INSTALLATION & COMMISSIONING

MANUAL FOR

BOILER PULSE JET BAG FILTER

(PJBF)

Boiler Bag filter in operation

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 INDEX

Sl. Description Page No

No.
1 Introduction to Manual
2 Guidelines on health and safety measures
3 Safety Risk Assessment for Bag filter installation activities
4 Facilities for Thermax site engineers
5 Principle of Bag filter operation & It’s nomenclature
6 G.A drawing for Boiler Bag filter
7 Basic technical terms used in Bag filter
8 General description on different components in Bag filter
9 Guidelines on storage facilities & Storage instructions
10 Guidelines on receiving & stacking materials at site
11 Guidelines on Bag filter pre-installation activities
12 Bag filter installation sequence and standard Bar Chart
13 Guidelines on mechanical installation component wise and
field quality assurance plan (FQAP)
14 Electrical/ Instruments installation
15 P&I diagram for Bag filter
16 Standard Control logic
17 Checklist for Pre-commissioning
18 Florescent powder leak detection procedure.
19 Pre-coating / seeding of bag prior to commissioning.
20 Commissioning Procedure and standard process parameters
21 Commissioning format
22 Trouble shooting in Bag filter operation
23 Bag filter maintenance guidelines
24 Reporting format on Bag failure
25 Stack Sampling procedure.

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 1. Introduction to Manual

This guideline manual covers the main features of installation and commissioning of
THERMAX make Boiler PJBF. The instructions given in this guideline manual are
intended to explain all the installation and commissioning work in detail. This guideline
manual has been prepared with a view to the following:

1. Assist in understanding the construction features of THERMAX make PJBF.

2. Guide the field staff to understand the working and importance of various parts
and care to be taken while handling the Bag filter parts.

3. Planning the schedule of Bag filter installation.

4. Help in achieving the best performance results of PJBF in it’s long run.

Though, it has been endeavoured to make this manual comprehensive and complete to
offer the best guideline for installation, there may still be questions regarding the finer
aspects of the installation and alignment of PJBF. Our team of qualified and experienced
erection engineers will assist in solving special problems related with PJBF installation
and commissioning.

For any doubts or clarification, feel free to contact us at following address –

M/s THERMAX LIMITED

ENVIRO DIVISION
PMT COMPLEX,
BEHIND PCMC BUILDING,
MUMBAI – PUNE ROAD,
PIMPRI,
PUNE – 411 018
Installation & Commissioning Department.
Phone : +91(20) 66122999,

E-mail ID : schandra@thermaxindia.com

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 2. Guidelines on Health and Safety Measures

During installation activity of the Bag filter, Customer / Erectors must take care of all
health and safety measures, as per the rules and regulations applicable in the local area
where installation and commissioning is to be done. For any failure/s, due to negligence
of safety and health issues, Thermax will not be responsible.

Following minimum health & safety measures are recommended.

1. First aid boxes must be kept at easily accessible places of the work site.

2. At least two trained persons in the first aid treatment must be present while the
work is in progress at erection and / or fabrication / assembly site.

3. Site contractor’s all workmen must be introduced to safety and health program,
before commencing the erection / fabrication / assembly activity.

4. Emergency telephone numbers like plant medical aid, fire station, plant security
gate, nearest hospital must be kept handy by contractor’s all supervisors. Also
these telephone numbers are to be displayed prominently in front of customer’s,
Thermax’s and contractor’s site offices for ready reference to all workmen.

5. All plant equipment / machines like cranes, winch, lifting equipment, welding
machines, gas cutting sets etc, must be operated by only trained and authorised
operators.

6. All personnel working at site must wear the basic PPEs like safety helmets,
safety shoes. The other safety items like safety belts, safety goggles, earplugs,
welding screens, masks and gloves etc, should be used as and when required.

7. Barricades and danger warning signs must be displayed at all locations to

prohibit the entry of unauthorized persons.

