You are on page 1of 361

MM

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

abcd
KKS-No

14
14
14
14
14
14
14
14
14
14
14
14
14
14
14

PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB
PAB

Shoaiba Steam Power Plant


Stage III
Doc. No. : SHA 14 M---C05MM100
Cust. Doc. No.: 14-P-M-35243
Revision: A

MAINTENANCE MANUAL
List of documents

Designation / Type

Type of document

Document No.

Revision

Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge

Operation & Maintenance Manual


Sectional drawing / Parts list
General Arrangement Drawing
Signal Exchange list
Cable Schedule
Electrical Load List
Piping & Instrumentation Diagram
Wiring Diagram
System Description
Handling Drawings
Lubrication Schedule
Data Sheet
Data Sheet
Data Sheet
Data Sheet

SHA/14/M/---C05/MM/001
SHA/14/M/---C05/DD/001
14-P-M-35139
SHA/14/M/---C05/IO/001
SHA/14/M/---C05/LC/001
SHA/14/M/---C05/EL/001
SHA/14/M/---C05/FD/001
SHA/14/M/---C05/WD/001
SHA/14/M/---C05/DM/001
SHA/14/M/---C05/MD/003
SHA/14/M/---C05/DS/100
SHA/14/M/---C05/DS/001
SHA/14/M/---C05/DS/002
SHA/14/M/---C05/DS/003
see 14 PAB 41AA015

B
A
H
C
B
D
C
E
B
A
A
B
D
C

41
41
41
41
41
41
41
41
41
41
41
41
41
41
41

AT
AT
AA
AA

010
010
015
201

14 PAB 41

CP

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

Taprogge

Data Sheet

SHA/14/M/---C05/DS/004

14 PAB 41

001 Condensor Debris Filter- Actuator

Taprogge

Data Sheet

SHA/14/M/---C05/DS/005

14
14
14
14
14

42
42
42
42
41

AT
AT
AA
AA

010
010
015
201

14 PAB 42

CP

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

see 14PAB41CP010

14 PAB 42

001 Condensor Debris Filter- Actuator

see 14PAB41M001

PAB
PAB
PAB
PAB
PAB

13 PAB 41

Condensor Debris Filter System


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

Supplier

Condensor Debris Filter System


Condensor Debris Filter/PR-BW 800
Condensor Debris Filter- LV Motor/ RA500/280
Condensor Debris Filter- Valves/DN 350
Condensor Debris Filter- Valves /DN 50

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

Condensor Debris Filter System

see 14PAB41
page: 1/5

Issued:
Supplier :__________

Checked and released:


Supplier :__________

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

Checked and released:


Consortium member :__________

abcd
KKS-No
13
13
13
14

PAB
PAB
PAB
PAB

MAINTENANCE MANUAL
List of documents

Designation / Type

Supplier

Type of document

Document No.

41
41
41
41

AT
AT
AA
AA

010
010
015
201

13 PAB 41

CP

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

see 14PAB41CP010

13 PAB 41

001 Condensor Debris Filter- Actuator

see 14PAB41M001

13
13
13
13
14

42
42
42
42
41

AT
AT
AA
AA

010
010
015
201

13 PAB 42

CP

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

see 14PAB41CP010

13 PAB 42

001 Condensor Debris Filter- Actuator

see 14PAB41M001

12
12
12
12
14

41
41
41
41
41

AT
AT
AA
AA

010
010
015
201

12 PAB 41

CP

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

see 14PAB41CP010

12 PAB 41

001 Condensor Debris Filter- Actuator

see 14PAB41M001

12
12
12
12

AT
AT
AA

Condensor Debris Filter System


010 Condensor Debris Filter/PR-BW 800
010 Condensor Debris Filter- LV Motor/ RA500/280
015 Condensor Debris Filter- Valves/DN 350

see 14PAB41
see 14PAB41AT010
see 14PAB41AT010
see 14PAB41AA015

PAB
PAB
PAB
PAB
PAB

PAB
PAB
PAB
PAB
PAB

PAB
PAB
PAB
PAB

42
42
42
42

Condensor Debris Filter/PR-BW 800


Condensor Debris Filter- LV Motor/ RA500/280
Condensor Debris Filter- Valves/DN 350
Condensor Debris Filter- Valves /DN 50

Shoaiba Steam Power Plant


Stage III
Doc. No. : SHA 14 M---C05MM100
Cust. Doc. No.: 14-P-M-35243
Revision: A
Revision

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

Condensor Debris Filter System


Condensor Debris Filter/PR-BW 800
Condensor Debris Filter- LV Motor/ RA500/280
Condensor Debris Filter- Valves/DN 350
Condensor Debris Filter- Valves /DN 50

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

Condensor Debris Filter System


Condensor Debris Filter/PR-BW 800
Condensor Debris Filter- LV Motor/ RA500/280
Condensor Debris Filter- Valves/DN 350
Condensor Debris Filter- Valves /DN 50

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

page: 2/5
Issued:
Supplier :__________

Checked and released:


Supplier :__________

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

Checked and released:


Consortium member :__________

abcd
KKS-No

Shoaiba Steam Power Plant


Stage III
Doc. No. : SHA 14 M---C05MM100
Cust. Doc. No.: 14-P-M-35243
Revision: A

MAINTENANCE MANUAL
List of documents

Designation / Type

Supplier

Type of document

Document No.

14 PAB 41

AA

201 Condensor Debris Filter- Valves /DN 50

see 14 PAB 41AA015

12 PAB 42

CP

010 Condensor Debris Filter- Pressure Transmitter /1151 DP4

see 14PAB41CP010

12 PAB 42

001 Condensor Debris Filter- Actuator

see 14PAB41M001

14
14
14
14
14
14
14
14
14
14
14
14
14
14

15
15
15
15
15
15
15
15
15
15
15
15
15
15

AT
AA
AA

010
016
201

14 PCB 15

AT

010

14 PCB 15

CP

010

14 PCB 15

002

AT
AA

Debris Filter- Condenser & CCW Exchanger


Debris Filter- Condenser & CCW Exchanger
CCW Exchanger Debris Filter System
010 CCW Exchanger Debris Filter/PR-BW 100
016 CCW Exchanger Debris Filter- Valves/DN 150

14
14
14
14
14

PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB

PCB
PCB
PCB
PCB
PCB

16
16
16
16
16

CCW Exchanger Debris Filter System


CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter System
Debris Filter- Condenser & CCW Exchanger
Debris Filter- Condenser & CCW Exchanger
CCW Exchanger Debris Filter/PR-BW 100
CCW Exchanger Debris Filter- Valves/DN 150
CCW Exchanger Debris Filter- Valves/DN 50
CCW Exchanger Debris Filter- LV Motor /SK02F-IEC80L/4
CCW Exchanger Debris Filter- Pressure
Transmitter/1151 DP4
CCW Exchanger Debris Filter- Actuator

Revision

Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge
Taprogge

Operation & Maintenance Manual


Sectional drawing / Parts list
Electrical Load List
Piping & Instrumentation Diagram
General Arrangement Drawing
Signal Exchange list
Cable Schedule
Wiring Diagram
System Description
Handling Drawings
Lubrication Schedule
Data Sheet
Data Sheet
Data Sheet

SHA/14/M/---C05/MM/002
SHA/14/M/---C05/DD/002
SHA/14/M/---C05/EL/002
SHA/14/M/---C05/FD/002
14-P-M-35140
SHA/14/M/---C05/IO/002
SHA/14/M/---C05/LC/002
SHA/14/M/---C05/WD/002
SHA/14/M/---C05/DM/002
See 14 PAB 41
See 14 PAB 41
SHA/14/M/---C05/DS/011
SHA/14/M/---C05/DS/013
See 14 PCB15AA016

B
A
D
C
G
C
B
G
B

Taprogge

Data Sheet

SHA/14/M/---C05/DS/012

Taprogge

Data Sheet

SHA/14/M/---C05/DS/014

Taprogge

Data Sheet

SHA/14/M/---C05/DS/015

Handling Drawings
Lubrication Schedule

See 14 PAB 41
See 14 PAB 41
see 14PCB15
See 14 PCB15AT010
See 14 PCB15 AA016

B
C

page: 3/5
Issued:
Supplier :__________

Checked and released:


Supplier :__________

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

Checked and released:


Consortium member :__________

abcd
KKS-No
14 PCB 16

AA

14 PCB 16

AT

14 PCB 16

CP

14 PCB 16

13
13
13
13
13
13

Designation / Type

AT
AA
AA

010
016
201

13 PCB 15

AT

010

13 PCB 15

CP

010

13 PCB 15

002

PCB
PCB
PCB
PCB
PCB
PCB

Supplier

Type of document

201 CCW Exchanger Debris Filter- Valves/DN 50


CCW Exchanger Debris Filter- LV Motor /SK02F-IEC010
80L/4
CCW Exchanger Debris Filter- Pressure
010
Transmitter/1151 DP4
002 CCW Exchanger Debris Filter- Actuator

15
15
15
15
15
15

13
13
13
13
13
13

PCB
PCB
PCB
PCB
PCB
PCB

MAINTENANCE MANUAL
List of documents

16
16
16
16
16
16

AT
AA
AA

010
016
201

13 PCB 16

AT

010

13 PCB 16

CP

010

13 PCB 16

002

Shoaiba Steam Power Plant


Stage III
Doc. No. : SHA 14 M---C05MM100
Cust. Doc. No.: 14-P-M-35243
Revision: A
Document No.

Revision

See 14 PCB15AA016
See 14 PCB15 AT010
See 14 PCB15 CP010
See 14 PCB15 M002

Debris Filter- Condenser & CCW Exchanger


Debris Filter- Condenser & CCW Exchanger
CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter/PR-BW 100
CCW Exchanger Debris Filter- Valves/DN 150
CCW Exchanger Debris Filter- Valves/DN 50
CCW Exchanger Debris Filter- LV Motor /SK02F-IEC80L/4
CCW Exchanger Debris Filter- Pressure
Transmitter/1151 DP4
CCW Exchanger Debris Filter- Actuator

Handling Drawings
Lubrication Schedule

Debris Filter- Condenser & CCW Exchanger


Debris Filter- Condenser & CCW Exchanger
CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter/PR-BW 100
CCW Exchanger Debris Filter- Valves/DN 150
CCW Exchanger Debris Filter- Valves/DN 50
CCW Exchanger Debris Filter- LV Motor /SK02F-IEC80L/4
CCW Exchanger Debris Filter- Pressure
Transmitter/1151 DP4
CCW Exchanger Debris Filter- Actuator

Handling Drawings
Lubrication Schedule

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

Issued:
Supplier :__________

Checked and released:


Supplier :__________

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

Checked and released:


Consortium member :__________

abcd
KKS-No

12
12
12
12
12
12

Designation / Type

15
15
15
15
15
15

AT
AA
AA

010
016
201

12 PCB 15

AT

010

12 PCB 15

CP

010

12 PCB 15

002

12
12
12
12
12
12

PCB
PCB
PCB
PCB
PCB
PCB

PCB
PCB
PCB
PCB
PCB
PCB

MAINTENANCE MANUAL
List of documents

16
16
16
16
16
16

AT
AA
AA

010
016
201

12 PCB 16

AT

010

12 PCB 16

CP

010

12 PCB 16

002

Supplier

Shoaiba Steam Power Plant


Stage III
Doc. No. : SHA 14 M---C05MM100
Cust. Doc. No.: 14-P-M-35243
Revision: A

Type of document

Document No.

Debris Filter- Condenser & CCW Exchanger


Debris Filter- Condenser & CCW Exchanger
CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter/PR-BW 100
CCW Exchanger Debris Filter- Valves/DN 150
CCW Exchanger Debris Filter- Valves/DN 50
CCW Exchanger Debris Filter- LV Motor /SK02F-IEC80L/4
CCW Exchanger Debris Filter- Pressure
Transmitter/1151 DP4
CCW Exchanger Debris Filter- Actuator

Handling Drawings
Lubrication Schedule

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

Debris Filter- Condenser & CCW Exchanger


Debris Filter- Condenser & CCW Exchanger
CCW Exchanger Debris Filter System
CCW Exchanger Debris Filter/PR-BW 100
CCW Exchanger Debris Filter- Valves/DN 150
CCW Exchanger Debris Filter- Valves/DN 50
CCW Exchanger Debris Filter- LV Motor /SK02F-IEC80L/4
CCW Exchanger Debris Filter- Pressure
Transmitter/1151 DP4
CCW Exchanger Debris Filter- Actuator

Handling Drawings
Lubrication Schedule

Revision

See 14 PCB15 AT010


See 14 PCB15 CP010
See 14 PCB15 M002
See 14 PAB 41
See 14 PAB 41
see 14PCB15
See 14 PCB15AT010
See 14 PCB15 AA016
See 14 PCB15AA016
See 14 PCB15 AT010
See 14 PCB15 CP010
See 14 PCB15 M002

page: 5/5
Issued:
Supplier :__________

Checked and released:


Supplier :__________

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

Checked and released:


Consortium member :__________

02.06.2010

Schmidlin

Gller

19.10.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
APPROVED

Revised acc. clients comments

FUS

First issue / Preliminary

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
MP

Title :

Operation & Maintenance Manual

Language
:E

for

Consortium Participant or Subcontractor Document No. : N/A

abcd

Condenser Debris Filter


No of
sheet : 87

Power Systems

Sheet :

Plants

Alstom document no :

SHA/14/M/---C05/MM/001

Client Document No. :

SHA/14/M/---C05/ MM/001

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

Rev. A

Maintenance manual number :

SHA/14/M/---C05/MM/001

Equipment component code :

See equipment schedule

Equipment description :

Filter System

Subcontractor name :

Taprogge

Subcontractor document N. :

K2009/20/1367

List of contents

1.

EQUIPMENT DESCRIPTION & OPERATING INSTRUCTIONS ..................................................................... 5


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

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

SHA/14/M/---C05/MM/001

19.10.2009

en

2/87

ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 8 of 361

Rev. A
1.3.10.
"Indication" and Operation"; Operator terminal screens ...........................................................................43
1.3.11.
Operational trouble-shooting.......................................................................................................................44
1.3.11.1. Backwash rotor fault...............................................................................................................................45
1.3.11.2. Fault of actuator of discharge valve ......................................................................................................46
1.3.11.3. Fault of differential pressure measuring system ..................................................................................47
1.3.11.4. p EXCESSIVE HIGH ...........................................................................................................................48
1.3.11.5. Voltage breakdown.................................................................................................................................49
1.3.11.6. PLC fault .................................................................................................................................................50
1.3.11.7. Battery low ..............................................................................................................................................51
2. ENVIRONMENTAL, HEALTH AND SAFETY .................................................................................................. 52
3. MAINTENANCE ................................................................................................................................................. 53
3.1. Preventive maintenance ............................................................................................................................ 53
3.1.1.
PREVENTIVE MAINTENANCE INSTRUCTIONS ....................................................................................53
3.1.1.1.
Debris filter ..............................................................................................................................................54
3.1.1.1.1. Filter section .......................................................................................................................................55
3.1.1.1.2. Backwash rotor ..................................................................................................................................56
3.1.1.1.3. Backwash pipe ...................................................................................................................................57
3.1.1.1.4. Rotor actuation...................................................................................................................................58
3.1.1.1.5. Bearing ...............................................................................................................................................60
3.1.1.2.
Differential pressure measuring system ...............................................................................................65
3.1.1.3.
Gear motor for backwash rotor .............................................................................................................68
3.1.1.4.
Pneumatic actuator of the discharge valve...........................................................................................69
3.1.1.5.
Valves......................................................................................................................................................70
3.1.1.5.1. Shut-off flap of discharge valve ........................................................................................................70
3.1.1.5.2. Isolation valves of differential pressure measuring system ............................................................71
3.1.1.5.3. Filter drain valve.................................................................................................................................72
3.1.1.6.
Control panel ..........................................................................................................................................73
3.1.2.
PREVENTIVE MAINTENANCE SCHEDULE ............................................................................................74
3.1.3.
LUBRICATION INSTRUCTIONS AND SCHEDULE .................................................................................78
3.1.4.
SPECIAL TOOLING AND HANDLING DEVICES .....................................................................................79
3.1.5.
STORAGE INSTRUCTIONS ......................................................................................................................80
3.1.6.
PRESERVATION INSTRUCTIONS ...........................................................................................................81
3.2. CORRECTIVE MAINTENANCE INSTRUCTIONS.................................................................................. 82
3.2.1.
Debris filter ...................................................................................................................................................82
3.2.2.
Differential pressure measuring system .....................................................................................................83
3.2.3.
Gear motor for backwash rotor ...................................................................................................................84
3.2.4.
Valves ...........................................................................................................................................................85
4. ACCESSORIES ................................................................................................................................................. 86
5. DRAWING AND PART LISTS .......................................................................................................................... 87

Originator

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

SHA/14/M/---C05/MM/001

19.10.2009

en

3/87

ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 9 of 361

Rev. A
EQUIPMENT SCHEDULE

KKS No.

