defective fabric must not be installed. The
fabric must be dried or replaced.
Ensure that the fabric cannot be damaged during installation.
D.4 Assembly
Position the flow pads in the container in accordance with the plant drawing. Then connect the com-
pressed air.
After final alignment, the flow pads are welded to the container bottom.
The fabric must be appropriately covered in order to avoid that weld spatter or hot parts reach the fabric
surface.
D.5 Disassembly
Remove the compressed air connection. Then sever the weld joints.
Page 12 712D
Flow Pad Name Date
Operating Instructions
E Operating Instructions
E.1 Safety Instructions
E.2 Description
charge system.
The illustration below shows the construction of the flow pad:

fxing straps are order-related data and are specifically stated.
E.3 Checking correct installation
Check :
- that the arrangement of the flow pads is in compliance with the plant drawing.
- the air distribution system and the air connections for leaks.
The fabric must be checked for damage.
Important
It is advisable to dehydrate the air system (also condensate) before
a compression test is made.
Page 13 712E
Flow Pad Name Date
E.5 Functional test
Before starting the functional test remove the foil to protect the fabric. When doing so take care that no
damage to the fabric occurs.
The air system must be cleaned and the suction filter must be attached to the fan prior to the func-
tional test in order to ensure that the fabric cannot be contaminated by the fluidization air.
The bottom must be cleaned from all covers and other assembly material.
Important
The functional test must always be carried out before any material
is filled into container.
The flow pads must be pressurized with air for the functional test. A pressure gauge (e.g. on the fan)
indicates a no-load pressure that builds up. This no-load pressure should reach at least 0.03 bar. If it
is lower there are leaks in the system which must be removed. Higher values do not constitute a
problem.
Inspection of the container while the fan is running is urgently recommended. In this way minor dam-
age to the fabric can be recognized and removed.
E.6 First start-up
Fill the container with material, but only partly.

Where problematic materials are concerned (e.g. oil ash in the starting stage of power plants) provide
the flow pads with a protective layer (e.g. ash or sand) before material filling is started in order to avoid
fouling of the fabric . Do not remove the protective layer before filling of these problematic materials
has been finished. If such problematic materials are produced over a longer period of time it may be
necessary to apply the protective layer repeatedly.
E.7 Start-up after short standstill
There are no special points to be observed.
E.8 Start-up after longer standstill
Dependent on the material conveyed hardening above the fabric may occur. Manual cleaning may be
necessary.
If any work is carried out on the air system during standstill care must be taken that no water can
enter. Otherwise the air system must be dehydrated.
E.9 Normal operation
E.10 Emergency operation
E.11 Normal shut-down
There are no special points to be observed. Shut-down is controlled by a program.
Page 14 712E
Flow Pad Name Date
E.12 Emergency Off
E.13 Malfunctions and how to remove them

Malfunction Cause Remedy
No pressure building up Fabric leaking Replace fabric
Air supply line leak Seal air supply line1
1
not described in this instruction manual
Page 15 712E
Flow Pad Name Date
Maintenance Instructions
F Maintenance Instructions
F.1 Safety Instructions
F.2 Description
charge system.
The illustration below shows the construction of the flow pad:

fixing straps are order-related data and are specifically stated.
F.3 Maintenance
Important
Prior to any work on the pneumatic flow pad, the container must
be completely emptied and the complete system must be shut down.
Fluidization air must be shut off.
Page 16 712F
Flow Pad Name Date
Replacing the fabric (9)
Tools required:
screw spanner SW13

small screw clamps
mandrel or drilling machine with 8 mm drill
Removal
Loosen and remove hexagon-cap screws (10)

Remove covering strips (3, 4) from pad trough (1)
Remove fabric (9) from pad trough (1)
Assembly
Important
Thoroughly clean the pad trough from material (by suction) be-
fore inserting the new fabric.
Place the fabric (9) on the pad trough (1)

Align the covering strips (3, 4) on the pad trough (1) and fix them by means of screw clamps
Using the drilling machine drill two holes into the fabric, one each at the front end and at the rear end
of the covering strips (3, 4)
Fix covering strips (3, 4) by means of screws (10)
Drill the other holes into the fabric
Screw the covering strips (3, 4) with the pad trough (1)
Page 17 712F
Flow Pad Name Date
F.3 Maintenance interval
Check the fabric every 2 years for tightness and contamination while the container is empty.
F.4 Proposals for spare parts depot
We recommend to keep the fabric (9) in stock.
Address for order:
FLSmith MÖLLER GmbH

