Work Instruction 1 (13)

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Checked and verified by Maintenance Manager, Approved by Station Manager, Date

Date

Jan Woch _____ / _____ Sauli Lehtinen _____ /

/ 2015 _____ / 2015
Effective date Distribution
6 April 2014 HC: Respective Managers, Respective Area
SC : Docushare
Keywords Replaces
BMS, (please fulfilled)
XXXX-YY-WIxx ROTARY VACUUM DRUM CLOTH REPLACEMENT

1 PURPOSED
This Work Instruction will be as the guideline for Maintenance personnel to perform
Rotary Vacuum Drum cloth replacement.

2 SCOPE
This Work Instruction will be applied for Rotary Vacuum Drum cloth replacement at
Tanjung Jati B Power Plant. The works not mentioned in this instruction will be
performed in accordance with drawings and appropriate specifications then will be
considered to be added in this Work Instrcution later. This Work Instruction is refer to
O&M manual from OEM.

3 RESPONSIBILITY
 The Maintenance Manager has responsibility for updating this instruction.
 The Maintenance Engineer has responsibility to control maintenance works made
according to the instruction and co-ordinate with other teams during planning and
report activities to the Maintenance Manager.
 The Maintenance Engineer and Supervisor have responsibility to plan, supervise and
report of maintenance works which are undertaken in accordance with this procedure.
 The Maintenance Technician has responsibility to implement the Works Instruction in
 Work Instruction 2 (13)
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safe manner.

4 DETAIL OF WORKS
4.1 Preparation
1. Work should be carried out by 5 peoples.
2. Prepare all necessary documents (Rotary Drum Filter Maintenance Instructions
Manual Doc. No. CSP0000706-01, Wire Winder FRAME ASSEMBLY Doc. No.
81430C51 and inspection report form prior to start of work).
3. Prepare the necessary parts, tools and equipment before commencing actual work.
4. Confirm that the equipment is isolated and a permit to work is available before
commencing work.
5. Prepare a suitable lay-down area.
6. Remove the auxiliary piping, piping supports and all instruments that may interfere
with the disassemble/reassemble procedures

4.2 Tools and Others

4.2.1 Personal Protective Equipment
1. Hand Gloves
2. Safety Glasses
3. Ear Plug or Ear Muff
4. Full Body Hardness

4.2.2 Consumable Material

1. Silicon Oil
2. WD 40
3. Cotton Rag
4. Molykote
5. Dow Corning 111
6. Abrasives Paper
7. Plastic Blanket
 Work Instruction 3 (13)
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4.2.3 Spare Part

Detail List of spare parts use for Rotary Vacuum Drum cloth replacement available on
attachment 1.

4.2.4 Tools and Special Tools

1. Wire winder set (special tool).
2. Webbing sling length 2 meter end loop capacity 2 Ton, 2 set.
3. Socket set: 14 mm, 19 mm, 24 mm.
4. Spanner set: 14 mm, 19 mm, 24 mm.
5. Hammer, punch, screw driver set, measuring tape.

4.3 Removal feed line piping

1. Please loosen and remove all flange bolts for suction pipe line by spanner 24 mm.
2. Loosen and remove support pipe U-bolt by spanner 19 mm.
3. Remove the suction pipe line carefully and lay on the lay down area.

Removal suction pipe line

4.4 Removal spray wash line piping and cover

1. Please loosen and remove all U-bolts which tight off the cover by spanner 14 mm.
2. Remove the cover carefully and put on the laydown area.
3. Loosen and remove all U-bolts which tight off the spray wash pipe by spanner 19
mm.
4. Close the main isolation valve for spray wash line pipe (ask operator to do so).
5. Remove the spray wash line pipe including on-off valve carefully and put on the
lyadown area.
 Work Instruction 4 (13)
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Removal spray wash cover Removal spray wash pipe line and valve

4.5 Installation wire winder

1. Please set up and put on the position the wire winder (special tools).
2. Tight off the wire winder to the Rotary Vacuum Drum casing by bolts set
provided by the wire winder by spanner 19 mm.
3. Connect the three phase power of the wire winder to the terminal box on the
beam support structure close to the Rotary Vacuum Drum.
4. Please to do run test and put the position of the roller in the beginning of winder.
5. Install also the tri angle roller.