DESCRIPTION

REFERENCE PROCEDURE

EQUIPMENT TYPE

AP-Code

V : Valve
E : Equipment
I : Instrumentation

PARTICIPANT
UNIT

SYSTEM

COMPONENT
FUNCTION

SEQUENCE
NUMBER

010

TAPROGGE

12/13/14 PAB41

AT

Debris filter PR-BW 800

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB42

AT

TAPROGGE

12/13/14 PAB41

CP

010

Debris filter PR-BW 800

SHA/14/M/---C05/MM/001

010

Differential pressure measuring system

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB42

CP

010

TAPROGGE

12/13/14 PAB41

AA

015

Differential pressure measuring system

SHA/14/M/---C05/MM/001

Discharge valve with actuator

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB42

AA

015

Discharge valve with actuator

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB41

GH

001

Control panel

SHA/14/M/---C05/MM/001

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SHA 14 M --- C05 MM 100, Rev A. Page 10 of 361

Rev. A

1.

EQUIPMENT DESCRIPTION & OPERATING INSTRUCTIONS

1.1.

Task and function description of the TAPROGGE filter system

1.1.1.

Task of the TAPROGGE filter system

A TAPROGGE debris filter is installed to prevent clogging of cooling tubes and all related
problems.

Schematic Arrangement
1
Filter
2
Discharge valve
3
Discharge pipe
4
Condenser / Heat exchanger
For scope of supply please see flow diagram SHA/14/M/---C05/FD/001.

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SHA 14 M --- C05 MM 100, Rev A. Page 11 of 361

Rev. A

1.1.2.

Function description of the TAPROGGE filter system

Debris filter type PR-BW 800


1
2
3
4

Filter PR-BW 800


Differential pressure measuring system
Gear motor
Discharge valve

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SHA 14 M --- C05 MM 100, Rev A. Page 12 of 361

Rev. A

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

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SHA 14 M --- C05 MM 100, Rev A. Page 13 of 361

Rev. A

The special performance of the debris filter is based on the concept of

PRESSURE-RELIEVED BACKWASH (PR-BW)


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

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

Rev. A

Pressure-relieved backwash (PR-BW procedure)


FILTRATION

water flow

fibres are retained


filter section
flow pressure forces fibres and debris onto
the filter section

PRESSURE-RELIEF

freeing and lifting of fibrous debris


the covering backwash rotor causes a
pressure-relieved area
backwash rotor

FILTER BACKWASH

flow pressure relief and initial flow reversal


produced by the opened discharge valve
help to untangle and flush out fibrous
debris from the filter section.

Backwash process

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SHA 14 M --- C05 MM 100, Rev A. Page 15 of 361

Rev. A

1.2.

Description of the filter system

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

1.2.1.

Assembly Debris Filter

1.2.1.1.

Debris Filter PR-BW 800

Debris filter type PR-BW 800


1
2
3
4
5
6

Filter housing
Filter section
Backwash rotor
Backwash pipe
Rotor actuation
Bearing

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SHA 14 M --- C05 MM 100, Rev A. Page 16 of 361

Rev. A

Filter section

consists of a bearing block with radially arranged partition sheets. The


bearing block houses the bearing 6. Filter elements are fixed between
the partition sheets thus forming the individual filter segments.

The filter elements are made of perforated stainless steel sheets with a
semiconical design to ensure proper stiffness.

Backwash rotor

is connected to the backwash pipe 4. During the backwash procedure,


the backwash rotor successively covers each filter segment.

Backwash pipe

Considering the pressure ratio, the diameter of the backwash pipe is


designed for the proper water discharge required for filter backwash.

Rotor actuation

consists of the gear box flanged to the bearing block (housing of bearing
6), a cardan shaft and the gear motor. The rotor actuation is isolated
from the cooling water.

Bearing

The bearing of the backwash rotor is equipped with multiple seals to


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

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SHA 14 M --- C05 MM 100, Rev A. Page 17 of 361

Rev. A

1.2.1.2.

Differential pressure measuring system

Differential pressure measuring system


1
2
3
6
7
9

Differential pressure transmitter


Remote seal PLUS
Remote seal with capillary tube MINUS
Isolation valves
Measuring nozzles
Operator terminal

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SHA 14 M --- C05 MM 100, Rev A. Page 18 of 361

Rev. A

The differential pressure measuring system (p system) monitors the amount of debris on the
filter by constantly measuring the differential pressure (p).
Differential pressure transmitter 1

The differential pressure is electronically converted to a


signal.

Operator terminal 9

indicates: 


the actual differential pressure


the programmed limit values

initiates:

signalling upon reaching or falling below


the programmed limit values

limit value 1:
(test function)

IN-SERVICE MONITORING
The proper functioning of the measuring system is
electrically monitored constantly. In the event of a fault,
the differential pressure falls below limit value INSERVICE MONITORING and an alarm message will be
signalled by the control system.

limit value 2:
(service function)

FILTER BACKWASH
If debris accumulates on the filter section, the
differential pressure increases. If the limit value FILTER
BACKWASH is reached, the automatic control system
initiates filter backwash, until the differential pressure
falls below the pre-set limit value.

limit value 3:
(security function)

p EXCESSIVE HIGH
If the differential pressure continues to increase in spite
of the existent backwash and reaches the limit value p
EXCESSIVE HIGH, the automatic control system
continues filter backwash. Simultaneously, a signal and
an alarm message are indicated. The customer can
connect the potential free alarm from the control panel
to the control room.

Isolation valves 6

The differential pressure measuring system can be


isolated from the cooling water flow for maintenance
purposes by means of the isolation valves.

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SHA 14 M --- C05 MM 100, Rev A. Page 19 of 361

Rev. A

1.2.1.3.

Gear motor

The backwash rotor is operated by a special gear motor designed for 100 % continuous
operation. It is equipped with a slip clutch, which protects the backwash rotor, the actuation and
the gear motor against overload by power interruption, if a pre-set torque is exceeded.
The automatic reverse of the backwash rotor is initiated when the rotation monitoring switch
has tripped. The rotation monitoring switch is coupled to the gear motor of the backwash rotor.

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SHA 14 M --- C05 MM 100, Rev A. Page 20 of 361

Rev. A

1.2.2.

Discharge valve

The discharge valve in this filter system is a shut-off flap operated by a specially designed
pneumatic actuator with short running time. In the open position, the valve allows an
unrestricted flow of the debris laden water.
The pneumatic actuator is equipped with limit switches signalling the end positions to the
control panel. It is electro-magnetically actuated. In case of voltage breakdown the shut-off flap
closes automatically.

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SHA 14 M --- C05 MM 100, Rev A. Page 21 of 361

Rev. A

1.2.3.

Control
The control system serves to operate, control and monitor the filter system. The control is a
programmable logic controller (PLC). All control and monitoring functions required for automatic
operation (programmes) are stored in a single programme (EEPROM).
By means of a selector switch at the control panel the operating mode AUTOMATIC or
MANUAL is selected.
All further operations are effected via function keys at the operator terminal.

Operating mode AUTOMATIC


The control system monitors the filter system and initiates filter backwash in any of the following
cases:


p limit value FILTER BACKWASH

control command FILTER BACKWASH from control room

function key FILTER BACKWASH

function key FILTER EXTENDED BACKWASH

malfunction differential pressure measuring system (intermittent backwash every 3


minutes)

every 24 hours, initiated by a timer

Backwash
Backwash of the debris filter proceeds as follows:


The pneumatic actuator opens the discharge valve

Simultaneously, the backwash rotor starts


The filter section is cleaned by backwashing. The debris is carried away through the
discharge pipe.

In the operating mode AUTOMATIC the actual differential pressure is processed by the
control system

After backwashing, the actual differential pressure is checked by the control system

If p < limit value FILTER BACKWASH, the backwash rotor stops and the discharge
valve closes

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SHA 14 M --- C05 MM 100, Rev A. Page 22 of 361

Rev. A

Operating mode MANUAL

Note:
The operating mode MANUAL is not permitted for routine filter operation and may be
selected for commissioning and in case of trouble in the operating mode AUTOMATIC
only!

All operations are initiated by the operating personnel by means of function keys at the operator
terminal.

Backwash
Filter backwash must be initiated if:


p limit value FILTER BACKWASH

p limit value p EXCESSIVE HIGH

Backwash of the debris filter shall be executed as follows:




Open the discharge valve

Start the backwash rotor


The filter section is cleaned by backwashing. The debris is carried away through the
discharge pipe.

Carefully check indication of differential pressure

If p < limit value FILTER BACKWASH:


stop the backwash rotor
close the discharge valve

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SHA 14 M --- C05 MM 100, Rev A. Page 23 of 361

Rev. A

Control panel

The control panel consists of all necessary devices for ...




...

control and operation of the filter system

...

transmission of control commands between the control room and control panel

...

control and power supply to the external electrical consumers

On the control panel front are:




main switch

selector switch for operating mode AUTOMATIC / MANUAL

signal lamp for indication of common alarm

operator terminal for


indication:

operation:

of the actual operational system status

of the actual differential pressure

individual alarms

running time meter of backwash rotor

reverse operation counter of the backwash rotor

limit values of the differential pressure measuring system

timers of control

information regarding trouble shooting

execution of all operations

setting of limit values

setting of timers

The control panel contains potential-free contacts which should be connected to the
control room by the customer.

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SHA 14 M --- C05 MM 100, Rev A. Page 24 of 361

Rev. A

1.3.

Operating instructions

1.3.1.

General
The filter system is automatically operated. The differential pressure measuring system
monitors debris accumulation on the filter section. When the differential pressure reaches the
pre-set limit value FILTER BACKWASH, the automatic control initiates the filter backwash.
If the automatic control failed, backwashing must be manually initiated upon reaching the limit
value FILTER BACKWASH.

Caution:
Operation of the cooling water circuit without the control panel switched on will lead to
mechanical damage of the filter.

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SHA 14 M --- C05 MM 100, Rev A. Page 25 of 361

Rev. A

1.3.1.1.

Definition of basic position

Operation starts from the basic position, which is defined as follows:

KKS *)

Component / subassembly

12/13/14PAB41 GH001

Status
selector switch MANUAL /
AUTOMATIC
in position AUTOMATIC

Control panel

main switch Q01 in position I


12/13/14PAB41 AT010
12/13/14PAB42 AT010

Gear motor for backwash rotor

12/13/14PAB41 AA015
12/13/14PAB42 AA015

Discharge valve

12/13/14PAB41 AA301
12/13/14PAB42 AA301
12/13/14PAB41 AA302
12/13/14PAB42 AA302

Isolation valves of differential


pressure measuring system

OFF

CLOSE

OPEN

*) see flow diagram SHA/14/M/---C05/FD/001


The filter system leaves the basic position under one of the following conditions:


p reaches the limit value FILTER BACKWASH

function key FILTER BACKWASH is pressed at the operator terminal

function key FILTER EXTENDED BACKWASH is pressed at the operator terminal

control command filter backwash is sent from the control room

filter backwash is initiated by timer

alarm message p SYSTEM DEFECT

Alarm messages are indicated at the control panel and at the control room

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SHA 14 M --- C05 MM 100, Rev A. Page 26 of 361

Rev. A

1.3.2.

Description of operating modes

1.3.2.1.

Operating mode AUTOMATIC LOCAL

In the operating mode AUTOMATIC LOCAL, all motor-operated components are actuated via
the control programmes. The isolation valves of the differential pressure measuring system
must be manually actuated. The operator terminal indicates the actual operating status of the
motor-operated components.
The accumulation of debris on the filter section causes an increasing differential pressure which
is constantly monitored by the differential pressure measuring system. During routine filter
operation the filter system is monitored by the differential pressure measuring system.
As a standard the debris filter must be backwashed once a day, unless operational experiences
require other backwash sequences. The debris filter can be backwashed by the function key
FILTER BACKWASH.
When the alarm p SYSTEM DEFECT is activated, a filter backwash cycle is initiated for a
pre-set duration (intermittent backwash).

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SHA 14 M --- C05 MM 100, Rev A. Page 27 of 361

Rev. A

1.3.2.2.

Operating mode MANUAL

In the operating mode MANUAL, all motor-operated components are individually actuated via
the appropriate function keys at the operator terminal. The actual operating status of the motoroperated components is indicated at the operator terminal.
The operating mode MANUAL is selected :

for commissioning

in the event of problems in the operating mode AUTOMATIC

Note:
The operating mode MANUAL is not permitted for routine filter operation !

In the operating mode MANUAL the differential pressure on the filter section is indicated.
However, the debris filter is not automatically backwashed upon reaching the limit value
FILTER BACKWASH.
Upon reaching the limit value FILTER BACKWASH, filter backwash must be manually initiated.
Upon reaching the limit value p EXCESSIVE HIGH, an alarm message is indicated at the
control panel and at the control room. The debris filter must be backwashed in the operating
mode MANUAL (for details see section 1.3.5.3). In operating mode MANUAL the filter
backwash programme will not be automatically initiated.

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SHA 14 M --- C05 MM 100, Rev A. Page 28 of 361

Rev. A

1.3.3.

Pre-commissioning settings and checks

Conditions:


All components are installed

All electrical connections have been made and checked to be in accordance with the
specified circuit diagram, operating voltage and frequency. For more information see
electrical documentation in section 5.

Verify rotating magnetic field of three-phase connection for clockwise rotation.

Cooling water line is not flooded

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SHA 14 M --- C05 MM 100, Rev A. Page 29 of 361

Rev. A

1.3.3.1.

Testing and setting of the control panel

Check the actual operating voltage; change transformer connection(s), if necessary

All manual motor starters in the position I

Connection of terminals checked

All fuses in working order

Insert main fuse F 01.

Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the


position MANUAL

Main switch Q01 in position

All miniature circuit breakers in the position ON

Connect voltage supply

Put selector switch on CPU 1 to RUN / REM / PROG on CPU to RUN:



RUN
lights up (CPU)

DH+
lights up (CPU)

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

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

HSSL
flashing on BACKUP SCANNER 1/1 (D1BSN)

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

HSSL
flashing on BACKUP SCANNER 1/2 (D1BSN1)
CPU 1 is now in operating status as MASTER (PRIMARY)

Put selector switch on CPU 2 to to RUN / REM on CPU to RUN:



RUN
lights up (CPU)

DH+
lights up (CPU)

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

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

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

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

HSSL
flashing on BACKUP SCANNER 2/2 (D2 BSN1)
CPU 2 is now in stand-by status as SLAVE (SECONDARY)

COMM lights up on ADAPTER on INPUT / OUTPUT CHASSIS

RUN lights up on ADAPTER on INPUT / OUTPUT CHASSIS

Check lamp for proper functioning by push-button LAMP TEST

Preliminary programming of limit values at the operator terminal (see section 4), as
follows:

limit value FILTER BACKWASH


limit value p EXCESSIVE HIGH


p = 145 mbar
p = 181 mbar

Set the timers to the following values; after commissioning, record timer settings and
send one copy to TAPROGGE

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SHA 14 M --- C05 MM 100, Rev A. Page 30 of 361

Rev. A

Time Table

Timer
(adjustable
by function
key)

Denomination

Factory set
value

time filter backwash

30 sec.

time filter backwash after start filter backwash


from the control room

300 sec.

start filter backwash, if differential pressure


measuring system is defective

180 sec.

start filter backwash

Value after
commissioning

24 h

execution time check: running time of discharge


valve

30 sec.

time filter extended backwash

900 sec.

