Filtros Cartuchos

FLUYTEC S.A.-6000172\QUEBRADA BLANCA 2 MPD 102.
360-00590\PO-1900082\SD-09055
Teck No.: TSC-400-MAN-0575-G-09055 Rev:00
Prepared by: Approved by:

Dpto. Calidad Engineering &
Quality Director
Ángel Blázquez MARTA OTEGUI
LANGUAGE: ENGLISH REVISION: 01 DATE: 28-02-2019

Operation and maintenance manual
FTP HF
O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 2
INDEX
1 Description .............................................................................................................................................4
2 Installation ..............................................................................................................................................5
2.1 Unpacking the equipment ................................................................................................................5
2.2 Handling and location .....................................................................................................................6
2.3 Connections ...................................................................................................................................9
3 Commissioning ....................................................................................................................................10
3.1 Critical points and functioning .......................................................................................................10
3.1.1 Hammer blow ..........................................................................................................................10
3.1.2 Excess operating pressure .....................................................................................................10
3.1.3 Excess operating temperature ................................................................................................10
3.2 Prior cleaning of the filter ...............................................................................................................11
3.3 Clarifying of wound cartridges .......................................................................................................11
3.3.1 Open the cover .......................................................................................................................11
3.3.2 Insert cartridges ......................................................................................................................11
3.3.3 Close the cover .......................................................................................................................11
3. 4 Filling and venting ........................................................................................................................11
4 Maintenance .......................................................................................................................................11
4.1 Filter body ......................................................................................................................................11
4.2 Cartridges (filtering element) .........................................................................................................12
4.3 Preparation for changing cartridges and internal parts .................................................................13
4.4 Replacement of internal parts .......................................................................................................13
4.4.1 Open the cover .......................................................................................................................13
4.4.2 Extract cartridges ....................................................................................................................15
4.4.3 Insert cartridges .....................................................................................................................16
4.4.4 Close the cover ......................................................................................................................16
4.5 Instructions for tightening the bolts on the main flange .................................................................18
5 Do and don´t table ..............................................................................................................................19
6 Troubleshooting ...................................................................................................................................20
The information herein is confidential and the property of Fluytec, SA and must be treated as such.
It must not be disclosed in any way to third parties without the written consent of Fluytec.
FTP HF
This manual contains the instructions for the installation, use and maintenance of cartridge
filters. To obtain the performance described by the manufacturer in the equipment data sheets, all the
instructions in this manual must be complied with and followed to work with safe and long-lasting
equipment.
Our commitment to the environment
Our interest in the total quality and maximum satisfaction of our customers, leads us
to take into account certain ecological aspects when designing our products, in a
market where the commitment to the environment is increasing.
For this reason, our environmental management system is based on the UNE-EN-ISO 14001:2015
standard, avoiding emissions and discharges, minimising wastes and facilitating recycling.
The management system for the search of Total Quality through efficiency and continuous
improvement is based on the UNE-EN-ISO 9001: 2015 standard, this being the way to achieve it.
Our goal is to give the customer the satisfaction of having a service / product that complies with its
legal requirements and applicable regulations, within the agreed deadline and at the lowest possible
cost.
Both used filter cartridges and seals that have already been used and must be disposed of must be
placed in an inert waste container.
Equipment naming description
Example: 70 FTP – 4 / 40” PN10 BE HTAL

Where,
• 70. Number of cartridges or filtering elements in the filter.

• FTP. – Filtro poliéster.
• 4. Length of cartridges in multiples of 250 mm.
• / 40”. Extension if the cartridges are in inches, blank if in millimetres.
• PN10. Filter design pressure. 10 bar is common to all models.
• BE. Added at the end of the filter has a built-in lifting arm, otherwise blank.
• HTAL. Added at the end of the name and depending on the position of the equipment,
HTAL = horizontal, VTAL = vertical
FTP HF
1 Description
This product is a filter in the FTP family, designed and made to filter fluids with solid particles
greater than a given filtration degree, using mechanical filtering.
HTAL
VTAL
The liquid enters the equipment through the inlet flange to the unfiltered water chamber and then
passes through the filter cartridges where the solid particles are retained. The filtered product passes
through the cartridge core to the filtered liquid chamber and exits through the outlet flange.
Physically, the filters consist of three elements, as shown in the following diagram.
Upper cap
False bottom
plate
Filter Filter packet
Cartridges
Lower body
FTP HF
Note: to identify the materials and other technical details, see the client’s drawing.
2 Installation
LOCATION COMMISSIONING MAINTENANCE
•Critical points and •Stop the