Wire winder setting and run test

4.6 Removal old hastelloy wire

1. Please install old empty drum on the triangle roller to roll up the old hastelloy wire to
be reused.
2. Restart the drum and the wire winder machine in the same time to roll up the old
hastelloy.
 Work Instruction 5 (13)
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3. Roll up the old hastelloy wire on to the empty drum carefully due will be reused again.
The condition of the wire must be still in good condition.

4.7 Removal old cloth

1. After all hastelloy wire is removed, please remove the gland packing on the cloth
groove.
2. Then continue with removal old cloth.

Old cloth removal

4.8 Installation new cloth and hastelloy wire

1. Please install new cloth carefully and cut as necessary.

2. Then continue with gland packing installation to the groove of the drum to strengthen
the cloth tension.
3. Please set up the hastelloy wire before start to roll the drum and the wire winder
machine.
4. After all setting already fix, please start to roll the drum and the wire winder machine
to roll the hastelloy wire to the drum. Please monitor the distance between wire + 1 ¾
to 2 IN.
5. After complete roll the hastelloy wire to the drum, please tight off the edge of the wire
to the wedge tightly and carefully.
 Work Instruction 6 (13)
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New cloth installation

4.9 Restoration Spray Wash Line, Cover and Suction Pipe Line

1. Please remove the wire winder from the Rotary Vacuum Drum system.
2. Then continue with installation spray wash pipe line (including the on-off valve) and
tight off the U-bolts by spanner 19 mm.
3. Continue with Install cover of spray wash line by spanner 14 mm.
4. For the last, please reinstall the suction pipe line by spanner 24 mm.

4.10 Testing and Recording Completion of Work

1. After inform, get permition (from PTW officer) and coordinate with operator to do
testing.
2. Please measure bearing temperature and vibration. Also please inspect visually the
layer thickness of the gypsum cake.
3. While in progress running test, please do nice housekeeping to clean our work place
from exused spare parts, remaining consumable, cotton rag and other rubbish. Also
please check and clean our tools (keep our personal tools is complete) to do next other
works.
4. After performance result is acceptable, please do not forget to closed the PTW and
handed over the pump to operator to operate and follow normal operation.
5. All data should be recorded in the inspection report form (replacement parts record
and finding documentation).
6. Supervisor will keep those inspection reports and upload to Work Order attachment in
Maximo during finishing (including fulfilling actual date started & finished,
Competence Person and engineering comment).
 Work Instruction 7 (13)
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5 REFERENCE
1. Rotary Drum Filter Maintenance Instructions Manual Doc. No. CSP0000706-01
2. Wire Winder FRAME ASSEMBLY Doc. No. 81430C51

6 ATTACHEMENT
1. List of spare parts use for Rotary Vacuum Drum cloth replacement.
2. Rotary Drum Filter Maintenance Instructions Manual Doc. No. CSP0000706-01
3. Wire Winder FRAME ASSEMBLY Doc. No. 81430C51
4. Inspection report form.
 Work Instruction 8 (13)
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1. List of spare parts use for rotary vacuum drum cloth replacement

Line Item Description Quantity

BEARING. - FLANGED, BALL. SCM 4-BOLT FLANGE, SERIES: 21
1 58-01-10-001 2. MFG: DODGE. DRAWNO: 0-BOL-K-BW-010. PARTNO: F4B- 1 EA
SC-207. SIZE: 2-7/16
GASKET - COVER. MFG: EIMCO. PARTNO: 850101A. O/D: 14 I
2 85-48-24-049 1 EA
N. MATL: NEOPRENE
SEAL - BOOT, MFG: EIMCO, DRAWNO: 0-BOL-K-BW-010, PA
3 43-04-70-009 1 EA
RTNO: 81453B-32C, MATL: NEOPRENE
BEARING - FOUR BOLT FLANGE. MFG: DODGE. PARTNO: F4B
4 58-01-10-002 1 EA
SC207, STK# 124217. SIZE: 2-7/16