The following internal timers are already factory pre-set, alterations are not permitted:

Timer

Denomination

Value

iT

execution time check: test contact of differential pressure


measuring system

5 sec.

iT

rotation monitoring time

10 sec.

iT

delay time direction of rotation left / right


of backwash rotor

2 sec.

iT

delay time limit value filter backwash

5 sec.

iT

delay time limit value "p excessive high"

10 sec.

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SHA 14 M --- C05 MM 100, Rev A. Page 31 of 361

Rev. A

1.3.3.2.

Dry function test

Before flooding the filter system, the function of the backwash rotor and the discharge valve
must be checked.
Conditions:


the check must be performed without water in the filter system

selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in position


MANUAL

main switch Q01 in position I = ON

Discharge valve
The pneumatic actuator of the discharge valve has already been factory pre-adjusted.
The running times for the pneumatic actuator can be adjusted at the exhaust regulator with
sound absorber.

Backwash rotor

Warning:
During the following functional test do not reach into the filter housing.
Otherwise severe injury will result due to rotating parts!

Start the backwash rotor by the function key backwash rotor ON at the operator
terminal. The backwash rotor should now rotate. The proper rotation should be visually
checked through the inspection hole.

Close the inspection hole and tighten bolts.

Turn the backwash rotor off by pressing the function key backwash rotor OFF at the
operator terminal.

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SHA 14 M --- C05 MM 100, Rev A. Page 32 of 361

Rev. A

1.3.3.3.

Commissioning of the actuators

selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the position


MANUAL
main switch Q01 in the position I

1.3.3.3.1.

Pneumatic actuator of discharge valve

The pneumatic actuator of the discharge valve has already been factory pre-adjusted.

1.3.3.3.2.

Gear motor for backwash rotor

The torque (automatic reverse) at the slip clutch of the gear motor has been factory preadjusted to approximately 279 Nm.
The switching point (reference frequency) has been factory pre-set.

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SHA 14 M --- C05 MM 100, Rev A. Page 33 of 361

Rev. A

1.3.4.

Commissioning of the filter system

1.3.4.1.

Flooding of the debris filter

Check the following prior to flooding:

Remove coarse debris from the cooling water system.

Inspection hole of the filter closed

Isolation valves of the differential pressure measuring system are closed

Flooding:


1.3.4.2.

Flood the cooling water pipe and vent the entire cooling water system.

Venting of the differential pressure measuring system

Venting of the differential pressure measuring system is not applicable.

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SHA 14 M --- C05 MM 100, Rev A. Page 34 of 361

Rev. A

1.3.4.3.

Commissioning of the differential pressure measuring system

Conditions :


Cooling water flow per filter as specified:



minimum

normal

maximum admissible

4993 kg/s
8336 kg/s
9125 kg/s

Filter system in basic position (see section 1.3.1.1)

Isolation valves of differential pressure measuring system are open

Setting of the differential pressure transmitter and programming at the operator


terminal:
Zero point and measuring range of the differential pressure transmitter have already been set.
The limit values shall be programmed at the operator terminal by selecting the screen "Setting"
(see section 1.3.10).

Determination of pclean:


Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in position


AUTOMATIC LOCAL

Main switch Q01 at the control panel in the position I

Backwash the filter repeatedly by means of the function key FILTER BACKWASH.
Read the differential pressure directly after each filter backwash. The mean value is
determined as the differential pressure of the clean filter (pclean).

Programming of the limit values at the operator terminal:




limit value FILTER BACKWASH:

p = 2.0 x pclean (preliminary value)

limit value p EXCESSIVE HIGH:

p = 2.5 x pclean (preliminary value)

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SHA 14 M --- C05 MM 100, Rev A. Page 35 of 361

Rev. A

1.3.4.4.

Functional test of the control and setting of the limit values at the differential
pressure measuring system

Conditions :


Cooling water flow per filter as specified:



minimum

normal

maximum admissible

4993 kg/s
8336 kg/s
9125 kg/s

Filter system in basic position (see section 1.3.1.1)

Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the


position AUTOMATIC LOCAL

Main switch Q01 at the control panel in position I

Check limit value FILTER BACKWASH




Programming of limit value FILTER BACKWASH at the operator terminal to a value <
pclean.

The programme "Filter backwash is initiated according to section 1.3.5.2.

Programming of limit value FILTER BACKWASH to the preliminary value (see section
1.3.4.3)
After the backwash procedure the differential pressure of the clean filter (pclean) will be
indicated (see section 1.3.4.3).

Check limit value p EXCESSIVE HIGH in the operating mode MANUAL




Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the


position MANUAL

Programming of limit value p EXCESSIVE HIGH at the operator terminal to a value <
pclean.

The following alarm messages are indicated:

individual alarm
(fault list at the operator terminal)
common alarm

at the control panel

at the control room

p EXCESSIVE HIGH

p EXCESSIVE HIGH

ALARM

common alarm

Programming of limit value p EXCESSIVE HIGH to the preliminary value (see section
1.3.4.3)

Reset the alarms by means of the push-button ALARM RESET according to section
1.3.11. If the alarm messages continue, trouble shooting must be carried out according
to the event messages of the operator terminal or section 1.3.11.

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SHA 14 M --- C05 MM 100, Rev A. Page 36 of 361

Rev. A

Check limit value p EXCESSIVE HIGH in the operating mode AUTOMATIC




Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the


position AUTOMATIC LOCAL

Programming of limit value p EXCESSIVE HIGH at the operator terminal to a value <
pclean.

The control initiates filter backwash according to section 1.3.5.2. Moreover, the following
alarm messages are indicated:

individual alarm
(fault list at the operator terminal)
common alarm

at the control panel

at the control room

p EXCESSIVE HIGH

p EXCESSIVE HIGH

ALARM

common alarm

Programming of limit value p EXCESSIVE HIGH to the preliminary value (see section
1.3.4.3)

Reset the alarms by means of the push-button ALARM RESET according to section
1.3.11. If the alarm messages continue, trouble shooting must be carried out according
to the event messages of the operator terminal or section 1.3.11.

Programming of the limit values at the operator terminal:




limit value FILTER BACKWASH:

= 2.0 x pclean

limit value p EXCESSIVE HIGH:

= 2.5 x pclean

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SHA 14 M --- C05 MM 100, Rev A. Page 37 of 361

Rev. A

1.3.4.5.

Filter system start-up


Cooling water flow per filter as specified:

minimum

normal

maximum admissible

4993 kg/s
8336 kg/s
9125 kg/s

Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the


position AUTOMATIC LOCAL

Main switch at the control panel in position I

The filter system is in the basic position (see section 1.3.1.1).

Filter backwash by the function key FILTER BACKWASH


Filter backwash according to section 1.3.5.2

The filter system is now ready for operation.

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SHA 14 M --- C05 MM 100, Rev A. Page 38 of 361

Rev. A

1.3.5.

Operation of the filter system

1.3.5.1.

Routine filter operation (AUTOMATIC):

In the basic position the debris filter separates debris from the cooling water

KKS*)

Component to be
operated
filter system

*)

Position

basic
position

12/13/14
PAB41
GH001

control panel

12/13/14
PAB41
AT010
12/13/14
PAB42
AT010

gear motor for


backwash rotor

OFF

12/13/14
PAB41
AA015
12/13/14
PAB42
AA015

discharge valve

CLOSE

12/13/14
PAB41
AA301
12/13/14
PAB42
AA301
12/13/14
PAB41
AA302
12/13/14
PAB42
AA302

isolation valves of
differential pressure
measuring system

OPEN

Action

Indication

according to section 1.3.1.1

p < limit value FILTER BACKWASH

selector switch MANUAL / AUTOMATIC LOCAL


/ AUTOMATIC REMOTE in the position
AUTOMATIC LOCAL
backwash rotor OFF

discharge valve CLOSE

see flow diagram SHA/14/M/---C05/FD/001

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SHA 14 M --- C05 MM 100, Rev A. Page 39 of 361

Rev. A

1.3.5.2.

Filter backwash in the operating mode Automatic

Under the following operating conditions, the debris filter must be backwashed several
times as a precautionary measure:


during start of the cooling water pump

before start of another condenser / heat exchanger

before start of another cooling water pump

during or after cleaning work at the cooling water pipe or at the cooling water pump
sump

when high tide

Backwash of the debris filter can be accomplished as follows:




in the operating mode AUTOMATIC LOCAL: repeatedly press the function key FILTER
EXTENDED BACKWASH at the operator
terminal

Before shutdown of the filter system the debris filter must be backwashed several times as
a precautionary measure:


in the operating mode AUTOMATIC LOCAL: repeatedly press the function key FILTER
BACKWASH at the operator terminal
or

by means of repeating the control


commands filter backwash from the
control room in AUTOMATIC REMOTE

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SHA 14 M --- C05 MM 100, Rev A. Page 40 of 361

Rev. A

1.3.5.2.1.

KKS*)

Programme "filter backwash"

Component to be
operated

Position

Action

Indication

initiated by one of the following conditions:

12/13/14
PAB41
AA015
12/13/14
PAB42
AA015

discharge valve

OPEN

12/13/14
PAB41
AT010
12/13/14
PAB42
AT010

gear motor for


backwash rotor

ON

p-indication reaches the limit value


FILTER BACKWASH

p limit value FILTER BACKWASH


FILTER BACKWASH

timer (recommended setting 24 h)

FILTER BACKWASH

function key FILTER BACKWASH

FILTER BACKWASH
discharge valve OPEN

backwash rotor ON
backwash rotor RIGHT or
backwash rotor LEFT

after the pre-set backwashing period:

*)

12/13/14
PAB41
AT010
12/13/14
PAB42
AT010

gear motor for


backwash rotor

OFF

12/13/14
PAB41
AA015
12/13/14
PAB42
AA015

discharge valve

CLOSE

p < limit value FILTER BACKWASH


backwash rotor OFF

discharge valve CLOSE

see flow diagram SHA/14/M/---C05/FD/001

Even after the pre-set backwash period has elapsed, the filter will automatically continue backwashing until the
differential pressure measured across the filter section falls below the limit value FILTER BACKWASH. The
backwash rotor then stops and the discharge valve closes.

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SHA 14 M --- C05 MM 100, Rev A. Page 41 of 361

Rev. A

1.3.5.2.2.

KKS*)

Programme "filter extended backwash"

Component to be
operated

Position

12/13/14
PAB41
AA015
12/13/14
PAB42
AA015

discharge valve

OPEN

12/13/14
PAB41
AT010
12/13/14
PAB42
AT010

gear motor for


backwash rotor

ON

Action

Indication

initiated by

p < limit value FILTER BACKWASH

- function key FILTER CONTINUOUS


BACKWASH

FILTER EXTENDED BACKWASH

- p reaches limit value p excessive high

FILTER EXTENDED BACKWASH


discharge valve OPEN

backwash rotor ON
backwash rotor RIGHT or
backwash rotor LEFT

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


12/13/14
PAB41
AT010
12/13/14
PAB42
AT010

*)

gear motor for


backwash rotor

OFF

discharge valve

CLOSE

p < limit value FILTER BACKWASH


backwash rotor OFF

discharge valve CLOSE

see flow diagram SHA/14/M/---C05/FD/001

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SHA 14 M --- C05 MM 100, Rev A. Page 42 of 361

Rev. A

1.3.5.3.

KKS*)
12/13/14
PAB41
GH001

Component to be
operated

Position

control panel

Action

Indication

selector switch MANUAL / AUTOMATIC LOCAL


/ AUTOMATIC REMOTE in the position MANUAL

12/13/14
PAB41
AA015
12/13/14
PAB42
AA015

discharge valve

OPEN

12/13/14
PAB41
AT010
12/13/14
PAB42
AT010

gear motor for


backwash rotor

ON

12/13/14
PAB41
AT010
12/13/14
PAB42
AT010

*)

Filter backwash in the operating mode MANUAL

gear motor for


backwash rotor

OFF

12/13/14
PAB41
AA015
12/13/14
PAB42
AA015

discharge valve

CLOSE

12/13/14
PAB41
GH001

control panel

p-indication reaches the limit value FILTER


BACKWASH

p limit value FILTER BACKWASH

function key discharge valve OPEN

discharge valve OPEN

function key backwash rotor ON

backwash rotor ON
backwash rotor RIGHT or
backwash rotor LEFT

after approximately 1 minute of backwash rotor


operation, check:

p < limit value FILTER BACKWASH

function key backwash rotor OFF

backwash rotor OFF

function key discharge valve CLOSE

discharge valve CLOSE

selector switch MANUAL / AUTOMATIC LOCAL /


AUTOMATIC REMOTE in the position
AUTOMATIC LOCAL

see flow diagram SHA/14/M/---C05/FD/001

Note:
The operating mode MANUAL is not permitted for routine filter operation. It is only intended for
commissioning and in case of trouble in the operating mode AUTOMATIC!

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SHA 14 M --- C05 MM 100, Rev A. Page 43 of 361

Rev. A

1.3.6.

Filter system shut-down

KKS*)
12/13/14
PAB41
GH001

Component to be
operated

Position

Action

Indication

Filter backwash:
selector switch MANUAL / AUTOMATIC LOCAL
/ AUTOMATIC REMOTE in the position
AUTOMATIC LOCAL

control panel

FILTER BACKWASH
function key FILTER BACKWASH
or
FILTER BACKWASH
control command FILTER BACKWASH
(from the control room)
12/13/14
PAB41
AA015
12/13/14
PAB42
AA015

discharge valve

OPEN

12/13/14
PAB41
AT010
12/13/14
PAB42
AT010

gear motor for


backwash rotor

ON

12/13/14
PAB41
AT010
12/13/14
PAB42
AT010
12/13/14
PAB41
AA015
12/13/14
PAB42
AA015

discharge valve OPEN

backwash rotor ON
backwash rotor RIGHT or
backwash rotor LEFT

p < limit value FILTER BACKWASH

after the pre-set backwashing period:


gear motor for
backwash rotor

OFF

discharge valve

CLOSE

backwash rotor OFF

discharge valve CLOSE

check:
filter system

basic
position

p < limit value FILTER BACKWASH

according to section 1.3.1.1

after filter backwash:


cooling water pump
12/13/14
PAB41
GH001

*)

control panel

OFF
selector switch MANUAL / AUTOMATIC LOCAL
/ AUTOMATIC REMOTE in the position MANUAL

see flow diagram SHA/14/M/---C05/FD/001

The filter system is now out of operation

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SHA 14 M --- C05 MM 100, Rev A. Page 44 of 361

Rev. A

1.3.7.

Measures to prevent corrosion due to stagnation


During prolonged shut-down periods the following must be strictly observed:
The corrosion resistance of stainless steel in aggressive water can be affected by the conditions
prevailing during shut-downs.
During shut-down periods, stagnant water, as well as evaporation of remaining water (e.g. drops),
is to be avoided.

The following measures are necessary to prevent corrosion damage :

Shut-downs up to 3 days:


Run the cooling water pump for a few minutes each day to circulate the cooling water and
to rinse deposits away.

If a high amount of debris is expected during operation of the cooling water pump turn the
main switch Q01 in the position I and backwash the debris filter according to section
1.3.5.3.