8. A considerable portion of the bag filter alignment work is done in confined space.
Hence precautions related to working in confined space must be adhered.

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9. For welding the temporary ladder / steps on casing columns, use only plain mild
steel rods. The tor steel rods should not be used for this purpose, as welding of
tor steel with mild steel is not proper because of different properties of materials.

10. While working at height, the workmen need to tie the safety belt (full body
harness) at one fixed location. For this purpose, always weld a proper lug on the
top area of the item being lifted, at needed places, so that workmen can tie his
safety belt to such lugs when ever he goes on top.

11. All the lifting equipment e.g. crane, winch, other material handling equipment like
chain blocks, hydra, fork lift, silings, wire ropes, D-shackles, rope pulleys
etc. must be tested for their safe work loads. Such test certificates from an
authorised agency must be submitted while bringing the equipment at site. All
safety alarm and controls of material handling equipment should be available in
working condition.

12. Whenever the erection work at height is going on, no man movements are
allowed below such area. Safe working barricades should be provided in such
area.

13. While shifting the material from store yard / assembly point to erection site the
necessary safety precautions to be taken to avoid the fall of material that could
result in serious accident.

14. The main distribution board at all places should be with ELCB (Electric Leakage
Circuit Breaker), of sufficient capacity / rating (30mA). Also TPN (Three Phase
Neutral) facility should be provided, near erection site.

15. Whenever required, use the proper extension board. Always avoid the unsafe
practices of cable joints like cable joints by twisting the cable strands and using
plastic on it etc. Always use proper sockets and plugs for individual equipment.

16. No personnel should put their fingers inside the rotating machines, while machine
is in operation.

17. Before taking trials / operating the rotating machinery, the coupling guards must
be fixed at their positions. If any foreign member / items are fixed on such rotating
machinery during installation & alignment, it should be removed before taking any
trials of rotating machinery.

18. Fire extinguishers should be available (minimum 2 nos.) at site for electrical and
other type of fires.

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 19. Safety postures should be displayed at site. Also tool-box talk should be imparted
regularly at site for all workmen. The proceedings of tool box talk should be
recorded regularly.

REFER THE SAFETY RISK ASSESSMENT SHEETS ENCLOSED SEPARATELY

WITH THIS MANUAL.

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3. Safety Risk Assessment for Bag filter Installation activities

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 4. Facilities for THERMAX Site Engineers

A lockable, well-ventilated office of minimum 10-sq.m area per person should be

provided for Thermax Site engineer.
The office equipment should be provided with following:

a. Desk
b. Chairs
c. Cupboard for documents.
d. Electrical Connection with sufficient illumination
e. Washing facilities.
f. Sanitary facilities
g. Communication facilities (Local / STD telephone)

The above facilities are considered adequate for a single supervisor. If necessary, such
facilities should be made available for additional engineers / supervisors.

Where guest house is to be provided by customer, guest house room should be well
ventilated (where AC facilities not available) with 12 X 12 sq. feet floor size. There should
be regular cleaning of room, provision of drinking water and dhobi facilities. Food
provided to site engineer should be hygienic.

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 5. Principle of Bag filter Operation

The housing of Boiler PJBF may be compartmentalized in case of OFF LINE model to
allow isolation during cleaning. Other wise it could be single chamber. Dust laden
gases from Boiler enter inside perforated duct plenum located in-between LHS
and RHS casing in by suction pressure. The heavier dust particles fall
immediately into the hopper by gravity, while the light dust is distributed and
deposited on the outer wall on the filter bags. When a uniform layer of dust has
been formed on the surface of the filter bags, it is removed by a predetermined
cycle of high pressure compressed air pulses. Cleaning effectiveness is increased
with the use of high efficiency venturi that shape the initial pulse into a mass of
air that travels down each filter bag expanding it and dislodging the dust layer
from its outer surface. The mass of air also draws secondary air behind it adding
the downward air flow. The dust removed falls into the hopper and is discharged
through discharge valve.