•Unpack and equipment.
prepare the filter. functioning.
•Cleaning of the filters. •Isolate the

•Install the filter in equipment.
its final location.
•Install the internal
elements and cadtriges •Extract the
•Connections. internal parts.
in the filter.
•Replace the
internal parts.
•Start-up.
Note: the filters are delivered suitably packed and in suitable packaging to facilitate their
unloading and movement.
2.1 Unpacking the equipment
The transport, handling, removal from packaging, erection and later assembly of the equipment
must be carried out with GREAT CARE to avoid any type of damage.
Fluytec accepts no liability for the incorrect handling of the equipment.
Once the equipment is loaded for transport and until its final location, its stability in the chosen
position must be checked to prevent any unexpected movement or change of position.
The packages containing the goods must be OPENED with EXTREME CARE.
All the packages must be kept away from any exposure to harmful environmental conditions and
must not be exposed without protection to any external situation that is potentially dangerous to the
goods. The goods must be stored in a dry place away from any bad weather such as rain, wind, snow,
etc. protected from sunlight and insulated from the damp on the floor.
FTP HF
The equipment must also be kept away from any source of heat, flame, etc. Welding work to the
equipment itself or near to it is forbidden.
Take care when removing the plastic from the cartridges to avoid leaving the cartridges on the
floor (leave them on a clean surface until their installation) since they could absorb dirt from the
location.
2.2 Handling and location
ALL LOADS MUST BE HANDLED WITH EXTREME CARE, due to the volume and weight of the
equipment. They must be handled with a gantry crane or other equivalent mechanical device, always
taking the recommended safety measures for persons and equipment.
Careless handling of the goods involves a serious risk for persons and installations. Do not
handle the goods without being certain that:
 The loads will be handled with a safe lifting system that can withstand the forces generated
with a suitable a safety margin.
 The materials to be moved are anchored in a balanced way to prevent swinging or risks of
hitting persons or thing.
The filters have been provided with supports to anchor them to the ground by means of anchor
bolts. Depending on the model
After the equipment is in its final location and before commissioning, it is good technical practice
to make a final general inspection of it to check its proper condition before operation.
IMPORTANT: The lugs must not be used to move the equipment full of liquid since they are
not designed for this weight.
FTP HF
FTP HF
Note: it is recommended as a safety measure that during the transfer of suspended loads
there is no operator below them, in this way possible accidents will be avoided.
FTP HF
2.3 Connections
- Inlet: may be on the lower or upper body of the equipment – see drawings. Its function is to
feed the equipment with unfiltered water.
- Outlet: may be on the lower or upper body of the equipment – see drawings. Its function is
to extract the product water from the equipment.
- Drainage: on the bottom of the equipment. Its function is to drain the equipment
completely.
- Vent: on the top of the equipment. Its function is to allow air to exit and enter the
equipment.
- Safety valve: on the top of the equipment (at the client’s request, this connection is the
same as that of the vent). Its function is to relieve over-pressure in the equipment.
Note: For the flanged connection of the equipment, we strong recommend the use of Kroll &
Ziller type gaskets and the use of a torque wrench to control the tightening torque to be
applied. The design of the Kroll & Ziller type gasket is a combination of flat and o-ring gasket
that reach a high reduction in the torque that must be applied in the bolts of the flange
(Recommended tightening torque: 25 - 40 Nm. tighten first the four(4) screws making a cross). It is
important to remember that an excessive (due to the non-use of Kroll & Ziller type gasket) or
uncontrolled tightening torque in the bolts (due to the non-use of a torque wrench) can result in a
superficial cracking in the internal radius of the connection flanges which are made of glass fiber
reinforced polyester. This cracking is limited to surface paint, but should try to avoid. In addition, with
these recommendations, we will facilitate the operations of installation and maintenance of pipelines,
and optimizing the times during the Plant shutdowns.
Note: it is recommended that the installation does not transmit forces to the connections; if
these exist, they must be reported to the design department for their calculation.
Note: Extraordinary circumstances (operating conditions outside the design, incorrect