BEARING. - HANGER. BALL BEARING: 210. MFG: DODGE. DR

5 58-01-99-001 1 EA
AWNO: 0-BOL-K-BW-010. PARTNO: SCHB-SC-200. SIZE: 2 IN

PIN. - ROLL. SPRING/SPRING. MFG: EIMCO. PARTNO: 46750

6 81-74-40-061 1 EA
KL. SIZE: 1/4 X 1-7/8 IN

GASKET. - COVER. MANWAY. MFG: EIMCO. PARTNO: 45005

7 85-48-24-050 1 EA
0A. MATL: NEOPRENE

GRID. - DRAINAGE. FILTER VACUUM DRUM. MFG: EIMCO. SI

8 43-46-19-004 1 SET
ZE: 24 X 24 (13/160). MATL: POLYP BLACK
GEAR - WORM, SINGLE, MFG: EIMCO, DRAWNO: 0-BOL-K-
9 58-72-50-014 1 EA
BW, PARTNO: 202320A, O/D: 75 MM, I/D: 37 MM
SHAFT. - WORM. 75T HSG STELL. MFG: EIMCO. PARTNO: 45
10 58-76-13-053 1 EA
0348A
SPACER. - THRUST. 75T HSG STEEL. MFG: EIMCO. PARTNO: 4
11 85-52-04-057 1 EA
50346A
KEY. - FLAT. MFG: EIMCO. PARTNO: 86475M. SIZE: 1 X 7/8 X
12 43-12-24-152 1 EA
2-1/4 IN. MATL: C1018/1035
KEY. - DRIVE. MFG: EIMCO. DRAWNO: 0-BOL-K-BW-010. PAR
13 81-75-12-132 TNO: 86952BB. LENGTH: 5-5/8 IN. WIDTH: 3/8 IN. THICK: 3/ 1 EA
8 IN
SEAL. - OIL. MFG: CR / SKR. PARTNO: 14247. SIZE: 1/2 X 2.25
14 85-52-04-058 1 EA
4
GEAR - WORM, RH, MFG: EIMCO, DRAWNO: 0-BOL-K-BW-
15 58-72-50-015 1 EA
010, PARTNO: 46760AW
RING. - RETAINING BEARING. DRIVE END. MFG: EIMCO. PAR
16 81-86-12-038 1 EA
TNO: 87374A
LINER. - BEARING. GATKE 11 DE HLF. MFG: EIMCO. PARTNO:
17 58-16-09-056 1 EA
450256
 Work Instruction 9 (13)
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RING. - RETAINING BEARING. NON DRIVE END. MFG: EIMCO.

18 81-86-12-039 1 EA
PARTNO: 87376A. MATL: SS316

LINER. - BEARING. GATKE 11 NON DRIVE HLF. MFG: EIMCO.

19 58-16-09-057 1 EA
PARTNO: 450257

BODY. - VALVE. POLYPG 11 CASTING. MFG: EIMCO. PARTNO

20 77-74-99-003 1 EA
: 250343F
BRIDGE SETTING. - ASSY. MFG: EIMCO. DRAWNO: 0-BOL-K-
21 36-62-15-001 1 SET
BW-010. PARTNO: L82705C52
WEARPLATE. - 12 PORT PPG. MFG: EIMCO. PARTNO: 450356
22 78-59-42-012 1 EA
AA1A
CONNECTOR. - NEOP. MULTIFLEX. MFG: EIMCO. PARTNO: 2
23 59-98-15-005 1 EA
04232H (127442H). I/D: 3-1/2 IN
GAUGE. - PRESSURE. VACUUM. MFG: ASHCROFT. PARTNO:
24 60-38-29-033 45-1279-ASO-2L-30/01MW. SIZE: 4-1/2 IN. RANGE: 30-0 MU 1 EA
. CONN: 1/4 IN LOWER
BUSHING. - LOCK. TAPPERED, 2012, 1-3/4. MFG: DODGE. DR
25 58-70-92-057 1 EA
AWNO: 0-BOL-K-BW-010. PARTNO: 86144AA

26 58-70-92-058 BUSHING. - TAPER LOCK. MFG: MARTIN. SIZE: 2517, 2-1/2 1 EA

BEARING. - BALL. PILLOW BLOCK. MFG: EIMCO. DRAWNO: 0
27 58-12-15-014 -BOL-K-BW-010. PARTNO: 450254F. MATL: POLYPG-EMET- 1 EA
M134
28 43-46-98-024 FILTER - MEDIA, POPR-853F, P/N; A1016A33A, MFG: EIMCO 1 SHEET