Shut-downs over 3 days require a dry conservation




Drain the TAPROGGE components

Clean the internals of the filter system with fresh water

Dry by natural aeration

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SHA 14 M --- C05 MM 100, Rev A. Page 45 of 361

Rev. A

1.3.8.

Filter system restart after shut-down

For shut-downs up to 3 days or maintenance of the debris filter


(with water in the filter system):


Functional test of control and


setting of the limit values at the
differential pressure measuring system

according to section 1.3.4.4

Filter system start-up

according to section 1.3.4.5

Resume routine filter operation

according to section 1.3.5.1

For shut-downs over 3 days or after maintenance of


the drained debris filter


Pre-commissioning settings and checks

according to section 1.3.3

Commissioning of the filter system

according to section 1.3.4

Resume of routine filter operation

according to section 1.3.5.1

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SHA 14 M --- C05 MM 100, Rev A. Page 46 of 361

Rev. A

1.3.9.

Operating Record
For documentation of the debris filter operation please use the attached form.
The documentation of the operational parameters of the TAPROGGE filter system on a regular
basis is helpful to evaluate special operational conditions, to optimize settings of the differential
pressure measuring system and timers and to trace the cause of damages.
We recommend recording the indicated differential pressure of the clean debris filter every 2
weeks and after each alarm p EXCESSIVE HIGH (potential-free contact)
We kindly ask you to have one completed copy of the form ready for information of the
TAPROGGE service department.

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SHA 14 M --- C05 MM 100, Rev A. Page 47 of 361

Rev. A

Operating Record

Date

Differential pressure
after last filter
backwash (pclean)

Backwash rotor
operation hours

Reverse operation
counter of
backwash rotor

Remarks

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SHA 14 M --- C05 MM 100, Rev A. Page 48 of 361

Rev. A

1.3.10. "Indication" and Operation"; Operator terminal screens

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SHA 14 M --- C05 MM 100, Rev A. Page 49 of 361

Rev. A

1.3.11. Operational trouble-shooting

Note:
Alarm messages are indicated at the operator terminal of the control panel and at the control room
(common alarm) and can be reset in operating mode MANUAL* / AUTOMATIC* by means of the
push-button ALARM RESET. If operational trouble cannot be solved by following the procedures
described herein, or if alarm messages continue, kindly inform the TAPROGGE Service
Department. After trouble shooting, continue filter operation according to section1.3.5.1.

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SHA 14 M --- C05 MM 100, Rev A. Page 50 of 361

Rev. A

1.3.11.1.

Backwash rotor fault

Indication at
operator terminal
manual motor starter
tripped

Potential-free
contact to
control room
common alarm

backwash rotor
blocked

Probable cause

Remedy

manual motor starter


tripped

Reclose the manual motor starter. If the manual motor


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

rotation monitoring
time elapsed

Electrically and mechanically check the gear


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

Inform the TAPROGGE Service
Department for checking and setting of timer

Check torque according to section 3.2.3 and section 4


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

Check the safety switch for crank handle actuation,


according to section 4 "Gear motor for backwash
rotor"
-

remove the crank handle and screw the cover to


the gear motor so that the electric circuit of the
motor is closed

check cabling

check electrical connections

check function of switching amplifier according to


section 4 "Switching amplifier"

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SHA 14 M --- C05 MM 100, Rev A. Page 51 of 361

Rev. A

1.3.11.2.

Fault of actuator of discharge valve

Indication at
operator terminal

Potential-free
contact to
control room

Probable cause

Remedy

miniature circuit
breaker tripped

common alarm

...........................

Reclose the miniature circuit breaker, if the miniature


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

malfunction both travel


limit switches actuated

not adjusted
defective cabling

running time exceeded

OPEN

CLOSE

restricted movability

Check setting travel limit switches according to section


4 "Pneumatic actuator discharge valve".
Check the electrical connections
Check compressed air supply
Check running time of discharge valve according to
the time table, section 1.3.3.1
Check the actuator of discharge valve electrically and
pneumatically
according
to
section
4
"Pneumaticactuator discharge valve".
Check the electrical connections
Check cabling according to the electrical
documentation"

Caution:
If the discharge valve has not opened due to a defect of the pneumatic actuator, the discharge
valve must be turned to the position OPEN by means of the emergency actuation at the solenoid
valve of the actuator. Precondition: compressed air is available.

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SHA 14 M --- C05 MM 100, Rev A. Page 52 of 361

Rev. A

1.3.11.3.

Fault of differential pressure measuring system

The filter is running in "intermittent backwash", i.e. the filter is backwashing every 180
seconds.

Indication at
operator terminal

Potential-free
contact to
control room

p SYSTEM DEFECT

common alarm

Probable cause
no signal from
differential pressure
transmitter
measuring range fault

p below limit value


IN-SERVICEMONITORING for
more than 5 sec.
current loop of transmitter interrupted

Remedy
Check the electrical connections

Check the calibration of the differential pressure


transmitter according to section 4 "Differential
pressure transmitter"
Check cabling according to the electrical
documentation in section 5.
Check the differential pressure transmitter according
to section 4 "Differential pressure transmitter".
Check cabling according to the electrical
documentation in section 5.

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SHA 14 M --- C05 MM 100, Rev A. Page 53 of 361

Rev. A

1.3.11.4.

p EXCESSIVE HIGH

Indication at
operator terminal

Potential-free
contact to
control room

Probable cause

Remedy

p excessive high

common alarm

setting of limit values

Check setting of limit values according to section


1.3.4.4

p excessive high

extraordinary amount
of debris

Check the pre-screening system

cooling water flow


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

Check setting of limit values according to section


1.3.4.4


Inform the TAPROGGE Service Department

Inform the TAPROGGE Service Department

Verify that the


- discharge valve is fully opened
- backwash pipe is not clogged
cooling water flow rate
is less than the design 
data (insufficient
backwash)

Inform the TAPROGGE Service Department

continuous reversal of Check the rotation monitoring switch according to


the backwash rotor
section 4 "Gear motor for backwash rotor":

frequent reversal of
the backwash rotor

Distance between proximity switch and rotor


Wiring between proximity switch of impulse generator and control panel

Take filter system out of operation at the next


opportunity according to section 1.3.6
Check the filter internals according to section
6.1.1 and remove coarse parts, if necessary

After trouble shooting: restart the filter system according to section 1.3.8

Complete the operating record after each alarm p EXCESSIVE HIGH

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SHA 14 M --- C05 MM 100, Rev A. Page 54 of 361

Rev. A

1.3.11.5.

Voltage breakdown

Caution:
In case of a voltage breakdown of more than 60 minutes the cooling water flow must be reduced to
ensure, that the design pressure of the filter section (1,0 bar) will not be exceeded. We recommend
an emergency power supply of the control panel.

Indication/Signal
at control panel

Potential-free
contact
to control room

no indication

common alarm

Probable cause

Remedy

no supply voltage to
the control panel

Check the main supply voltage


Clear any short-circuits

no control voltage

Check the manual motor starter of the control


voltage transformer
Check miniature circuit breaker(s)
Clear any short-circuits

Check miniature circuit breaker(s)


Clear any short-circuits

no auxiliary voltage

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SHA 14 M --- C05 MM 100, Rev A. Page 55 of 361

Rev. A

1.3.11.6.

PLC fault

Indication at
operator terminal
and CPU

Potential-free
contact to
control room

no indication

LED at CPU:
FLT

Probable cause

Remedy

common alarm

no auxiliary voltage

Replace fuse, check wiring according to the electrical


documentation in section 8 and section 9
"Programmable controller"

common alarm

CPU fault

Check hardware according


documentation in section 8

to

the

electrical

data bus fault

Check hardware according


documentation section 5

to

the

electrical

at operator terminal:
no active nodes found
on network

Compare error number, section 4, "Operator Terminal"

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SHA 14 M --- C05 MM 100, Rev A. Page 56 of 361

Rev. A

1.3.11.7.

Battery low

Indication at
operator terminal
and CPU

Potential-free
contact to
control room

battery low

common alarm

Probable cause

Remedy

battery of PLC has run Replace / add the battery of the CPU as soon as
out
possible
(see
also
manufacturer's
manual
"programmable logic controller")

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SHA 14 M --- C05 MM 100, Rev A. Page 57 of 361

Rev. A

2.

ENVIRONMENTAL, HEALTH AND SAFETY

The operating instructions contain basic information on erection, operation and maintenance. For
this reason it is essential that the operating instructions are carefully read before erection and
commissioning by both the installation personnel as well as those responsible for operation and
maintenance. The operation manual must always be available.

In order to prevent personal injury or property damage particular note must be taken of the
following:

the technical data and information as described in the operating instructions

accident prevention regulations

safety regulations of plant operator

electric protective measures acc. to local safety regulations

technical information on manufacturing plates

warning plates at components

regulations concerning environmental protection

all work on or near the system is to be done by qualified personnel

Moreover, the operating instructions contain safety notes which, if ignored, may cause
damage to persons, machinery or environment and which can be identified by the
following symbols:
Warning:

means that danger to life may result if corresponding measures are


not taken or ignored.

Caution:

means that personal injury or considerable material damage may


result if corresponding measures are not taken or ignored.
Note:

points out important information to which the readers specific


attention is drawn.

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SHA 14 M --- C05 MM 100, Rev A. Page 58 of 361

Rev. A

3.

MAINTENANCE
3.1. Preventive maintenance

3.1.1.

PREVENTIVE MAINTENANCE INSTRUCTIONS

In general the following must be observed during maintenance work:

Lightly grease metal parts before assembly.

In order to avoid crevice corrosion, the non-rubberlined sealing surfaces are to be


cleaned and completely covered with a permanently flexible sealing material during
maintenance work.

Only lubricate and grease o-rings with a silicone-based valve grease free of
hydrocarbons (see lubrication list)

Avoid excessive force, especially in case of rubberlined components

Pipes shall be connected stress-free. Take care of fixing points and expansion joints
to avoid unexpected forces at the components.

Restart the filter system according to section 1.3.8. after the maintenance work has been
completed.

If maintenance work cannot be performed according to the procedures described herein


kindly inform the TAPROGGE Service Department.

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SHA 14 M --- C05 MM 100, Rev A. Page 59 of 361

Rev. A

3.1.1.1.

Debris filter

For execution of maintenance work described in section 3.1.1.1, it is not necessary to remove
the filter from the cooling water pipe.

Warning:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and
make it safe. Ensure that the voltage supply to the electric actuators and the
compressed air supply for the discharge valve has been interrupted. Voltage-carrying
adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
has been drained. It is absolutely necessary to ensure that people are not exposed to
danger due to an inrush of water into the filter during maintenance work.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

To replace wear parts, several subassemblies of the filter must be completely disassembled.
We recommend to have this work done by the TAPROGGE Service Department.

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SHA 14 M --- C05 MM 100, Rev A. Page 60 of 361

Rev. A

3.1.1.1.1.

Filter section

(see drawing K2009/20/1367-0503, subassembly 4)

Replacement of filter elements

Filter elements 4.9 are not wear parts. However, if an element has been damaged, please
replace as follows:

Dismantling


hexagon bolt 4.19, 4.25, washer 4.21, 4.26, 4.27 and hexagon nut 4.22, 4.28

bracket 4.2 (consisting of a round steel and 2 clamping sheets with


right / left hand execution) and support 4.3 and 4.4

hexagon bolt 4.29, washer 4.21 and hexagon nut 4.22

replace filter element 4.9

Assembly:


Apply securing for bolts and nuts 4.18 (Loctite 242)


to the thread and contact surfaces of the screw heads and nuts

filter element 4.9 (attach to flange pipe of bearing block 4.1 without clearance)

support 4.3, 4.4 and bracket 4.2 (observe arrangement of clamping sheets)

hexagon bolt 4.19, 4.25, 4.29, washer 4.21, 4.26, 4.27 and hexagon nut 4.22, 4.28
(Do not tighten yet!)

Press bracket 4.2 against the filter element without clearance, secure the hexagon nut 4.22 and
4.28 according to tightening torque listed in the drawing.

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SHA 14 M --- C05 MM 100, Rev A. Page 61 of 361

Rev. A

3.1.1.1.2.

Backwash rotor

(see drawing K2009/20/1367-0503, subassembly 5)

Wear part: head piece 5.4

For assembly, you will need securing for bolts and nuts (Loctite 270).

Dismantling


remove hexagon bolt 5.13 *)

remove sheet 5.7 and head piece 5.4

Assembly


Loosely screw the new head piece 5.4 together with the sheet 5.7 and hexagon bolt 5.13

carefully adjust the head piece 5.4 to filter section 4

fix hexagon bolt 5.13

secure hexagon bolt 5.13 (and 5.11, if necessary) with securing for bolts and nuts 5.20
(Loctite 270)

*)

If it is not possible to remove the hexagon bolts 5.13 during dismantling, please proceed
as follows:


remove the parallel pin 5.9

support the backwash nozzle 5.2

remove the hexagon nut 5.15 and hexagon bolt 5.11

remove the backwash nozzle far enough such that the hexagon bolt 5.13, sheet
5.7 and head piece 5.4 can be dismantled

for the assembly with new head piece, proceed in reverse order and strictly
observe instructions given under Assembly

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SHA 14 M --- C05 MM 100, Rev A. Page 62 of 361

Rev. A

3.1.1.1.3. Backwash pipe


(see drawing K2009/20/1367-0503, subassembly 6)

Wear part:

flange
bearing housing
o-ring

6.2
6.4
6.5

For assembly, you will need securing for bolts and nuts (Loctite 270 and Loctite 242).

Dismantling:


support the backwash pipe 6.1

loosen screw connection 6.20, 6.21, 6.22 and 6.18, 6.19 and remove support 6.16

remove the hexagon bolt 6.11

remove the hexagon bolt 6.7 and washer 6.8

remove backwash pipe 6.1 with gasket 6.12 and remove bearing housing 6.4

dismantle the slotted set screw 6.9, flange 6.2 and bearing flange 6.3, replace the
bearing housing 6.4 and flange 6.2

replace the o-ring 6.5 of the bearing flange 6.3

remove the o-ring 6.6, check for damage and replace, if necessary

Assembly:


insert the o-ring 6.5 into the bearing flange 6.3

assemble the bearing flange 6.3, flange 6.2 with slotted set screw 6.9. Secure the
slotted set screw 6.9 with securing for bolts and nuts 6.13 (Loctite 270)

assemble the bearing housing 6.4 with the o-ring 6.6 with the backwash pipe 6.1; secure
with the hexagon bolt 6.7 and washer 6.8; ensure correct position of the hexagon bolt
6.7 and the threaded rod 6.10 with hexagon nut 6.14! Observe the tightening torque and
secure with securing for bolts and nuts 6.13 (Loctite 270).

assemble backwash pipe 6.1 with gasket 6.12 and fix with hexagon bolt 6.11. Secure
with securing for bolts and nuts 6.15 (Loctite 242).

assemble support 6.16 with screw connection 6.20, 6.21, 6.22 and 6.18, 6.19

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SHA 14 M --- C05 MM 100, Rev A. Page 63 of 361

Rev. A

3.1.1.1.4.

Rotor actuation

(see drawing K2009/20/1367-0503, subassembly 7)

Wear parts:

washer
cardan joint
cardan joint
bush
spring pin
washer
securing for bolts and nuts
corrosion protection
surface seal

7.18
7.22
7.23
7.25
7.28
7.29
7.32
7.38
7.43

Dismantling

Note:
During execution of work ensure that the white and red indicator hoses 7.39 and 7.40 will
not be damaged!

Remove the gear motor according to section 9 Gear motor for backwash rotor.

Remove the hexagon nut 7.24 and washer 7.26.

Loosen the pipe union 7.48 from connection piece 7.47 and remove lantern 7.5, washer
7.29, bush 7.25 and seal washer 7.4 with o-ring 7.11 and gasket 7.27.