maintenance operations…), can lead to the appearance of solids downstream of the cartridge
filters. In order to avoid any damage to the downstream equipment, the installation of a coarse
filter is recommended.
FTP HF
3 Commissioning
3.1 Critical points and functioning
3.1.1 Hammer blow
A hammer blow is an over-pressure in the installation due to the immediate closure of a valve,
which generates a violent and instantaneous thrust of the fluid still in movement. This effect can break
pipes or components in the equipment.
To prevent this, it is necessary to ensure that the inlet/outlet flow in the filter varies slowly. It is
recommended that slow opening and closing valves and/or static starters or frequency shifters be used
in the feed pumps.
If manual valves are used, the operators must take special care when operating them, especially
with butterfly valves or lever-operated ball valves since the flow variation takes place rapidly with a
small opening percentage.
3.1.2 Excess operating pressure
Excess pressure (above the design value) can break or permanently deform the equipment. It is
necessary to install safety valves or rupture discs rated at the equipment’s nominal pressure to avoid
this. In addition, as further protection, it is recommended that pressure switches or pressure alarms be
installed that stop the operation of the system if the maximum forecast operating pressure is exceeded.
According to the design code, it is obligatory to install a device that protects the equipment from
over-pressure, such as a safety valve or rupture disc which must be rated at the equipment’s design
pressure.
3.1.3 Excess operating temperature
Excess temperature degrades the mechanical properties of the plastic materials.
Do not exceed the temperature for which the fluid was designed.
IMPORTANT: The typical design parameters of the equipment are shown in the properties
plate carried on all equipment. Do not exceed any of them.
FTP HF
3.2 Prior cleaning of the filter
The filter must be clarified to clean it of dirt accumulated during transport. The resulting water
flow may contain high solids content and must be sent to the drain. Never feed a sensitive system (e.g.,
osmosis membranes) with the effluent generated during this phase. This clarifying must be carried out
for some minutes until no dirt is seen in the outlet to the drain.
3.3 Clarifying of wound cartridges
If the cartridges are wound, they should be clarified for some minutes before being put into
operation. In this case, install the internals.
3.3.1 Open the cover
To install the equipment and fill with cartridges, open the cover. See maintenance sections 4.3
and 4.4.1.
3.3.2 Insert cartridges
Follow the steps in maintenance section 4.4.3 to insert the cartridges.
3.3.3 Close the cover
Before the rinse close the cover See maintenance sections 4.4.4 and 4.5.
3. 4 Filling and venting
Once the filter is completely full of water, start the installation in nominal operating conditions,
completely purging (with the vent valve on top of the equipment) the air in the filter. If a vacuum occurs
in the filter, it is essential to install an accessory that breaks the vacuum – e.g., double effect vents –
that also act as an automatic air purge.
We have to check for leaks and that the equipment functions correctly.
4 Maintenance
4.1 Filter body
These filter casings require no special or regular maintenance. However, we recommend that
each time the cartridge is changed, a visual inspection be made of the recipient to check that all the
parts are in perfect condition.
It is possible that corrosion may appear in the closure bolts over time, or even on the legs if they
have received impacts that have lifted the surface treatment. To prevent corrosion from appearing on
the bolts, we recommend that anti-corrosion grease or oil be used. For the legs, if any signs of
corrosion are seen, the affected area should be sandpapered and a C-5M treatment applied locally.
FTP HF
4.2 Cartridges (filtering element)
When designing the installation, it is important to remember that a minimum free space is
necessary from the main flange for replacing the cartridges. This distance is equal to the length of the
cartridges plus a safety distance for handling the filtering element.
This distance may vary (in vertical equipment) depending on the lifting system of the closing lid. If it is
with lifting arm that carries the equipment (optional) or with a mechanism of the customer's installation.
It is difficult to predict the service life of the filtering elements given that this varies according to
the analytical parameters of the unfiltered water entering the equipment.
The parameter that warns that the cartridges must be changed due to clogging is the differential
pressure, a value show in the cartridge’s data sheet. The maximum differential pressure allowed in the
equipment is 2 bar. For Fluytec cartridges, the recommended replacement value for the cartridges is
1.2 bar.
For cartridge replacement instructions, see section 4.4, “Replacement of internal parts.”
FTP HF
Note: as a safety measure during the movement of hanging loads, it is recommended that
nobody remains under them, to prevent accidents.
4.3 Preparation for changing cartridges and internal parts
Follow these instructions for the proper replacement of internal parts (consumables and long-life
components).
• Firstly: isolate the recipient by closing the inlet and outlet valves. To prevent accidents, it is