BUSHING - BEARING, MFG: EIMCO, DRAWNO: 21139A111, P

29 58-11-29-036 1 EA
ARTNO: 21139A111A

COLLAR - SET, MFG: EIMCO, DRAWNO: 85876, PARTNO: 858

30 22-10-10-005 1 EA
76X, MATL: STEEL

PULLEY - WIRING, MFG: EIMCO, DRAWNO: 851119, PARTNO

31 36-46-02-067 1 EA
: 851119A, SIZE: 2-3/16 IN DIA, MATL: STEEL

PIN - PULLEY, MFG: EIMCO, DRAWNO: 851120, PARTNO: 85

32 81-74-40-062 1 EA
1120A, MATL: STEEL

LOCKNUT - SET, PIN, MFG: EIMCO, DRAWNO: 851175, PART

33 68-80-56-134 1 EA
NO: 851175A
COLLAR - SET, MFG: EIMCO, DRAWNO: 87014, PARTNO: 870
34 22-10-10-006 1 EA
14A
FRAME - MOUNTING, TRACK, MFG: EIMCO, DRAWNO: BHW
35 22-10-10-007 1 EA
2442-164, PARTNO: BHW2442-164-01, MATL: STEEL
 Work Instruction 10 (13)
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KEY - DRIVE, MFG: EIMCO, DRAWNO: 86950, PARTNO: 8695

36 81-75-12-133 1 EA
0M, LENGTH: 1/4 IN, WIDTH: 1-1/2 IN

NIPPLE - GREASE, MFG: EIMCO, DRAWNO: 901218, PARTNO

37 56-15-27-029 1 EA
: 901218A, SIZE: 1/8 IN NPT

COUPLING - ASSY, ELASTOMERIC, MFG: EIMCO, DRAWNO: 8

38 22-10-10-008 1 EA
3079A38, PARTNO: 83079A38A

PIN - COTTER, MFG: EIMCO, PARTNO: F10935, LENGTH: 1/8

39 81-74-40-063 1 EA
IN, WIDTH: 1 IN, MATL: 18-8

PIN - COTTER, MFG: EIMCO, PARTNO: F10931, LENGTH: 3/1

40 81-74-40-064 1 EA
6 IN, WIDTH: 2 IN, MATL: STEEL

PIN - COTTER, MFG: EIMCO, PARTNO: F14325, LENGTH: 3/3

41 81-74-40-065 1 EA
2 IN, WIDTH: 1 IN, MATL: 18 - 8

SCREW - CAP, HEX HEAD, MFG: EIMCO, PARTNO: F10243, SI

42 81-62-50-009 1 EA
ZE: 3/8 IN UNC, LENGTH: 1-3/4 IN, MATL: GR5

SCREW - CAP, HEX HEAD, MFG: EIMCO, PARTNO: F10104, SI

43 81-62-50-010 1 EA
ZE: 5/8 IN UNC, LENGTH: 2 IN, MATL: GR5

SCREW - CAP, HEX HEAD, MFG: EIMCO, PARTNO: F10102, SI

44 81-62-50-011 1 EA
ZE: 5/8 IN UNC, LENGTH: 2-1/2 IN, MATL: GR5

SCREW - CAP, HEX HEAD, MFG: EIMCO, PARTNO: F10246, SI

45 81-62-50-012 1 EA
ZE: 3/8 IN UNC, LENGTH: 1 IN, MATL: GR5

NUT - HEX HEAD, MFG: EIMCO, PARTNO: F10876, SIZE: 3/8 I

46 81-41-51-105 1 EA
N UNC, MATL: GR5

NUT - HEX HEAD, MFG: EIMCO, PARTNO: F10870, SIZE: 1/2 I

47 81-41-51-106 1 EA
N UNC, MATL: GR5

NUT - HEX HEAD, MFG: EIMCO, PARTNO: F10871, SIZE: 5/8 I

48 81-41-51-107 1 EA
N UNC, MATL: GR5

NUT - HEX HEAD, MFG: EIMCO, PARTNO: M011763, SIZE: 1/

49 81-41-51-108 1 EA
2 IN UNC, MATL: 316

50 43-12-24-047 WASHER - FLAT, MFG: EIMCO, PARTNO: F11178 1 EA

WASHER - FLAT, MFG: EIMCO, PARTNO: F11190, MATL: STE
51 43-12-24-048 1 EA
EL
WASHER - FLAT, MFG: EIMCO, PARTNO: F11177, MATL: STE
52 43-12-24-049 1 EA
EL
 Work Instruction 11 (13)
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SHAFT - SHEAVE, MFG: EIMCO, DRAWNO: 851112, PARTNO:

53 22-10-10-009 1 EA
851112A, LENGTH: 1 IN, WIDTH: 31 IN, MATL: STEEL

COLLAR - SET, MFG: EIMCO, DRAWNO: 85876, PARTNO: 858

54 22-10-10-010 1 EA
76T, SIZE: 1-5/8D X 5/8 WD IN, MATL: STEEL

SHAFT - REEL, MFG: EIMCO, DRAWNO: 81430A104, PARTNO

55 22-10-10-011 1 EA
: 81430A104A, MATL: STEEL

WHEEL - BRAKE, MFG: EIMCO, DRAWNO: 202025, PARTNO:

56 22-10-10-012 1 EA
202025A, MATL: STEEL
PULLEY - DRIVE, MFG: EIMCO, DRAWNO: 251972, PARTNO:
57 79-92-90-031 1 EA
251972A
ROLLER - WIRE, ASSY, MFG: EIMCO, DRAWNO: 851113, PAR
58 22-10-10-013 1 EA
TNO: 851113A, SIZE: 3 IN, MATL: STEEL

PIN - PULLEY, WIRING, MFG: EIMCO, DRAWNO: 851120, PA

59 22-10-10-014 1 EA
RTNO: 851120A, MATL: STEEL

SCREW - CAP, HEX HEAD, MFG: EIMCO, PARTNO: F10273, SI

60 81-62-50-013 1 EA
ZE: 1/2 IN UNC, LENGTH: 2-1/2 IN, MATL: GR5

SPRING - SCRAPER, MFG: EIMCO, DRAWNO: 450252, PARTN

61 22-10-10-015 1 EA
O: 450252A, MATL: STEEL

NUT - WING, MFG: EIMCO, PARTNO: F10922, SIZE: 1/2 IN U

62 81-41-44-001 1 EA
NC, MATL: ZINC

SCREW - CAP, HEX HEAD, MFG: EIMCO, PARTNO: F10298, SI

63 81-62-50-275 1 EA
ZE: 1/4 IN UNC, LENGTH: 3/4 IN, MATL: GR5

NUT - HEX HEAD, MFG: EIMCO, PARTNO: F10875, SIZE: 7/16

64 81-41-51-109 1 EA
IN UNC, MATL: GR5

PIN - COTTER, MFG: EIMCO, PARTNO: M023203, LENGTH: 1/

65 81-74-40-066 1 EA
8 IN, WIDTH: 1-3/4 IN, MATL: STEEL

PIN - COTTER, MFG: EIMCO, PARTNO: F10930, LENGTH: 1/8

66 81-74-40-067 1 EA
IN, WIDTH: 1 IN, MATL: STEEL
NIPPLE - GREASE, 45 DEG, MFG: EIMCO, DRAWNO: 85702, P
67 56-15-27-030 ARTNO: 85702P, SIZE: 1/8 NPT X 7/16 IN HEX HEAD, MATL: S 1 EA
TEEL
BOLT - SET, MFG: EIMCO, DRAWNO: 851117, PARTNO: 8511
68 81-26-86-004 1 EA
17A, SIZE: 1/2 IN UNC, LENGTH: 2-1/2 IN, MATL: STEEL
 Work Instruction 12 (13)
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WINDER - WIRE, ASSY, MFG: EIMCO, DRAWNO: 0-BOL-K-