Completely remove the cardan shaft, consisting of 7.8, 7.22, 7.23, 7.28.

Remove the hexagon bolt 7.13 and carefully remove pipe channel 7.3; note position of
channel for protection hoses 7.54.

Remove the hexagon bolt 7.17 and gear housing 7.2.

Remove the cardan joints 7.22 and 7.23 and spring pins 7.28.

Remove the connector 7.42, remove hoses

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SHA 14 M --- C05 MM 100, Rev A. Page 64 of 361

Rev. A

Remove the hexagon bolt 7.19 and hexagon nut 7.20.

Remove the planetary reduction gear 7.1 together with intermediate flange 7.9; loosen
the connection of planetary reduction gear 7.1 and intermediate flange 7.9 only if fixing
parts 7.15, 7.16, 7.18, 7.30 and 7.55 are no longer in an acceptable condition!

Check tightness of the planetary reduction gear 7.1. In the event of considerable grease
leakage, it is necessary to repair or replace the gear. We strongly recommend informing
the TAPROGGE Service Department.

Check the o-rings 7.10, 7.11, 7.12, gasket 7.27, hoses 7.39, 7.40 as well as connector
7.42 for damage and replace, if necessary.

Clean those surfaces to which surface seal 7.43 has been applied to.

Assembly
Observe the following while reassembling in reverse order:


Carefully mount the connector 7.42 for connection of the indicator hoses

Pay attention to the exact positioning of the spring pins 7.30 and 7.55 according to the
drawing.

Clean the shaft 7.8 and check for damages.

Assemble the new cardan joints 7.22 and 7.23 with spring pins 7.28.

Provide the shaft 7.8 with corrosion protection 7.38 (Chesterton 740).

Apply surface seal 7.43 according to the above mentioned drawing

Assemble the pipe channel 7.3.

Replace the washer 7.29 and bush 7.25 and secure all bolts with Loctite 270 (Pos. 7.32)
according to the instructions in the drawing.

Mount the gear motor according to section 4 Gear motor for backwash rotor.

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SHA 14 M --- C05 MM 100, Rev A. Page 65 of 361

Rev. A

3.1.1.1.5.

Bearing

(see drawing K2009/20/1367-0503, subassembly 11)

groove ball bearing


wiper
needle bearing
o-ring
o-ring

Wear parts:

11.3
11.6
11.8
11.9

11.10
o-ring
11.11
surface seal
11.12
V-seal
11.14
wearing ring
11.21
special-purpose grease
11.26
securing for bolts and nuts
11.28
sealing adhesive
11.29
sealing tape
11.32
adhesive
11.33

For assembly of the bearing you need special-purpose grease (Klber, Syntheso GLEP1)
11.26, multi-purpose grease (see lubrification list; grease G5) 11.27, sealing adhesive (Loctite
577) 11.29 and surface seal (Loctite 510) 11.12.
The bearing of the backwash rotor is multiple sealed. Leakage from the sealing system can be
traced via the two indicator hoses (white and red). When the white indicator hose 11.19
indicates leakage, the wear parts of the sealing system (i.e. 11.6, 11.9, 11.10, 11.11, 11.14,
11.21, 11.28, 11.32, 11.33) must be replaced with the next repair.

Caution:
When the red indicator hose 11.20 indicates leakage, the sealing system must be
replaced immediately. Please contact the TAPROGGE Service Department.

Before dismantling the rotor bearing the following subassemblies must be removed in
the following sequence:




backwash pipe, subassembly 6


backwash rotor, subassembly 5
rotor actuation, subassembly 7

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SHA 14 M --- C05 MM 100, Rev A. Page 66 of 361

Rev. A

Note:
When dismantling / assembling the bearing ensure that the two indicator hoses (white
hose 11.19 and red hose 11.20) will not be damaged or switched.

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SHA 14 M --- C05 MM 100, Rev A. Page 67 of 361

Rev. A

Dismantling

Loosen the three locking screws at the circumference of the slotted round nut 11.13 with
a hexagon socket screw key.

Loosen the locking screws by careful blows with a plastic tip hammer onto the surface
area of the slotted round nut.

Loosen the slotted round nut 11.13 with the respective socket wrench (Taprogge supply)
and remove it.

Remove o-ring 11.11 and wiper 11.6

Pull out the rotor shaft 11.1 with the inner ring of the needle bearing 11.8 in direction of
backwash rotor; use existing tap holes, if necessary

Remove hexagon nut 11.24, screwed to stud 11.36

Loosen hexagon nut 11.24, screwed to hexagon bolt 11.17.

Tighten hexagon bolt 11.17 to push out the subassembly consisting of items 11.5, 11.3,
11.7, 11.25, 11.35. By removing the retaining ring 11.35, the groove ball bearing 11.3
can be taken out easily.

Remove the inner ring of needle bearing 11.8 from rotor shaft; warm up before removing
as the inner ring is press-fit

Remove hexagon socket head cap screw 11.23, then remove the wearing ring 11.21
from the seal housing 11.4 together with the V-seal 11.14.

Remove the V-seal 11.14

Check wearing ring 11.21 and replace according to maintenance schedule, section
6.3.1.

Loosen connector 11.39.

Remove hexagon bolt 11.15

Remove seal housing 11.4 with o-ring 11.9, 11.10 and indicator hoses 11.19, 11.20
using existing tap holes.

Loosen pipe union 11.18 of indicator hoses 11.19, 11.20

Remove hexagon socket head cap screw 11.31

Remove bearing housing 11.30, outer ring and needle ring of the needle bearing 11.8

Remove (push out) needle bearing 11.8

Carefully clean all parts. Check rotor shaft and overhaul, if necessary.
Replace all wear parts according to the maintenance schedule in section 3.2.1.

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SHA 14 M --- C05 MM 100, Rev A. Page 68 of 361

Rev. A

Assembly
Assemble in reverse order; tolerances and tightening torque must be followed according to
drawing K2009/20/1367-0503.
During re-assembly, seal the pipe unions 11.18 of the indicator hoses with sealing tape 11.32.
For positions with indices 11.28 use LOCTITE 242, for position 11.12 surface seal Loctite 510.
For positions with indices 11.26 use grease KLBER Syntheso GLEP1.
V-seal 11.14 to be glued in with LOCTITE 495 11.33.
Grease needle bearing 11.8 with special grease 11.26 (KLBER Syntheso GLEP1)
Grease groove ball bearing 11.3 with multi-purpose grease 11.27.


Clean bearing surfaces of slide bush 11.5 and bearing housing 11.30 of debris and
grease.

Grease rotor shaft 11.1 with special-purpose grease 11.26 and move a few times
forward and backward in the bearing in order to allow grease to spread

Rotate rotor shaft 11.1 for ten times

Adjust flange of rotor shaft 11.1 with wearing ring 11.21 (see drawing):


In order to move the flange of the rotor shaft 11.1 towards backwash pipe, tighten
hexagon nut 11.24 screwed onto stud 11.36.

In order to move the flange of the rotor shaft 11.1 in opposite direction, tighten
hexagon bolt 11.17.

Screw slotted round nut 11.13 with the stepped side (contact surface) onto the exterior
thread and firmly tighten by means of the socket wrench.

Secure slotted round nut against loosening by evenly and step-wise tightening the
locking screws at the circumference.

Check sealings for leakage




Connect a valve with a gauge to the connector 11.39 for the indicator hoses
(white and red) and expose the union under an air pressure of 2,0 bar (20000 Pa;
30 psi 5), close the valve and check the pressure by gauge for 15 minutes.
There is no pressure decrease allowed in this time.

Insert wiper 11.6 and o-ring 11.11

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SHA 14 M --- C05 MM 100, Rev A. Page 69 of 361

Rev. A

After assembly of bearing, reassemble in the following sequence according to operating


instructions and relevant drawings
 rotor actuation
 backwash rotor
 backwash pipe

Again, check rotor for correct running and pay attention to clearance between backwash
rotor and filter section!

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SHA 14 M --- C05 MM 100, Rev A. Page 70 of 361

Rev. A

3.1.1.2.

Differential pressure measuring system

(see drawing K2009/20/1367-0501)

Caution:
As long as the differential pressure measuring system is out of order the debris
accumulated on the filter section cannot be monitored.
Therefore the filter shall be backwashed continuously while performing the following
work in the operating mode MANUAL (see section 1.3.5.3).
After the work has been completed, resume the operating mode AUTOMATIC.

Check tightness of the differential pressure measuring system as follows:


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


If the p indication decreases:


check PLUS side of the differential pressure measuring system for leakage and repair it
accordingly.

If the p indication increases:


check MINUS side of the differential pressure measuring system for leakage and repair
it accordingly.

If it may become necessary to replace parts or the complete isolation, see section
3.1.1.5.2 as well as section 9.

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SHA 14 M --- C05 MM 100, Rev A. Page 71 of 361

Rev. A

Cleaning of the differential pressure measuring system

Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and make
it safe. Ensure that the voltage supply to the electric consumers has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
must be drained.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

Close and lock the isolation valves of the differential pressure measuring system.

Remove differential pressure transmitter with remote seal / remote seal with capillary
tube. Take care, that the measuring diaphragm will not be damaged.

Caution:
Do not use the capillary tube for carrying and do not bend it. Do not loosen the
connection between capillary tube and remote seal. Deposits may not be removed using
sharp objects.

Clean the isolation valves of the differential pressure measuring system and the
diaphragm of the differential pressure transmitter.

Clean the sealing between remote seal and isolating valve

Assemble differential pressure transmitter and remote seal, tighten bolts crosswise.

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SHA 14 M --- C05 MM 100, Rev A. Page 72 of 361

Rev. A

Calibration of the differential pressure measuring system

Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and make
it safe. Ensure that the voltage supply to the electric consumers has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
must be drained.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

Close and lock the isolation valves of the differential pressure measuring system.

Remove differential pressure transmitter with remote seal / remote seal with capillary
tube. Take care, that the diaphragm will not be damaged.

Caution:
Do not use the capillary tube for carrying and do not bend it. Do not loosen the
connection between capillary tube and remote seal. Deposits may not be removed using
sharp objects.

Calibration according to manufacturer's instructions "Differential pressure transmitter",


section 4.

Assemble differential pressure transmitter and remote seal, tighten bolts crosswise.

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SHA 14 M --- C05 MM 100, Rev A. Page 73 of 361

Rev. A

3.1.1.3.

Gear motor for backwash rotor

Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and
make it safe. Ensure that the voltage supply to the electric consumers has been
interrupted. Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
must be drained because the debris accumulation at the filter section cannot be
monitored or discharged.
After the work is completed, restart the filter system according to section 1.3.8 of
these operating instructions.

Electric motor
Repairs according to the manufacturers instructions (see section 4, Gear motor for backwash
rotor).

Worm gear
For replacement of wear parts listed in section 3.2.3 as well as to check and adjust the slip
clutch of the worm gear, see the manufacturers instructions in section 4: Gear motor for
backwash rotor.

Caution:
Do not increase the torque of the slip clutch of the gear motor without consulting
TAPROGGE Service Department.

Rotation monitoring switch


For replacement of parts as well as for the electrical function test and adjustment of the rotation
monitoring switch, see electrical documentation (see section 5) and manufacturers instructions
(section 4, Gear motor for backwash rotor).

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SHA 14 M --- C05 MM 100, Rev A. Page 74 of 361

Rev. A

3.1.1.4.

Pneumatic actuator of the discharge valve

(see drawing K2009/20/1367-0502)


The pneumatic actuator has no wear parts and should be completely replaced in case of
defect.

Caution:
As long as the discharge valve is closed the debris accumulated cannot be removed.
Therefore the filter shall be backwashed in the operating mode MANUAL before
starting maintenance work. During replacement of actuator the differential pressure
must not reach the limit value p EXCESSIVE HIGH.

Replacement and repairs according to section 4 "Pneumatic actuator discharge valve "

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SHA 14 M --- C05 MM 100, Rev A. Page 75 of 361

Rev. A

3.1.1.5.

3.1.1.5.1.

Valves

Shut-off flap of discharge valve

(see drawing K2009/20/1367-0502)

Warning:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and
make it safe. Ensure that the voltage supply to the electric actuators has been
interrupted. Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
has been drained. It is absolutely necessary to ensure that people are not exposed to
danger due to an inrush of water during maintenance work.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

To replace parts or make repairs on the valves, please proceed as follows:

Remove the pneumatic actuator of discharge valve (see section 3.1.1.4)

Drain the discharge pipe

Remove the valve from the discharge pipe

Repairs according to section 4 Shut-off flap

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SHA 14 M --- C05 MM 100, Rev A. Page 76 of 361

Rev. A

3.1.1.5.2.

Isolation valves of differential pressure measuring system

(see drawing K2009/20/1367-0501)

Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and make
it safe. Ensure that the voltage supply to the electric actuators has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
must be drained.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

Replace the wear parts (section 3.2.4) or perform repairs according to section 4 Diaphragm
valve

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SHA 14 M --- C05 MM 100, Rev A. Page 77 of 361

Rev. A

3.1.1.5.3.

Filter drain valve

Warning:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and
make it safe. Ensure that the voltage supply to the electric actuators has been
interrupted. Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
has been drained.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

Replace the wear parts (section 3.2.4) or perform repairs according to section 4 Diaphragm
valve

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SHA 14 M --- C05 MM 100, Rev A. Page 78 of 361

Rev. A

3.1.1.6.

Control panel

Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and make
it safe. Ensure that the voltage supply to the electric actuators has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the filter must run in emergency actuation according to section 1.3.5.4.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

The control panel contains no wear parts. Signal lamps are spare parts and are included in the
control panel.
For repairs of the electrotechnical components see the electrical documentation, section 5 and
the manufacturers' instructions, section 4.

Originator

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Date

Lang.

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SHA 14 M --- C05 MM 100, Rev A. Page 79 of 361

Rev. A

3.1.2.