recommended that the feed pump be stopped or, alternatively, ensure that the valves do
not open during the operation – e.g., using valve lockouts.
• Secondly: open the drainage and vent valves to empty the equipment.
• Thirdly: choose a suitable tool according to the size of the nuts. An adjustable spanner can
be used but it should be of the torque wrench type. A pneumatic gun is recommended.
Special care must be taken during all the processes to avoid losing small parts that are
temporarily out of their normal working position, such as rings, nuts, gaskets and similar parts.
4.4 Replacement of internal parts
4.4.1 Open the cover
Step 1: stop the installation to proceed to isolate the equipment. We release the bolts of the
main flange of the filter body and the bolts of the inlet flanges, air purge and safety valve.
We use the tool of the dimension corresponding to the size of the hardware and once removed
remove the lid of the equipment.
(Horizontal example images)
Special care must be taken during all processes in order to avoid losses of small elements that are
temporarily out of their normal working position, pieces such as rings, nuts, gaskets or similar
elements. We will operate the opening of the equipment depending on the model (horizontal or
vertical).
FTP HF
Take into account the different processes that must be followed to lift the lid since, being horizontal or
vertical, this process could vary.
Step 2: remove the lid from the equipment. Separate the lid by moving it sideways along the
longitudinal line on the recipient, using the articulated arm built into the equipment and guiding it with
the hands. Depending on the model, the operation of the arm will be different, in horizontal it would be
a support arm and in vertical a lifting arm in case it is brought.
(Vertical illustration images)
(Horizontal illustration images)
Step 3: For both models follow the following instructions, applying them depending on the
position (Vertical - Horizontal). Remove the nuts from the clamping plate of the stop plate taking special
care because they are objects that due to their size can be lost.
FTP HF
Step 4: remove the fixing plate, the function of which is to press the assembly, recipient +
cartridge.
4.4.2 Extract cartridges
Step 5: remove each of the high-flow clogged cartridges by extracting them horizontally or
vertically taking into account the model. The basket will remain on the computer.
Remember that to remove the cartridges from the equipment, the area of the main flange must
be clear for at least the length of the cartridge.
Step 6: it is not necessary to remove the baskets during the process.
FTP HF
4.4.3 Insert cartridges
Step 7: disassemble the high flow cartridges from their protective plastic packaging. Place them
inside the PP baskets by pushing in the same position as the previous ones either (horizontally or
vertically) which were clogged up to the top of the false bottom plate. Check that all the cartridges are
installed and the fixing plate and basket have no empty holes.
4.4.4 Close the cover
Step 8: fit the cartridges fixing plate in its position, guiding it through the holes via the lugs fixed
to the false bottom plate.
Step 9: fix the system, threading and adjusting the internal closure nuts on the fixing plate.
FTP HF
Step 10: refit the closure lid, handling with the lifting arm to its original position, moving it
sideways and guiding it with the hands to the front line of the equipment horizontally and vertically
proceed depending on whether it bears lift arm or does not carry it. Before closing, check the two O-
rings, ensuring that both are in their positions to prevent movements.
There is a reference line along the main bridles. Take that line into account to ensure that the set
is going to be assembled in the same position it has in origin.
Step 11: with the filter closed, open its inlet, outlet and purge valves.
When the pressure in the filter has stabilised, read the inlet and outlet pressure gauges – the
difference between them is the load loss of the clean filter.
Keep the filter in operation until the pressure difference between the pressure gauges and the
increased pressure over the clean filter reaches that recommended for changing the cartridges.
The valves should be opened/closed slowly (since these are normally manual ball valves,
operations could be almost instantaneous) to avoid hammer blows.
FTP HF
4.5 Instructions for tightening the bolts on the main flange
Once the upper cap is in place, the tightening torque for the bolts on the exterior closure flange of
the body must be that of the DIN standard according to the bolts’ size.
The approximate tightening torque for equipment with O-rings is 150 – 200 Nm and some 250 –
300 Nm if the gaskets are flat. We recommend fitting the bolts and tightening them all slightly before
the definitive tightening with a torque wrench. Our experience shows that in a high percentage of filters
installed, the tightening torque applied is excessive.
Excessively low tightening involves only a slight loss of liquid and is easily solved by
depressurising the filter and re-tightening.
Install the complete assembly of bolts, washers and nuts in each hole in the main lid of the casing
flanges.
Once installed, lightly adjust the four bolts near the main axis,
following the sequence in the drawing.
Then tighten the rest of the bolts clockwise.
Then apply a greater torque to all the bolts with a torque