69 22-10-10-016 1 EA
BW-010, PARTNO: BHW2442-151L
FRAME - ASSY, A, MFG: EIMCO, DRAWNO: 0-BOL-K-BW-010,
70 22-10-10-017 1 EA
PARTNO: BHW2442-152L
WASHER - PLAIN, MODEL M015067, MFG: EIMCO, DRAWNO
71 43-12-32-088 : 0-BOL-K-BW-010, PARTNO: TYPE-A-W, SIZE: 1/2 IN, MATL: 1 EA
HAST-C
NUT - HEX HEAD, M011736, MFG: EIMCO, DRAWNO: 0-BOL-
72 81-59-54-062 K-BW-010, PARTNO: TYPE-A-W, SIZE: 1/2 IN UNC, MATL: HA 1 EA
ST-C
ANCHOR - PLATE, MFG: EIMCO, DRAWNO: 0-BOL-K-BW-010,
73 81-26-05-001 1 EA
PARTNO: BHW2442-161, MATL: HAST-C
74 58-14-28-065 V-BELT - DRIVE, MFG: OPTIBELT, SIZE: 5VX 1120 4 EA
PUMP - ROTARY DISPLACEMENT VACUUM. MODEL: SHR-
75 30-64-25-002 1950. MFG: HICK HARGREAVES & CO. LTD. DRAWNO: AI018 1 SET
D2. POWER: 45 KW. CAP: 1615 CU M/H. SPEED: 980 RPM

FILTER - VACUUM, MFG: EIMCO, SIZE: TANK VOL: 54 FT3, CA

76 43-46-98-074 P: 30.130 KG/HR(DRY SOLIDS), O/D: DIA 6 FT, LENGTH: 8 FT, 1 EA
MATL: MILD STEEL/NEOPRENE LINED

77 58-14-23-002 BELT - TIMING, SIZE: 35 X 855 MM, MFG: MAX BELT 2 EA

78 MG01-000501 BEARING. - BALL. MFG: SKF. PARTNO: 6307 2 EA
79 85-52-04-084 SEAL - OIL, MFG: TTO, SIZE: 28/29 X 50 X 10 MM 2 EA
ROTARY - DRUM, DRIVE UNIT ASSEMBLY . - INCLUDED: GEA
R REDUCER, ELECTRIC REMOTE CONTROL (WITH MASTER GE
80 43-99-99-010 1 SET
AR MOTOR). MOTOR DRIVE IDENT NO.R377587-001-CA. SIZ
E: 0222
81 85-53-98-139 SEAL - O-RING, SIZE: 11 MM, MATL: NBR 1 ROLL
WIRE. - NICKLE CHROME 80/20. MFG: HYNDMAN INDUSTRI
AL. O/D: 2 MM. LENGTH: 1 ROLL (900 M). MATL: Cr: 0.005%,
82 68-99-99-002 1 ROLL
Si: 1.28%, Mn: 0.02%, Cr: 19.7%, Fe: 0.19%, Ni: BALANCE%, S
: <0.01%
83 MG06-000138 O-RING, ø 11 MM, NBR 1 ROLL
SPOOL - RETAINING, WIRE, MFG: PLATINUM, DRAWNO: 0-
84 68-99-99-001 2 EA
BOL-K-BW-010, LENGTH: 300 FT, O/D: 1.8, MATL: SS316
BEARING. - BALL. MFG: SKF. PARTNO: 6313-2Z. SIZE: OD: 14
85 67-65-81-010 2 EA
0 MM, ID: 65 MM
BEARING - BALL, SINGLE ROW, MFG: SKF, PARTNO: 6313, SIZ
86 58-01-27-047 2 EA
E: 65 MM
WIRE. - HASTELLOY. TYPE: C276, FOR ROTARY DRUM. LENGT
87 79-69-80-001 1 ROLL
H: 900 M. O/D: 2 mm

88 58-05-10-162 BEARING. - BALL. MFG: FAG. PARTNO: 6313-2Z 2 EA

VARIABLE FREQUENCY DRIVE (VFD), MODEL: M1420C, ENCL
89 43-99-15-002 OSURE: IP65/ TYPE 4, 3PH, 2 HP, 1.5KW, 400/480V, 50/60HZ 1 SET
, 4.7/4.1A, MFG: AC TECH
 Work Instruction 13 (13)
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VALVE. - DRAIN. AUTO, FOR FILTER. - ROTARY VACUUM DRU

90 75-74-40-002 1 SET
M. MFG: EIMCO