PREVENTIVE MAINTENANCE SCHEDULE

DESCRIPTION
ITEM No.
PARTICIPANT

UNIT

SYSTEM

COMPONENT

SEQUENCE

FUNCTION

NUMBER

PERIO
D

ACTION

SPARES
REQUIREMENT

REFERENCE PROCEDURE

TAPROGGE

12/13/14 PAB41/42

AT

010

filter housing
(Debris filter)

coating of housing, external damage,


signs of corrosion

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB41/42

AT

010

sealings (Debris
filter)

tightness of flange connections

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB41/42

AT

010

bearing (Debris
filter)

tightness of bearing (check by means


of indicator hoses)

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB41/42

AT

010

rotor actuation
(Debris filter)

movability : filter backwash in the


operating mode MANUAL (section
1.3.5.3) differential pressure must
drop

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB41/42

AT

010

rotor actuation
(Debris filter)

3Y

tighness of planetary reduction gear

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB41/42

AT

010

filter section,
backwash rotor
and backwash
pipe (Debris
filter)

3Y

fastening of internals, rubberlining of


internal filter housing, damage of
internal parts

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB41/42

AT

010

drain valve
(Debris filter)

coating, external damage, signs of


corrosion, internals

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB41/42

AT

010

drain valve
(Debris filter)

movability of actuation

SHA/14/M/---C05/MM/001

TAPROGGE

12/13/14 PAB41/42

AT

010

drain valve
(Debris filter)

tightness of flange connections

SHA/14/M/---C05/MM/001

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SHA 14 M --- C05 MM 100, Rev A. Page 80 of 361

Rev. A
DESCRIPTION

PERIO
D

entire differential
pressure
measuring
system
isolation valves
(Differential
pressure
measuring
system)
isolation valves
(Differential
pressure
measuring
system)
isolation valves
(Differential
pressure
measuring
system)
flushing valves
with flushing
rings (Differential
pressure
measuring
system)
flushing valves
with flushing
rings (Differential
pressure
measuring
system)
flushing valves
with flushing
rings (Differential
pressure
measuring
system)

proper function, cleaning of


differential pressure measuring
system, tightness

SHA/14/M/---C05/MM/001

coating, external damage, signs of


corrosion, internals

SHA/14/M/---C05/MM/001

movability of actuation

SHA/14/M/---C05/MM/001

tightness of flange connections

SHA/14/M/---C05/MM/001

external damage, signs of corrosion

SHA/14/M/---C05/MM/001

movability of actuation

SHA/14/M/---C05/MM/001

tightness of flange connections and


screwed-in connections

SHA/14/M/---C05/MM/001

ITEM No.
PARTICIPANT

UNIT

SYSTEM

COMPONENT

SEQUENCE

FUNCTION

NUMBER

TAPROGGE

12/13/14 PAB41/42

CP

010

TAPROGGE

12/13/14 PAB41/42

CP

010

TAPROGGE

12/13/14 PAB41/42

CP

010

TAPROGGE

12/13/14 PAB41/42

CP

010

TAPROGGE

12/13/14 PAB41/42

CP

010

TAPROGGE

12/13/14 PAB41/42

CP

010

TAPROGGE

12/13/14 PAB41/42

CP

010

ACTION

SPARES
REQUIREMENT

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SHA 14 M --- C05 MM 100, Rev A. Page 81 of 361

REFERENCE PROCEDURE

Rev. A

DESCRIPTION

PERIO
D

remote seals
with capillary
tubes
(Differential
pressure
measuring
system)
electric motor
(Gear motor for
backwash rotor)

fastening, tightness

SHA/14/M/---C05/MM/001

coating, cleanliness, external


damage, signs of corrosion,
operability and movability: proper
cable connection + quiet running,
compare setting current of manual
motor starter with nominal current of
motor
setting of the motor controller for soft
starting

SHA/14/M/---C05/MM/001

cleanliness, quiet running, tightness,


coating

SHA/14/M/---C05/MM/001

circumferential backlash, torque of


slip clutch

SHA/14/M/---C05/MM/001

3Y

wear of worm gear

SHA/14/M/---C05/MM/001

function test

SHA/14/M/---C05/MM/001

function test

SHA/14/M/---C05/MM/001

coating, external damage, signs of


corrosion, internals

SHA/14/M/---C05/MM/001

movability of actuation, tightness of


flange connections

SHA/14/M/---C05/MM/001

ITEM No.
PARTICIPANT

UNIT

SYSTEM

COMPONENT

SEQUENCE

FUNCTION

NUMBER

TAPROGGE

12/13/14 PAB41/42

CP

010

TAPROGGE

12/13/14 PAB41/42

AT

010

TAPROGGE

12/13/14 PAB41/42

AT

010

TAPROGGE

12/13/14 PAB41/42

AT

010

TAPROGGE

12/13/14 PAB41/42

AT

010

TAPROGGE

12/13/14 PAB41/42

AT

010

TAPROGGE

12/13/14 PAB41/42

AT

010

TAPROGGE

12/13/14 PAB41/42

AT

010

TAPROGGE

12/13/14 PAB41/42

AA

015

TAPROGGE

12/13/14 PAB41/42

AA

015

electric motor
(Gear motor for
backwash rotor)
gear (Gear
motor for
backwash rotor)
gear (Gear
motor for
backwash rotor)
gear (Gear
motor for
backwash rotor)
rotation
monitoring
switch (Gear
motor for
backwash rotor)
manual
emergency
actuation (Gear
motor for
backwash rotor)
shut-off flap
(Discharge
valve)
shut-off flap
(Discharge
valve)

ACTION

SPARES
REQUIREMENT

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Date

Lang.

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SHA 14 M --- C05 MM 100, Rev A. Page 82 of 361

REFERENCE PROCEDURE

SHA/14/M/---C05/MM/001

Rev. A

DESCRIPTION
ITEM No.
PARTICIPANT

UNIT

SYSTEM

COMPONENT

SEQUENCE

FUNCTION

NUMBER

TAPROGGE

12/13/14 PAB41/42

AA

015

TAPROGGE

12/13/14 PAB41/42

AA

015

TAPROGGE

12/13/14 PAB41/42

AA

015

TAPROGGE

12/13/14 PAB41/42

GH

TAPROGGE

12/13/14 PAB41/42

TAPROGGE

12/13/14 PAB41/42

PERIO
D

ACTION

SPARES
REQUIREMENT

REFERENCE PROCEDURE

pneumatic
actuator
(Discharge
valve)
pneumatic
actuator
(Discharge
valve)

coating, external damage, tightness,


cleanliness

SHA/14/M/---C05/MM/001

SHA/14/M/---C05/MM/001

001

Switching and
signalling device
(Discharge
valve)
control panel

operability, tightening of pneumatic


and electrical connection, tightening
of fastening screws between actuator
and valve, adjustments: final positions
+ limit switches + mechanical position
indicator
operability

SHA/14/M/---C05/MM/001

GH

001

control panel

GH

001

control panel

2Y

lamp for common alarm (by the


function key on control panel door)
external damage, cleanliness,
terminal connections, check
adjustable times, proper function of
control (in the operating mode
AUTOMATIC)
replace battery of PLC (if existing),
replace battery of OP (if existing)

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SHA/14/M/---C05/MM/001

SHA/14/M/---C05/MM/001

SHA/14/M/---C05/MM/001

Rev. A

3.1.3.
PARTICIPANT

LUBRICATION INSTRUCTIONS AND SCHEDULE


EQUIPMENT

ITEM No.
UNIT

Taprogge

Filter system

SYSTEM

12/13/14 PAB41/42

PARTS TO BE
LUBRICATED
COMPONENT
FUNCTION

SEQUENCE
NUMBER

AT

010

PERIO
D

NUMBER OF
LUBRICATION

LUBRICANT

POINTS

REF 1

REF 2

REF 3

ARAL Degol
GS220

BP Enersyn
SG-XP220

Mobil
Glygoyle
HE460

Worm gear of gear


motor (hexagon
head screw plug)

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Lang.

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SHA 14 M --- C05 MM 100, Rev A. Page 84 of 361

QUANTITY

DRAIN
FREQUENCY

1025 ccm

3Y (exchange)

Rev. A

3.1.4.

SPECIAL TOOLING AND HANDLING DEVICES

Tools for Maintenance

Part name

Material

crank handle 160-B14-D

*)

GGG

shaft crown

*)

1.4301

socket wrench for shaft nut WSS 160

*)

steel

see also section 4, Gear motor for backwash rotor, drawing 1/20/0143-0286

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SHA 14 M --- C05 MM 100, Rev A. Page 85 of 361

Rev. A

3.1.5.

STORAGE INSTRUCTIONS

Storage of parts

Caution:
The packing is prepared for a life of 6 or 24 months.
A storage below 5 C (41 F), in particular of rubberlined parts, is not admissible.
The packing is not suitable for outdoor storage.
Parts which cannot be immediately installed shall be stored in dry and lockable rooms.

Delivery

covered with foil in


boxes or on pallets

Inspection

packing

Frequency of
inspections
every 3 months

provide packing (not


splash-proof) with waterrepellent covering
close or repair damaged
packing

(maximum storage 6
months)
in sealed vinyl cover in
boxes

Remarks

packing

every 6 months

(maximum storage 24
months)

provide packing (not


splash-proof) with waterrepellent covering
in case of open packing:
reseal cover

moisture indicator
(if applicable)

every 6 months

desiccant

every 6 months

check moisture indicator

renew desiccant

Note:
Parts which are not sealed in vinyl cover shall be removed from packing and stored in
dry rooms. If parts cannot be stored as indicated please inform the TAPROGGE Service
Department.

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SHA 14 M --- C05 MM 100, Rev A. Page 86 of 361

Rev. A

Disposal of packing material

Note:
Our products are protected for the transport ex works by environmentally friendly
materials (wood, cardboard, paper and PE foil) which can easily be separated and
recycled according to local regulations.

3.1.6.

PRESERVATION INSTRUCTIONS

See sections 1.3.6 and 1.3.7.

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Date

Lang.

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SHA 14 M --- C05 MM 100, Rev A. Page 87 of 361

Rev. A

3.2. CORRECTIVE MAINTENANCE INSTRUCTIONS

Wear part

3.2.1.

Drawing no.

Position

Replacement frequency

Debris filter

(12/13/14PAB41AT010 / 12/13/14PAB42AT010)

Backwash rotor
head piece

K2009/20/1367-0503

5.4

every 3 years

Backwash pipe
flange
bearing housing

6.2
K2009/20/1367-0503

6.4

o-ring

every 3 years

6.5

Rotor actuation
washer
cardan joint

7.18
K2009/20/1367-0503

7.22/7.23

bush

7.25

spring pin

7.28

washer

7.29

securing for bolts and nuts

7.32

corrosion protection

7.38

surface seal

7.43

every 3 years

Inspection hole
gasket

K2009/20/1367-0503

8.3
8.4

with every opening, after 3 years


latest

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SHA 14 M --- C05 MM 100, Rev A. Page 88 of 361

Rev. A

Wear part

Drawing no.

Position

K2009/20/1367-0503

11.3

Replacement frequency

Bearing
groove ball bearing
needle bearing

11.8

wiper

11.6
11.9
11.10
11.11

o-rings

every 3 years, after 5000 rotor


operation hours latest (see
running time meter at the control
panel)
every 3 years or in case of
leakages at the indicator hoses
(11.19, 11.20), after 5000 rotor
operation hours latest (see
running time meter at the control
panel). In order to check sealing
of bearing see section 3.1.1.1.5!

V-Seal

11.14

wearing ring

11.21

every 3 years or if shortened by


approximately 0.5 0.8 mm due
to wear

special-purpose grease

11.26

securing for bolts and nuts

every 3 years, or after every


disassembly

11.28

sealing adhesive

11.29

sealing tape

11.32

adhesive

11.33

surface seal

11.12

3.2.2.

Differential pressure measuring system

(12/13/14PAB41CP010 / 12/13/14PAB42CP010)
none

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SHA 14 M --- C05 MM 100, Rev A. Page 89 of 361

Rev. A

Wear part

3.2.3.

Drawing no.

Position

Replacement frequency

Gear motor for backwash rotor 1)

Worm wheel
Set of wear parts V1:

K2009/20/13670503

worm wheel rim

(see section 4)

every 3 years
20

worm shaft

38

groove ball bearing

53, 91

oil
Set of wear parts V2:

K2009/20/13670503

worm wheel hub

(see section 4)

every 3 years
22

thrust ring

23

parallel key

95

Set of wear parts V3:


shaft seal

1)

K2009/20/13670503
(see section 4)

every 3 years
61,97,157

During replacing wear parts of the gear motor or spare part electric motor please note the
indication of the running time meter and the reverse operation counter of backwash rotor as
additional information (see operating record section 1.3.9)

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SHA 14 M --- C05 MM 100, Rev A. Page 90 of 361

Rev. A

Wear part

3.2.4.

Drawing no.

Position

Replacement frequency

Valves

(12/13/14PAB41AA015 / 12/13/14PAB42AA015)

Shut-off flap
none

Diaphragm valve
diaphragm

see section 4

443

every 5 years

Note:
See disassembled material to a sound disposal or to separate recycling according to
materials. Observe the national regulations for waste disposal.
After the end of the service life, old rubberlined system parts can be recycled easily via
valuable metal recycling companies (smelting).

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Date

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SHA 14 M --- C05 MM 100, Rev A. Page 91 of 361

Rev. A

4.

ACCESSORIES
KKS

MATERIAL / TYPE

SUPPLIER

12/13/14PAB41CP010
12/13/14PAB42CP010

Differential pressure transmitter / 1151 DP 4 S

Emerson

12/13/14PAB41CP010
12/13/14PAB42CP010

Remote seal / 1199

Emerson

12/13/14PAB41AT010
12/13/14PAB42AT010

Gear motor for backwash rotor (incl. slip clutch and rotation monitoring
switch) / 80.1

Rhein-Getriebe

12/13/14PAB41AA015
12/13/14PAB42AA015

Pneumatic actuator of discharge valve / EB12-DW

Ebro

12/13/14PAB41AA301
12/13/14PAB41AA302
12/13/14PAB42AA301
12/13/14PAB42AA302

Diaphragm valve / SISTO KB

KSB

12/13/14PAB41AA015
12/13/14PAB42AA015

Shut-off flap / F012-A

Ebro

12/13/14PAB41GH001

Programmable logic controller /

Allen Bradley

12/13/14PAB41GH001

Operator Terminal /

Allen Bradley

12/13/14PAB41GH001

Analogue data repeater /

Turck

12/13/14PAB41GH001

Isolating switching amplifier /

Turck

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SHA 14 M --- C05 MM 100, Rev A. Page 92 of 361

Rev. A

5. DRAWING AND PART LISTS


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

Taprogge Index no.


K2009/20/1367-0001
K2009/20/1367-0505
K2009/20/1367-0503
K2009/20/1367-0060
K2009/20/1367-0020
K2009/20/1367-0501
K2009/20/1367-0502

SHA/14/M/---C05/WD/001
SHA/14/M/---C05/DS/001

K2009/20/1367-1000

SHA/14/M/---C05/DS/002
SHA/14/M/---C05/DS/003
SHA/14/M/---C05/DS/004
SHA/14/M/---C05/DS/005

Title
Flow Diagram
Assembly debris filter
Debris filter PR-BW 800
Filter section
Inspection hole
Differential pressure measuring system
Discharge valve
Electrical documentation of control
panel
Data sheet Condenser Debris filter
Data sheet LV Motor Condenser
Debris filter
Data sheet Valves Condenser Debris
filter
Data sheet Pr. Transmitter Condenser
Debris filter
Data sheet Actuator Condenser Debris
filter

Originator

Identification number

Rev.

Date

Lang.

Sheet

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SHA 14 M --- C05 MM 100, Rev A. Page 93 of 361

16.09.2009

Schmidlin

Gller

Neugebauer

First issue

FUS

REV

DATE

PREPARED

CHECKED

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DD

Title :

Sectional drawing of Condenser


Debris Filter with parts list

Language
:E

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 8

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/DD/001

SHA 14 M --- C05 MM 100, Rev A. Page 94 of 361

Stand/Status: 11.12.2007
Erstellt/prepared: 16.09.2009/Bo

Blatt/Sheet: 1/4

TL2009201367.xls

TEILELISTE / PARTS LIST


FILTER PR-BW 800
Dokumenten-Nr. / Document No.
entstanden aus / originating from:
zugehrige Zeichnung / relevant drawing:
entstanden aus / originating from:

Pos.
Pos.

Part name

Benennung

Stk
No

QA2008/20/1367-0030
4/20/0150-0109

K2008/20/1367-0503
Sach-Nr.
Ident-No.