wrench set to 70Nm and following the same sequence and
instructions in points 2 and 3 above – first the four bolts near the axis
and then the rest.
After this operation, increase the maximum torque value to

150Nm. Apply this to all the bolts, but this time starting with the first
bolt, then the next, to the last one.
Finally, make another round for all the bolts with a torque of
200 Nm.
FTP HF
5 Do and don´t table
DO DON’T
Do not roll the filter.

Check the condition of the packaging
and compliance with the instructions
Transport and Do not drag the filter.
store
“General handling, transport, storage
Do not transport the equipment when
and preservation” procedure.
full.
Do not install in a sloping or unstable

Installation Install in a totally flat and stable place.
place.
Do not install the internal parts

Check the proper condition of the without checking them and starting the
internal parts. commissioning of the equipment.
Commissioning
Carry out a washing before putting Do not commission without checking
into operation. the start-up conditions (see section 3.2
and 3.3).
Do not exceed the maximum working

pressure.
Check the filter’s pressure regularly.
Do not exceed the maximum working
Change the cartridges when the
Functioning temperature.
differential pressure is greater than that
given in the data sheet - 1.2 bar (for
Do not use highly concentrated
Fluytec cartridges).
chemical products that may damage
the filter’s components.
FTP HF
6 Troubleshooting
Problem Possible cause Solution
Avoid opening and closing valves quickly. Install

Hammer blow static starters or frequency shifters on the feed
pumps.
Filter breakage Excessive differential Install and check a differential pressure gauge
pressure (check the operating conditions).
Excessive relative Install safety elements: safety valve/rupture disc,

pressure pressure switch, pressure alarms, etc.
Apply the indicated tightening torque (see section

Insufficient closure
4.4.4).
Water leaks
Gasket damaged Replace the gasket.
Drop in filtered water Check the differential pressure; replace the

Cartridge clogged
flow cartridges at the indicated pressure.
Solids passing Stop and open the filter as per the instructions.
Filtering elements
through the filtering Visual check of the location of the cartridges and
incorrectly installed
elements all internal parts.
Note: if the above problems cannot be solved, contact the Fluytec technical department.
E-mail: info@fluytec.com
Telephone: (+34) 94 467 61 50

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FLUYTEC S.A.-6000172\QUEBRADA BLANCA 2 MPD 102.

Teck No.: TSC-400-MAN-0575-G-09055 Rev:00

Prepared by: Approved by:

LANGUAGE: ENGLISH REVISION: 01 DATE: 28-02-2019

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 2

5 Do and don´t table ..............................................................................................................................19

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 3

Our commitment to the environment

Equipment naming description

Example: 70 FTP – 4 / 40” PN10 BE HTAL

• 70. Number of cartridges or filtering elements in the filter.

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 4

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 5

LOCATION COMMISSIONING MAINTENANCE

•Critical points and •Stop the

•Cleaning of the filters. •Isolate the

2.1 Unpacking the equipment

Fluytec accepts no liability for the incorrect handling of the equipment.

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 6

2.2 Handling and location

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 7

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 8

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 9

Note: Extraordinary circumstances (operating conditions outside the design, incorrect

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 10

3.1.2 Excess operating pressure

3.1.3 Excess operating temperature

Excess temperature degrades the mechanical properties of the plastic materials.

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 11

3.2 Prior cleaning of the filter

3.3 Clarifying of wound cartridges

3.3.1 Open the cover

3.3.2 Insert cartridges

Follow the steps in maintenance section 4.4.3 to insert the cartridges.

3.3.3 Close the cover

3. 4 Filling and venting

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 12

4.2 Cartridges (filtering element)

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 13

4.3 Preparation for changing cartridges and internal parts

4.4 Replacement of internal parts

4.4.1 Open the cover

(Horizontal example images)

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 14

(Vertical illustration images)

(Horizontal illustration images)

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 15

4.4.2 Extract cartridges

Step 6: it is not necessary to remove the baskets during the process.

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 16

4.4.3 Insert cartridges

4.4.4 Close the cover

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 17

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 18

4.5 Instructions for tightening the bolts on the main flange

Then tighten the rest of the bolts clockwise.

Then apply a greater torque to all the bolts with a torque

After this operation, increase the maximum torque value to

O&M Manual FTP HTAL - VTAL Revision: 01 Date: 28-02-2019 Page 19

5 Do and don´t table

Do not roll the filter.

Do not install in a sloping or unstable

Do not install the internal parts