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 DIFFERENT MODELS OF THERMAX MANUFACTURED BAG FILTERS

- This is a standard bag filter with hopper entry of dust laden gases
TK, TP SERIES
and top outlet for clean gases.

TKC, TPC, AJC This is a standard bag filter with casing entry of dust laden gases
-
SERIES and top outlet for clean gases.

- This is a custom built bag filter with casing entry employed with
TFC, TS
custom built bag spacing to accommodate varying nature of dust in
SERIES
furnace installations for metallurgical applications.

This is a standard circular on line bag filter with hopper entry or top
TKR SERIES
- entry of dust laden gases & top outlet for clean gases.

This is a standard on line bag filter with casing entry (with a baffle in
TKB SERIES
- front) of dust laden gases and top outlet for clean gases.

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DESCRIPTION OF NOMENCLATURE

Thermax is adopting following procedure for describing pulse jet bag filter units as
follows :

--- No. of tube sheet holes (Actual No. of bags) ---

Length of bags in cm

For Example if the Model No. appeared as TKC -216 (180) -360, this means

TKC is the type of entry. 216 Nos. holes are available in tube sheet. 180 Nos. bags are
required to be installed over tube sheet. 360 cm is the length of bags. In this case 36
Nos. bags are to be dummied.

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6. General Arrangement Drawing for Boiler Bag filter.

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 7. Basic technical terms used in Bag filter.

Abrasion Resistance: Ability of fabric to withstand surface wear.

Abrasion surface: Fabric wears on surface of bags caused by erosion, rubbing,

scuffing.

Air to Cloth Ratio : The ratio between Vol. of flue gas in m3/min and filtration surface
area in m2. Higher the A/C ratio, higher wills the DP across Bag filter.

Perforated Plates: These are the plates located at the sides of inlet duct plenum to
evenly distribute the gases casing so that loading on bags will be uniform.

Bleed through: This is the phenomena where particulate matters pass through fabric
media causing emission in chimney. This happen when proper dust cake has not built up
on inner surface of bags. Proper pre-coating / bag seeding helps to reduce bled through.

Choking/ Blinding: This is the phenomena where porosity on fabric blocked by dust,
moisture, fumes and particulate matters does not fall during cleaning mechanism. This
causes reduction of flow and increase of D.P.

Dust Bridging: When dislodged dust from fabric forms a cavity over RAV and does not
fall easily called bridging.

Bursting Strength: It can be defined as force required to rupture a fabric applied at 900
to the fabric plane under specific condition. Normally it expressed as pound/ sq. inch.

Tube Sheet: It is a MS plate where bags are clamped. Below the tube-sheet, gases are
dirty and above the tube-sheet, gases are clean.

Dew Point: Temperature at which flue gas get condensed.

Differential Pressure: It is the static pressure difference between outlet of equipment

and inlet of equipment.

Dust cake: Dust layer above fabric surface. Certain amount of dust cake is essentially
required on bag surface for better filtration efficiency.

Dust Loading: It is the amount of solid particles suspended in flue gas. It is expressed
as gm/ m3

ID Fan : It is a device which creates suction pressure to suck the entire gas volume into
the system and after filtration, it exhaust the same to atmosphere through chimney.

Null Point : In a closed circuit system where FD and ID fan is connected, null point is a
point in duct route where + ve pressure created by FD fan and (–) ve pressure created
by ID fan became neutralised and became ZERO.

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Opacity: Visual density of dust in Chimney expressed in %.

Permeability: It is a measure of fabric porosity or openness expressed in ft3/min/ft2 at

13 mm WC differential pressure.

Poppet valves: These are used to isolate module during cleaning cycle for OFF LINE
model. Typically constructed of a flat wafer plate assembled on the end of shaft of a
pneumatic cylinder which drives the wafer plate (Poppet) into position against a seat or
ring which causes seal. Inlet ICBD (Inlet cum bypass damper) is also poppet type.