Bemerkungen
Remarks

FILTER

FILTER

FILTER GEHUSE

FILTER HOUSING

FILTEREINSATZ
Lagerblock
Halter
Absttzung
Absttzung
Filterelement
Sechskantschraube
Sechskantmutter
Scheibe
Dichtung
Ausgleichblech
Dichtung
Scheibe
Kleber
Schraubensicherung
Sechskantschraube
Scheibe
Sechskantmutter
Sechskantschraube
Scheibe
Scheibe
Sechskantmutter
Sechskantschraube

FILTER SECTION
Bearing block
Bracket
Support
Support
filter element
Hexagon bolt
Hexagon nut
Washer
Gasket
Adjusting sheet
Gasket
Washer
Adhesive
Securing for bolts and nuts
Hexagon bolt
Washer
Hexagon nut
Hexagon bolt
Washer
Washer
Hexagon nut
Hexagon bolt

K2009/20/1367-0060

RCKSPLROTOR
Rotorgehuse
Splstutzen
Kopfleiste
Randwinkel
Randwinkel
Blech
Zylinderstift
Zylinderstift
Sechskantschraube
Sechskantschraube
Sechskantschraube
Sechskantschraube
Sechskantmutter
Scheibe
Scheibe
Schraubensicherung

BACKWASH ROTOR
Rotor housing
Backwash nozzle
Head piece
Border angle
Border angle
Sheet
Parallel pin
Parallel pin
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon nut
Washer
Washer
Securing for bolts and nuts

1/20/0145-0052

4
4.1
4.2
4.3
4.4
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.21
4.22
4.25
4.26
4.27
4.28
4.29

1
1
12
12
12
12
12
12
12
12
12
12
12
1
1
24
120
84
12
48
24
12
60

5
5.1
5.2
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.13
5.14
5.15
5.16
5.17
5.20

1
1
1
1
2
2
1
2
2
12
10
5
14
10
12
14
1

R
R
R
R
R
R
R
R

R
R
R
R
R
R
R

R = Reserveteil/Spare part
V = Verschleiteil/Wear part

SHA 14 M --- C05 MM 100, Rev A. Page 95 of 361

Stand/Status: 11.12.2007
Erstellt/prepared: 16.09.2009/Bo

Blatt/Sheet: 2/4

TL2009201367.xls

TEILELISTE / PARTS LIST


FILTER PR-BW 800
Dokumenten-Nr. / Document No.
entstanden aus / originating from:
zugehrige Zeichnung / relevant drawing:
entstanden aus / originating from:

Pos.
Pos.

Benennung

Stk
No

6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22

1
1
1
1
1
1
1
6
8
3
2

7
7.1
7.2
7.3
7.4
7.5
7.8
7.9
7.10
7.11
7.12
7.13
7.15
7.16
7.17
7.18
7.19
7.20
7.21
7.22
7.23
7.24

1
1
1
1
1
1
1
1
2
1
1
8
8
8
12
8
4
4
8
1
1
16

V
V
V
R
R

4 R
1 R
1
4
1 R
2
2 R
4 R
4
4 R
4
8

RCKSPLLEITUNG
Splleitung
Flansch
Lagerflansch
Lagergehuse
O-Ring
O-Ring
Sechskantschraube
Scheibe
Gewindestift
Gewindestange
Sechskantschraube
Dichtung
Schraubensicherung
Sechskantmutter
Schraubensicherung
Absttzung
Dichtung
Sechskantschraube
Scheibe
Sechskantschraube
Sechskantmutter
Scheibe

ROTORBETTIGUNG
R Planetengetriebe
Getriebegehuse
Durchfhrung
Dichtungsscheibe
Laterne
R Welle
Zwischenflansch
R O-Ring
R O-Ring
R O-Ring
R Sechskantschraube
R Stiftschraube
Sechskantmutter
R Sechskantschraube
V Scheibe
R Sechskantschraube
R Sechskantmutter
R Stiftschraube
V Wellengelenk
V Wellengelenk
Sechskantmutter

R = Reserveteil/Spare part
V = Verschleiteil/Wear part

Part name

QA2008/20/1367-0030
4/20/0150-0109

K2008/20/1367-0503
Sach-Nr.
Ident-No.

Bemerkungen
Remarks

BACKWASH PIPE
Backwash pipe
Flange
Bearing flange
Bearing housing
O-ring
O-ring
Hexagon bolt
Washer
Slotted set screw
Threaded rod
Hexagon bolt
Gasket
Securing for bolts and nuts
Hexagon nut
Securing for bolts and nuts
Support
Gasket
Hexagon bolt
Washer
Hexagon bolt
Hexagon nut
Washer

1/20/0144-0063

ROTOR ACTUATION
planetary reduction gear
Gear housing
Pipe channel
Seal washer
Lantern
Shaft
Intermediate flange
O-ring
O-ring
O-ring
Hexagon bolt
Stud
Hexagon nut
Hexagon bolt
Washer
Hexagon bolt
Hexagon nut
Stud
Cardan joint
Cardan joint
Hexagon nut

1/20/0143-0236

SHA 14 M --- C05 MM 100, Rev A. Page 96 of 361

Stand/Status: 11.12.2007
Erstellt/prepared: 16.09.2009/Bo

Blatt/Sheet: 3/4

TL2009201367.xls

TEILELISTE / PARTS LIST


FILTER PR-BW 800
Dokumenten-Nr. / Document No.
entstanden aus / originating from:
zugehrige Zeichnung / relevant drawing:
entstanden aus / originating from:

Pos.
Pos.

7.25
7.26
7.27
7.28
7.29
7.30
7.31
7.32
7.33
7.38
7.39
7.40
7.42
7.43
7.46
7.47
7.48
7.49
7.51
7.52
7.53
7.54
7.55
8
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.8
8.10
8.11
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8

Benennung

Stk
No

1
16
1
2
1
4
2
1
1
1
1
1
2
1
1
1
2
4
4
4
4
2
4

V
R
V
V
R
R
V
V
R
R
R
V

R
R

4/20/0150-0109

K2008/20/1367-0503
Sach-Nr.
Ident-No.

Bemerkungen
Remarks

Buchse
Scheibe
Dichtung
Schwerspannstift
Scheibe
Schwerspannstift
Zylinderstift
Schraubensicherung
Getriebefett
Korrosionsschutz
Schlauch, wei
Schlauch, rot
Gerader Verbinder
Flchendichtung
Schlauchmanschette
Anschlustck

Bush
Washer
Gasket
Spring pin
Washer
Spring pin
Parallel pin
Securing for bolts and nuts
Gear grease
Corrosion protection
Hose, white
Hose, red
Connector
Surface seal
Collar
Connection piece
Gerade Einschraubverschraubung Pipe union
Verschluschraube
Hexagon head screw plug
Stiftschraube
Stud
Sechskantmutter
Hexagon nut
Scheibe
Washer
Schutzschlauch
Protection hose
Schwerspannstift
Spring pin

INSPEKTIONSFFNUNG
rund
1
Flanschstutzen
1
Deckel
1 V Dichtung
1 V Dichtung
1
Bolzen
3
Scheibe
1
Splint
20
Sechskantschraube
40
Scheibe
20
Sechskantmutter
1
Schraubensicherung
1
1
1
1
1
1
1
1
1

Part name

QA2008/20/1367-0030

LAGERUNG
Rotorwelle
Distanzring
Rillenkugellager
Dichtungstrger
Gleitbuchse
V Abstreifer
Distanzring
V Nadellager
R
R
V
R

R = Reserveteil/Spare part
V = Verschleiteil/Wear part

INSPECTION HOLE
round
Flange nozzle
Cover
Gasket
Gasket
Clevis pin
Washer
Split pin
Hexagon bolt
Washer
Hexagon nut
Securing for bolts and nuts

K2009/20/1367-0020

BEARING
Rotor shaft
Distance ring
Groove ball bearing
Seal housing
Slide bush
Wiper
Distance ring
Needle bearing

1/20/0142-0091

SHA 14 M --- C05 MM 100, Rev A. Page 97 of 361

Stand/Status: 11.12.2007
Erstellt/prepared: 16.09.2009/Bo

Blatt/Sheet: 4/4

TL2009201367.xls

TEILELISTE / PARTS LIST


FILTER PR-BW 800
Dokumenten-Nr. / Document No.
entstanden aus / originating from:
zugehrige Zeichnung / relevant drawing:
entstanden aus / originating from:

Pos.
Pos.

11.9
11.10
11.11
11.12
11.13
11.14
11.15
11.16
11.17
11.18
11.19
11.20
11.21
11.22
11.23
11.24
11.25
11.26
11.27
11.28
11.29
11.30
11.31
11.32
11.33
11.34

Benennung

Stk
No

3
2
1
1
1
1
3
2
3
2
1
1
1
1
12
9
6
1
1
1

V
V
V
V
R
V
R

Part name

4/20/0150-0109

K2008/20/1367-0503
Sach-Nr.
Ident-No.

Bemerkungen
Remarks

O-Ring
O-Ring
O-Ring
Flchendichtung
Wellenmutter
V-Seal
Sechskantschraube
Zylinderstift
R Sechskantschraube
R
R
V
R
R
R
R
V
V

1 V

1
3 R
1 V
1 V
3 R

O-ring
O-ring
O-ring
Surface seal
Slotted round nut
V-Seal
Hexagon bolt
Parallel pin
Hexagon bolt
Gerade Einschraubverschraubung Pipe union
Schlauch, wei
Hose, white
Schlauch, rot
Hose, red
Verschleiring
Wearing ring
Verschluschraube
Hexagon socket screw plug
Zylinderschraube
Hexagon socket head cap screw
Sechskantmutter
Hexagon nut
Scheibe
Washer
Spezialfett
Special-purpose grease
Mehrzweckfett
Multi-purpose grease
Schraubensicherung
Securing for bolts and nuts
Dichtkleber
Sealing adhesive
Lagertrger
Bearing housing
Zylinderschraube
Hexagon socket head cap screw
Dichtungsband
Sealing tape
Kleber
Adhesive
Sechskantschraube
Hexagon bolt

QA2008/20/1367-0030

Kopfhhe der Schraube auf k=4 mm


verkrzen (abplanen) / Shorten
(plane) screwhead down to k=4 mm

11.35
11.36
11.39
11.40
11.41

1R
3R
2R

2
3

Sicherungsring
Stiftschraube
Gerader Verbinder
Schutzschlauch
Dichtung

R = Reserveteil/Spare part
V = Verschleiteil/Wear part

Retaining ring
Stud
Connector
Protection hose
Gasket

SHA 14 M --- C05 MM 100, Rev A. Page 98 of 361

Stand/Status: 27.07.2009
Erstellt/prepared: 16.09.2009/Bo

Blatt/Sheet: 1/1

TL2009201367.xls

TEILELISTE / PARTS LIST


DIFFERENZDRUCK-MESYSTEM /
DIFFERENTIAL PRESSURE MEASURING SYSTEM
Dokumenten-Nr. / Document No.

QA2008/20/1367-0031
4/00/0983-0926

entstanden aus / originating from:


zugehrige Zeichnung / relevant drawing:

K2008/20/1367-0501
1/15/0005-0285

entstanden aus / originating from:

Pos.
Pos.

Part name

Benennung

Stk
No

DIFFERENZDRUCKMESYSTEM
Emerson-MD03

Bemerkungen
Remarks

DIFFERENTIAL PRESSURE
MEASURING SYSTEM
Emerson-MD03

1 R Differenzdrucktransmitter
Typ Rosemount 1151 DP4

Differential pressure transmitter


type Rosemount 1151 DP4

Druckmittler

Remote seal

Druckmittler

Remote seal

Kapillarrohr

Capillary tube

2 R Membranschieber
1 V Membrane

Diaphragm valve
Diaphragm

2 R Dichtung

Gasket

Sechskantschraube

Hexagon bolt

Sechskantmutter

Hexagon nut

16

Scheibe

Washer

R = Reserveteil/Spare part
V = Verschleiteil/Wear part

Sach-Nr.
Ident-No.

SHA 14 M --- C05 MM 100, Rev A. Page 99 of 361

eingestellter Mebereich /
adjusted measuring range
- 10 - + 360 mbar

in Pos. 5 enthalten/included in pos. 5

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

SHA 14 M --- C05 MM 100, Rev A. Page 101 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 102 of 361

16.09.2009

Schmidlin

Gller

08.09.2009

Schmidlin

Gller

19.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
Neugebauer
APPROVED

Updated

FUS

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
IO

Title :

Condenser Debris Filter

Language
:E

Signal Exchange List

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/IO/001

SHA 14 M --- C05 MM 100, Rev A. Page 103 of 361

signals
s - Instrument
Instrumentation
List for iinput/output
nput/output signal
ation Setpoint - Debris Filters 12/13/14PAB41AT010 & 12/13/14PAB42AT010

R
e
v

Sensor / Signal number

Service description

Typical
connection
diagram

I/O
information
for the DCS

Measurement
range
(mbar)
Min.

12 PAB41

EA101

DF1 ALARM

BI

yes

12 PAB41

EA102

DF1 FLUSHING

BI

yes

12 PAB41

EA103

DF1 ON

BI

12 PAB41

EA104

DF1 OFF

13 PAB41

EA101

DF2 ALARM

13 PAB41

EA102

DF2 FLUSHING

BI

yes

13 PAB41

EA103

DF2 ON

BI

13 PAB41

EA104

DF2 OFF

BI

14 PAB41

EA101

DF3 ALARM

BI

yes

14 PAB41

EA102

DF3 FLUSHING

BI

yes

14 PAB41

EA103

DF3 ON

BI

14 PAB41

EA104

DF3 OFF

12 PAB42

EA101

12 PAB42

12 PAB42

Set
point
(mbar)

Process
unit

Event &
Alarm
coding

Signal
user

specif

Max.

EC1

C05

EC0

C05

yes

EC0

C05

BI

yes

EC0

C05

BI

yes

EC1

C05

EC0

C05

yes

EC0

C05

yes

EC0

C05

EC1

C05

EC0

C05

yes

EC0

C05

BI

yes

EC0

C05

DF4 ALARM

BI

yes

EC1

C05

EA102

DF4 FLUSHING

BI

yes

EC0

C05

EA103

DF4 ON

BI

yes

EC0

C05

12 PAB42

EA104

DF4 OFF

BI

yes

EC0

C05

13 PAB42

EA101

DF5 ALARM

BI

yes

EC1

C05

13 PAB42

EA102

DF5 FLUSHING

BI

yes

EC0

C05

13 PAB42

EA103

DF5 ON

BI

yes

EC0

C05

13 PAB42

EA104

DF5 OFF

BI

yes

EC0

C05

14 PAB42

EA101

DF6 ALARM

BI

yes

EC1

C05

14 PAB42

EA102

DF6 FLUSHING

BI

yes

EC0

C05

14 PAB42

EA103

DF6 ON

BI

yes

EC0

C05

14 PAB42

EA104

DF6 OFF

BI

yes

EC0

C05

-10

-10

-10

-10

-10

-10

360

360

360

360

360

360

90

90

90

90

90

90

SHA 14 M --- C05 MM 100, Rev A. Page 104 of 361

Comment

08.09.2009

Schmidlin

Gller

26.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
APPROVED

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems

Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Title :

Language
:E
Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
LC

Cable Schedule
Condenser Debris Filter

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

SHA/14/M/---C05/LC/001

Client Document No. :

SHA/14/M/---C05/ LC/001

SHA 14 M --- C05 MM 100, Rev A. Page 105 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 106 of 361

27.07.2009

Schmidlin

Gller

10.07.2009

Schmidlin

Gller

03.07.2009

Schmidlin

Gller

06.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
Neugebauer
Neugebauer

Revised according to customer comments

FUS

Revised according to customer comments

FUS

Revised according to customer comments

FUS

First issue

FUS

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
EL

Title :

Condenser Debris Filter

Language
:E

Electrical Load List

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

SHA/14/M/---C05/EL/001

Client Document No. :

SHA/14/M/---C05/ EL/001

SHA 14 M --- C05 MM 100, Rev A. Page 107 of 361

ELECTRICAL LOAD LIST - C05


R
E
V

Functional number
of the electrical
auxiliary

Unit

System

Equipment

Designation
of the driven machine
or of the electrical auxiliary

Load
type

Rated
volt.
V

Voltage

Consumer
type

Nature

Red
und
ancy
(Y/N)

Std
Inter
face
(Y/N)

Rated

Rated
power
factor

power

Rated
eff.

SC
/
FLC

Star
ting
time
(s)

kW/
kVA

Load
conn
diag

Local
Fuse
(A)

Loc.