Spare parts department
Haderslebener Str. 7
D-25421 Pinneberg
Telephone: +49 (0)4101 788-159

Fax: +49 (0)4101 788-108
Page 18 712F
Flow Pad Name Date
Spare parts
H Spare parts
H.1 Spare parts drawing
The spare parts drawing shows the schematic design of a flow pad. Dependent on the order con-
cerned it may deviate from the flow pad delivered.
H.2 Spare parts list

W - Wear part
S - Spare part
Kit number
Kit item
Item Art. Weight

Qty. Designation Material
no. no. kg
1 1 Airslide trough Steel

2 2 Front plate Steel
3 2 Covering strip Steel
4 2 Covering strip Steel
5 1 Air distribution plate Steel
6 1 Half sleeve Steel
7 Fixing lug Steel
8 1 Fabric support Steel
9 1 Fabric W
10 Hexagon cap screw M8x20 8.8 galZn 106.028
11 Hexagonal nut M8 8 galZn 125.303
The above spare parts list covers the basic design of the flow pad. Further data from the order
concerned are necessary for ordering a flow pad.
Use the enclosed spare parts list of the fabric for ordering the consumable fabric (9).
Page 19 712H
Fabric Name Date
Issued: TD/Reineke 02.08.1999
Spare parts
H Spare parts
H.1 Spare parts drawing
H.2 Spare parts list
Sortimentnummer
V - Verschleißteil
E - Ersatzteil
Sortimentes
Teil eines
Pos. Sach- Gewicht
Stück Benennung Werkstoff
Nr. Nr. kg
Fabric Nomex 273.289 W
The details on spare and wear parts are general and can differ in the respective order. The details
always are definite according to spare part offer.
Page 20 273_289H

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Flow Pad Size12 Name Date

Issued: TD/Willmer 28.04.1998

Order No: ...................................................40550/734

This document contains 20 pages.

FLSmidth MÖLLER GmbH

D-25 421 Pinneberg

Tel.: +49 (0)4101 788-0 (Reception)

Fax: +49 (0)4101 788-140 (Reception)

Flow Pad 712 ..................................................................................................................... 6

A Safety Instructions ........................................................................................... 6

Flow Pad 712 ..................................................................................................................... 9

B Technical Data .................................................................................................. 9

Flow Pad 712 ................................................................................................................... 11

C Transport Instructions ................................................................................... 11

D Assembly and Disassembly .......................................................................... 12

Flow Pad 712 ................................................................................................................... 13

E Operating Instructions ................................................................................... 13

Flow Pad 712 ................................................................................................................... 16

F Maintenance Instructions .............................................................................. 16

Flow Pad 712 ................................................................................................................... 19

A.2 Basic operation; designated use

A.3 Organizational measures

A.4 Selection and qualification of personnel - Basic responsibilities

A.5 Safety instructions governing specific operational phases

A.5.1 Standard operation

Avoid any operational mode that might be prejudicial to safety.

A.6 Warning of special dangers

A.6.2 Gas, dust, steam, smoke

A.6.3 Pneumatic equipment

1 Pad trough 9 Fabric

B.5 Place and position of installation

C.5 Lifting gear

C.7 Transport at the site

D Assembly and Disassembly

See chapter A: Safety Instructions.

D.3 Preparation for installation

See chapter A: Safety Instructions.

1 Pad trough 9 Fabric

E.3 Checking correct installation

E.5 Functional test

E.6 First start-up

Fill the container with material, but only partly.

E.7 Start-up after short standstill

There are no special points to be observed.

E.8 Start-up after longer standstill

E.9 Normal operation

There are no special points to be observed.

E.10 Emergency operation

There are no special points to be observed.

E.11 Normal shut-down

There are no special points to be observed. Shut-down is controlled by a program.

E.12 Emergency Off

There are no special points to be observed.

E.13 Malfunctions and how to remove them

See chapter A: Safety Instructions.

1 Pad trough 9 Fabric

Replacing the fabric (9)

screw spanner SW13