Impingement: The physical contact of a dust laden gas flow against a filter media.
Typically referred to the abrasive wear caused by the impact.

Pre-coat: Before taking the Bag filter into system, material (dust) added on the fabric to
establish an initial dust cake on fabric. This is very important activity to generate actual
filter media over bag surface which filters the flue gas. It also helps release of dust in
cake form and hence increases cleaning efficiency.

Re- entrainment: It is the phenomenon where during dislodging dust from bags surface,
it breaks/ fragmented and it returned to the main air stream and once again deposits on
bag surface. This phenomenon caused subsequent rise in DP.

Filter Drag: It can be defined as filter resistance across fabric dust layer. The equation
for filter drag can de given as

Differential Pressure across bag mm WC

Filter drag = ------------------------------------------------------------
Filtration velocity in m3/min/m2

The true filtering surface of a woven filter is not the bag itself but the dust layer deposited
on bag surface. Dust deposits over pores/ opening in the weave plugging the opening
with particles increasing the drag

Magnehelic gauge: This is an instrument used to measure differential pressure across

tube sheet. It has a dial indicator with a niddle which shows the value.

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 8. General Description on different components.

Supporting Structure: It consists of single ISMC or double ISMC channel box which
forms column. Bottom part grouted over foundation. Adjacent columns are hold together
by bracing. Normally bracings are welded with columns.

Hopper : Bottom part of bag filter called as hopper. During cleaning cycle, dust particles
falls into hopper and then get discharged through Rotary Air Lock Valve.

RAV : Rotary air lock valve located at the bottom of hopper. A 200 NB RAV has
volumetric discharge capacity of 4m3/hr at 50% filling capacity at 20 RPM.

Casing: This is box shaped. It houses filter bags, cages, tube sheet, and Pulse pipes.

Filter Bags & Cages : Filter bags separates the dust from flue gas. Bags hanged from
tube sheet and the top part gets clamped with tube sheet. Cages are inserted into the
bags and it gives bags a proper cylindrical shape. There are few varities of bag material
used for Boiler Bag filter application. 1) Ryton (PPS) 2) Glass bags, 3) Vetrocore 4) P84
fabric 5) Nomex. For details kindly refer General Arrangement Drg.

Sequence Controller : The sequential operation of the micro controller based Timer,
controls the solenoid valve ‘ON’ Time and ‘OFF’ Time, which in turn allows the
compressed air to be injected into the filter bags for cleaning purpose. There is a Time
base (clock) which generates the clock pulses for the operation of the timer. These clock
pluses are shaped and processed through micro controller based circuitry to get required
pulse for triac firing circuit. These triacs in turn control the solenoid valves. The clock
pulses are adjustable to get the required ‘ON’ and ‘OFF’ duration.

TYP. SEQUENCE CONTROLLER

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Cleaning mechanism : It consists of Pneumatic air line, Air header, Pulse Sol valves,
Rubber hose, pulse pipe and sequence controller. Air header stores compressed air @ 6
kg/cm2 (for non woven bags) and @ 3.5 kg/cm2 (for woven bags). Pulse valve purged
compressed air in sequence and the air travel into the bags through pulse pipe.

Ventury : Ventury is a component fitted over the bag opening. This helps increasing the
velocity of purged air so that the pressure waves can travel up to bottom of filter bags.
Hence this increases efficiency of bag cleaning.

ICBD (Inlet cum Bypass Damper) : It is located at the inlet of Bag filter. It allows the
flue gas inside bag filter when all process parameters are within designed limits. During
process upset, it stopped flue gas entry at bag filter and opens the By-pass line.
Installation and functioning of this damper is very important for the safety of bags.

Instrumentation : These are discussed separately on page No.

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 9. Guidelines on Storage Facilities & Storage Instructions

The typical storage area required for storing the PJBF material should be:
• Approx. 500 sq. meter of fenced lockable open yard.
• Approx. 100 sq. meter of covered lockable area in sheds.

• The storage area should be located near to the unit to be installed.

• The storage area should be practicable for driving with mobile cranes and other
transport vehicles.
• The above requirements are worked out considering sequential supply and
erection of items. If the erection activities are delayed, bigger space (both open &
shed) would be required.

Storage Instruction
In mutual interest for a trouble free installation, handling of the material should be as
below:
• Large steel structural parts, delivered unpacked, for example casing, hopper,
internal duct plates, damper parts etc. have to be properly stacked on a flat
surface (not lying on the floor) with adequate packing to avoid sagging.

• The special long and straight parts like fabricated hollow casing column, tube
sheets, hopper frames are also to be kept on a flat surface with sufficient care
and adequate packing. It is essential not to have too many parts above each
other, because the parts below can be damaged.

• All accessories delivered in crates, especially electrical parts, such as pneumatic

cylinders, geared motors, controllers, electrical panels, heaters, thermostats,
transmitters etc., must be stored in a covered dry room.

• Material delivered in boxes must be stored in a dry place, as it may contain the
electrical & instrument components.

• During handling of the parts, observe the various markings and the lift markers.

• Filter bags delivered in boxes. These particular boxes have to be handled very
carefully and they can only be lifted at the marked places. Store cartoon boxes
under covered shed only. There should not be more than 3 cartoon boxes to
stack one above another. Follow storage/ handling instruction printed on box.

• Do not store any material in sloping position (oil content).

• If THERMAX erection engineer is already at site at the time of arrival of material,

his suggestions shall be taken before unloading the parts, since he will know

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 which parts are required first and where and accordingly he can advice for
unloading of the material.

• If the material arrives before THERMAX erection engineer, suitable people are to
be deputed to supervise the unloading. Under any circumstances the
transporters should not unload the material without supervision. From
experience, THERMAX know that rough handling slows down the erection work
by necessitating much adjustment and repair work at later stages.

ATTENTION: Non observance of the above instructions will absolve

THERMAX from every liability concerning erection problems.

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 10 . Guidelines on Receiving & Stacking of Material

The instructions given below are to be used as guidelines for receiving & storing the
materials at site.

Receiving the Material:

a. Prior to reaching Bag filter materials at site, the storage area is to be identified
& barricaded with a gate under lock & key. The area should be levelled without
any potholes & ridges. In the storage area, the trailer / truck should have easy
approach. Also sufficient place for movement of crane / Hydra should be
available during unloading & shifting the material to erection site.
b. As soon as the material (loose / package / boxes) arrived at site, it should be
checked for any transit damages. In case of major transit damage to the
material, all the details pertaining to the consignment is to be noted along with
the identity of the driver. The nature of the damage to be recorded along with
the acknowledgement from the transport driver / representative. If possible, the
photographs shall be taken in all possible angles. The scope of transit
Insurance is to be checked and accordingly intimation to M/s THERMAX LTD.
(ENVIRO DIVISION) – Pune, should be given.
In the damage report, the details like L.R. No., Truck No., Transporters Name,
Delivery Challan and Description of the materials damaged must be mentioned.
While unloading, the material should be reconciled with Thermax’s and / or its
vendor’s respective delivery challan / packing slip / loading report.
c. While unloading, all loose materials should be counted and ensured while
unloading.
Any shortages or damages of the material should be recorded on the L.R. and
should be acknowledged by the truck driver.
All packed cases should be opened and checked within 7 days of receipt of
material at site and any discrepancy should be informed to the concerned
project engineer at Pune immediately. All such packed cases, which were
opened for material inspection, should be re-packed properly to avoid any theft /
loss of the material.
d. Record Keeping: All delivery challans / packing slips / loading reports should be
filed serially.
Once the received materials are unloaded and verified with packing slips /
delivery challans / loading reports, these materials should be checked with
respect to respective BOM (Bill of Material). Then remarks shall be made on
BOM i.e. on the right hand side of BOM showing the D.C. no. and no. of pieces
received.

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Stacking of Material :

Normally in a project site, material will be stacked for a long time. If they are not
properly stacked, in course of time they may get damaged. Hence, all the
material should be stacked properly. Before opening the site, the site engineer
should request the customer to allot area exclusively for our equipments. Then
demarcate the area for stacking different category of material.

1. Structural Material:
This can be stacked in open preferably over wooden sleepers to keep it above
ground so as to prevent rusting. It is advisable to keep all the structural material
in one place. No covering is required.

2. CASING AND HOPPER :

This also should be stacked in open over sleepers to prevent rusting. Keep them
stacked at one place and not trapped one over the other. Keep the panels stacked
one over the other but not more than 6 panels. Otherwise they may topple. Sub
assembly of panel should be stacked together.

3. STAIRCASES AND PLATFORM :

These also can be kept together. However, as large number of small loose
members is involved, it is better to stack them together systematically. All loose
members should be properly stacked together. All gratings should be stacked
one over the other size wise. Hand rails are prone to pilferage and hence should
be kept safely.

4. BAGS :
Bags are normally despatched to site wrapped in polythene bags and packed in
card board boxes in bundles of 3 or 4. These cartoons should be kept under
covered shed free from insects, rats, wet surface. Maximum 3 cartoons could be
stacked one above another. More than 3 cartoons can cause deformation of
bottom cartoon boxes which may cause unnecessary pressure on bag. Under any
circumstances it should not be kept outside under open sky. Tarpaulin or plastic
covers may not be suitable enough to protect them from rain water,

CAUTION :

DO NOT REMOVE THE BAGS FROM THE POLYTHENE COVERS AS THEY MAY
GET DAMAGED IN THE PROCESS. THE BAGS ARE TO BE REMOVED FROM THE
POLYTHENE COVERS ONLY AT THE TIME OF FITMENT. (JUST BEFORE
COMMISSIONING.)
“PLEASE NOTE THAT BAGS ARE THE MOST WEAK / DELICATE PART OF A BAG
HOUSE. HENCE, IT SHOULD BE HANDLED AND STORED WITH UTMOST CARE.”
ANY CARELESSNESS IN HANDLING OF BAGS WILL ULTIMATELY AFFECT THE
PERFORMANCE OF THE BAG HOUSE.

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Wrong procedure of bag storage

Correct procedure of Bag storage

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5. BAG FIXING ARRANGEMENT, PNEUMATIC CYLINDERS :
Bag fixing accessories like washer, nuts, venturies, cages, pneumatic cylinders
should be kept in covered storage as they are all delicate items prone to damages
and pilferage. Poppet dampers and damper shafts should be store over wooden
sleepers. Then they should be covered by tarpaulin to prevent rusting and
corrosion.

6. EXPANSION JOINTS :
Non-metallic expansion joints should be stored and covered properly as it consists
of glass cloth which can be damaged by sharp edges and by mishandling.
Metallic expansion joints should be kept on sleepers and one over the other not
exceeding 2 Nos. No other material should be stored over expansion joints as
this will damage the expansion joints.

7. RAV, SCREW CONVEYOR :

Screw Conveyors can be stored in the open over wooden sleeper. They should
be covered by tarpaulin.
There are two types of RAV’s. One comes from Pune with the geared motor
fixed. This should be kept inside a covered area. The other one is RAV along with
gear box and Motor to be assembled at site. The gear box and motor can be kept
in the stores while the RAV can be kept out side on wooden sleepers and covered
with tarpaulin.
However we recommend keeping RAV and geared units under covered shed if
not going to get installed in 3-4 months.

8. INSULATION MATERIAL :

This consists of mineral wool / LRB.

a) Aluminium sheets.
b) Holding fixtures, screw, asbestos mill board etc.

All these should be kept under covered storage.

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