Load
Term
panel

D
u
t
y
(1)

Feeding
Cubicle

Mechanical absorbed power


During
Stop of
the Unit

At Startup of the
Unit

During
normal
running

D
I
E
S
E
L

U
P
S

SIGNAL EXCHG WITH


DCS FOR INDICATION /
Supplied internally via
control panel
Supplied internally via
control panel

IFU
D

12/13/14PAB41AT010

12/13/14 PAB41

AT010

12/13/14PAB41AA015

12/13/14 PAB41

AA015

MN CW DEBRIS FILTER 1 MOTOR


MN CW DEBRIS FILTER 1 DISCHARGE
VALVE

12/13/14PAB41GH001

12/13/14 PAB41

GH001

CONTROL PANEL

12/13/14PAB41GH001B

12/13/14 PAB41

GH001B

CONTROL PANEL UPS

12/13/14PAB41GH001C

12/13/14 PAB41

GH001C

CONTROL PANEL UPS

460 AC TRI 60 Hz
IFU
IFU
IFU
IFU

3 kw

B63/400

14PAB41GS100

0,01 kw

B63/400

14PAB41GS100

8 kw

B63/400

14PAB41GS100

120 AC MONO 60 Hz L

0,25 kw

B63/400

14PAB41GS100

120 AC MONO 60 Hz L

0,25 kw

B63/400

14PAB41GS100

24 DC
460 AC TRI 60 Hz

IFU
D

12/13/14PAB42AT010

12/13/14 PAB42

AT010

12/13/14PAB42AA015

12/13/14 PAB42

AA015

MN CW DEBRIS FILTER 2 MOTOR


MN CW DEBRIS FILTER 2 DISCHARGE
VALVE

460 AC TRI 60 Hz
IFU

24 DC

3 kw

0,01 kw

SHA 14 M --- C05 MM 100, Rev A. Page 108 of 361

B63/400

14PAB41GS100

B63/400

14PAB41GS100

Comments

To be supplied by client
X

To be supplied by client

To be supplied by client
SIGNAL EXCHG WITH
DCS FOR INDICATION /
Supplied internally via
control panel
Supplied internally via
control panel

Scope

Package
no.

C05
C05
C05
C05
C05

C05
C05

AT010

SHA 14 M --- C05 MM 100, Rev A. Page 109 of 361

22.06.2010

Schmidlin

Gller

01.06.2010

Schmidlin

Gller

19.02.2010

Schmidlin

Gller

30.11.2009

Schmidlin

Gller

28.08.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
Neugebauer
Neugebauer
Neugebauer

Integration of clients comments

FUS

Integration of clients comments

FUS

Integration of clients comments

FUS

Integration of clients comments

FUS

First issue

FUS

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
WD

Title :

Electrical and Control Cabinet /

Language
:E

Wiring Diagram

Consortium Participant or Subcontractor Document No. : N/A

abcd

for Condenser Debris Filter


No of
sheet : 45

Power Systems

Sheet :

Plants

1/45

Alstom document no :

SHA/14/M/---C05/WD/001

Client Document No. :

SHA/14/M/---C05/ WD/001

SHA 14 M --- C05 MM 100, Rev A. Page 110 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 111 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 112 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 113 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 114 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 115 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 116 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 117 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 118 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 119 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 120 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 121 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 122 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 123 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 124 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 125 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 126 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 127 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 128 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 129 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 130 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 131 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 132 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 133 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 134 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 135 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 136 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 137 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 138 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 139 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 140 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 141 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 142 of 361

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SHA 14 M --- C05 MM 100, Rev A. Page 154 of 361

02.07.

Schmidlin

Gller

12.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
APPROVED

First issue

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DM

Title :

Condenser Debris Filter

Language
:E

System Description

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 17

Power Systems

Sheet :

Plants

1
Alstom document no :

Client Document No. :

SHA/14/M/---C05/DM/001

SHA 14 M --- C05 MM 100, Rev A. Page 155 of 361

Table of Content
1.

TASK AND FUNCTION DESCRIPTION OF THE TAPROGGE FILTER SYSTEM ........................................................3


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

2
SHA 14 M --- C05 MM 100, Rev A. Page 156 of 361

1. TASK AND FUNCTION DESCRIPTION OF THE TAPROGGE FILTER SYSTEM

1.1.

Task of the TAPROGGE filter system


A TAPROGGE debris filter is installed to prevent clogging of cooling tubes and all related problems.

Fig. 2-1: Schematic Arrangement


1
Filter
2
Discharge valve
3
Discharge pipe
4
Condenser / Heat exchanger
For scope of supply please refer flow diagram SHA/14/M/---C05/FD/001.

3
SHA 14 M --- C05 MM 100, Rev A. Page 157 of 361

1.2.

Function description of the TAPROGGE filter system

Fig. 2-2: Debris filter type PR-BW 800


1
2
3
4

Filter PR-BW 800


Differential pressure measuring system
Gear motor
Discharge valve

4
SHA 14 M --- C05 MM 100, Rev A. Page 158 of 361

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

5
SHA 14 M --- C05 MM 100, Rev A. Page 159 of 361

The special performance of the debris filter is based on the concept of

PRESSURE-RELIEVED BACKWASH (PR-BW)

The PR-BW procedure works as follows (see sketches on the following page):

During the backwash procedure, the backwash rotor is moving over the entire filter section. The
debris, which had been collected in that area of the filter section which is covered by the
backwash rotor, is relieved from flow pressure. Simultaneously, the flow direction in this area
reverses and the pressure-relieved debris is flushed away by the backwash flow of the filtered
water.

The PR-BW procedure easily handles all kind of debris, especially fibrous debris which is easily
removed from the filter section.

Since the area of the filter section covered by the backwash rotor is completely isolated from the
differential pressure of the cooling water during backwashing, the debris filter is fully operational
even if it is loaded with high amount of debris.

If extremely large debris like twigs or pieces of wood block the backwash rotor, the control system
initiates the
automatic reverse of the backwash rotor
Should the backwash rotor drive against an obstacle which impedes the rotor's path, the direction
of rotor revolution is reversed automatically! The automatic reverse feature functions in each
operating mode. This results in the extraordinary operational reliability of the debris filter.

6
SHA 14 M --- C05 MM 100, Rev A. Page 160 of 361

Pressure-relieved backwash (PR-BW procedure)


FILTRATION

water flow

fibres are retained


filter section
flow pressure forces fibres and debris onto
the filter section

PRESSURE-RELIEF

freeing and lifting of fibrous debris


the covering backwash rotor causes a
pressure-relieved area
backwash rotor

FILTER BACKWASH

flow pressure relief and initial flow reversal


produced by the opened discharge valve
help to untangle and flush out fibrous
debris from the filter section.

Fig. 2-3: Backwash process

7
SHA 14 M --- C05 MM 100, Rev A. Page 161 of 361

2. DESCRIPTION OF THE FILTER SYSTEM


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

2.1.

Assembly Debris Filter

2.1.1.

Debris Filter PR-BW 800

Fig. 2-4: Debris filter type PR-BW 800


1
2
3
4
5
6

Filter housing
Filter section
Backwash rotor
Backwash pipe
Rotor actuation
Bearing

8
SHA 14 M --- C05 MM 100, Rev A. Page 162 of 361

Filter section

consists of a bearing block with radially arranged support sheets.


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

Backwash rotor

is connected to the backwash pipe 4. During the backwash


procedure, the backwash rotor successively covers each filter
segment.

Backwash pipe

Considering the pressure ratio, the diameter of the backwash


pipe is designed for the proper water discharge required for filter
backwash.

Rotor actuation

consists of the gear box flanged to the bearing block (housing of


bearing 6), a cardan shaft and the gear motor. The rotor
actuation is isolated from the cooling water.

Bearing

The bearing of the backwash rotor is equipped with multiple


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

9
SHA 14 M --- C05 MM 100, Rev A. Page 163 of 361

2.1.2.

Differential pressure measuring system

Fig. 2-5: Differential pressure measuring system


1
2
3
6
7
9

Differential pressure transmitter


Remote seal PLUS
Remote seal with capillary tube MINUS
Isolation valves
Measuring nozzles
Operator panel

10
SHA 14 M --- C05 MM 100, Rev A. Page 164 of 361

The differential pressure measuring system (p system) monitors the amount of debris on the filter
by constantly measuring the differential pressure (p).

Differential pressure transmitter 1

The differential pressure is electronically converted to a signal.

Operator panel 9

indicates:




the actual differential pressure


the programmed limit values

initiates:

signalling upon reaching or falling below


the programmed limit values

limit value 1:
(test function)

IN-SERVICE MONITORING
The proper functioning of the measuring system is electrically
monitored constantly. In the event of a fault, the differential
pressure falls below limit value IN-SERVICE MONITORING and
an alarm message will be signalled by the control system.

limit value 2:
(service function)

FILTER BACKWASH
If debris accumulates on the filter section, the differential
pressure increases. If the limit value FILTER BACKWASH is
reached, the automatic control system initiates filter
backwash, until the differential pressure falls below the pre-set
limit value.

limit value 3:
(security function)

p EXCESSIVE HIGH
If the differential pressure continues to increase in spite of the
existent backwash and reaches the limit value p EXCESSIVE
HIGH, the automatic control system continues filter backwash.
Simultaneously, a signal and an alarm message are indicated.
The customer can connect the potential free alarm from the
control panel to the control room.

11
SHA 14 M --- C05 MM 100, Rev A. Page 165 of 361

Isolation valves 6

The differential pressure measuring system can be isolated


from the cooling water flow for maintenance purposes by
means of the isolation valves.

12
SHA 14 M --- C05 MM 100, Rev A. Page 166 of 361

2.1.3.

Gear motor

The backwash rotor is operated by a special gear motor designed for 100 % continuous operation.
It is equipped with a slip clutch, which protects the backwash rotor, the actuation and the gear
motor against overload by power interruption, if a pre-set torque is exceeded.

The automatic reverse of the backwash rotor is initiated when the rotation monitoring switch has
tripped. The rotation monitoring switch is coupled to the gear motor of the backwash rotor.

13
SHA 14 M --- C05 MM 100, Rev A. Page 167 of 361

2.2.

Discharge valve
The discharge valve in this filter system is a shut-off flap operated by a specially designed part-turn
actuator (electric or pneumatic) with short running time. In the open position, the valve allows an
unrestricted flow of the debris laden water.

The part-turn actuator is equipped with limit switches signalling the end positions to the control
panel. It is also equipped with torque limit switches protecting the valve as well as the actuator
against overload.

14
SHA 14 M --- C05 MM 100, Rev A. Page 168 of 361

2.3.

Control
The control system serves to operate, control and monitor the filter system. The control is a
programmable logic controller (PLC). All control and monitoring functions required for automatic
operation (programmes) are stored in a single programme (Flashcard).
By means of a selector switch at the control panel the operating mode AUTOMATIC or MANUAL is
selected.
All further operations are effected via function keys at the operator panel.

Operating mode AUTOMATIC

The control system monitors the filter system and initiates filter backwash in any of the following
cases:


p limit value FILTER BACKWASH

control command FILTER BACKWASH from control room

function key FILTER BACKWASH

function key FILTER CONTINUOUS BACKWASH

malfunction differential pressure measuring system (intermittent backwash every 3 minutes)

function key p SYSTEM FLUSH

every 24 hours, initiated by a timer

Backwash
Backwash of the debris filter proceeds as follows:


The part-turn actuator opens the discharge valve

Simultaneously, the backwash rotor starts


The filter section is cleaned by backwashing. The debris is carried away through the
discharge pipe.

In the operating mode AUTOMATIC the actual differential pressure is processed by the
control system

After backwashing, the actual differential pressure is checked by the control system

If p < limit value FILTER BACKWASH, the backwash rotor stops and the discharge valve
closes

15
SHA 14 M --- C05 MM 100, Rev A. Page 169 of 361

Operating mode MANUAL

Note:
The operating mode MANUAL is not permitted for routine filter operation and
may be selected for commissioning and in case of trouble in the operating
mode AUTOMATIC only!

All operations are initiated by the operating personnel by means of function keys at the operator
panel.

Backwash
Filter backwash must be initiated if:


p limit value FILTER BACKWASH

p limit value p EXCESSIVE HIGH

Backwash of the debris filter shall be executed as follows:




Open the discharge valve

Start the backwash rotor


The filter section is cleaned by backwashing. The debris is carried away through the
discharge pipe.

Carefully check indication of differential pressure

If p < limit value FILTER BACKWASH:


stop the backwash rotor
close the discharge valve

16
SHA 14 M --- C05 MM 100, Rev A. Page 170 of 361

Control panel

The control panel consists of all necessary devices for ...




...

control and operation of the filter system

...

transmission of control commands between the control room and control panel

...

control and power supply to the external electrical consumers

On the control panel front are:




main switch

selector switch for operating mode AUTOMATIC / MANUAL

signal lamp for indication of common alarm

operator panel for


indication:

operation:

of the actual operational system status

of the actual differential pressure

individual alarms

running time meter of backwash rotor

reverse operation counter of the backwash rotor

limit values of the differential pressure measuring system

timers of control

information regarding trouble shooting

alternative language

execution of all operations

setting of limit values

setting of timers

selection of language

The control panel contains potential-free contacts which should be connected to the control room
by the customer.

17
SHA 14 M --- C05 MM 100, Rev A. Page 171 of 361

13.10.2009

Schmidlin

Gller

Neugebauer

First issue

FUS

REV

DATE

PREPARED

CHECKED

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

progge
SUBCONTRACTOR Ta
G e s e l l s c h a f t mb H

N/A

58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Format :
A4

Title :

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
MD

Handling drawings

Language
:E

for Debris Filters

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 3

Power Systems

Sheet :

Plants

Alstom document no :

SHA/14/M/---C05/MD/003

Client Document No. :


SHA/14/M/---C05/MD/003

SHA 14 M --- C05 MM 100, Rev A. Page 172 of 361

Rev.A

Handling instructions for Condenser Debris Filter BW 800

Lifting points

Lifting device

Weight 5900 kg

Remark: observe the maximal load of the chains and check if the chains are correctly fastened. The length of
chains must allow having an angle smaller than 60.
Originator

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

SHA/14/M/---C05/MD/003

13.10.2009

EN

2/3

ALSTOM 2006. All rights reserved.

SHA 14 M --- C05 MM 100, Rev A. Page 173 of 361

Rev.A

Handling instructions for CCW Exchanger Debris Filter BW 100

Lifting points

Lifting device

Gear motor

Weight 1100 kg

Remark: according to the length of chains, its necessary to demount the gear motor in order to avoid the
deteriorations during the handling of debris filter.
Remark: observe the maximal load of the chains and check if the chains are correctly fastened. The length of
chains must allow having an angle smaller than 60.
Originator

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

SHA/14/M/---C05/MD/003

13.10.2009

EN

3/3

ALSTOM 2006. All rights reserved.

SHA 14 M --- C05 MM 100, Rev A. Page 174 of 361

28.05.2009

Schmidlin

Gller

Neugebauer

First issue

FUS

REV

DATE

PREPARED

CHECKED

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Title :

Debris Filters

Language
:E

Lubrication Schedule

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 3

Power Systems

Sheet :

Plants

Alstom document no :

SHA/14/M/---C05/DS/100

Client Document No. :

SHA/14/M/---C05/ DS/100

SHA 14 M --- C05 MM 100, Rev A. Page 175 of 361

PARTICIPANT

EQUIPMENT

ITEM No.
UNIT

Taprogge

Filter system for


Condenser

SYSTEM

12/13/14 PAB41/42

PARTS TO BE
LUBRICATED
COMPONENT
FUNCTION

SEQUENC
E NUMBER

AT

010

Worm gear of
gear motor
(hexagon head
screw plug)

PERIOD

NUMBER OF
LUBRICATION

LUBRICANT

POINTS

REF 1

REF 2

REF 3

ARAL Degol
GS220

BP Enersyn
SG-XP220

Mobil
Glygoyle
HE460

SHA 14 M --- C05 MM 100, Rev A. Page 176 of 361

QUANTITY

DRAIN FREQUENCY

1025 ccm

3Y (exchange)

PARTICIPANT

EQUIPMENT

ITEM No.
UNIT

SYSTEM

PARTS TO BE
LUBRICATED
COMPONENT
FUNCTION

SEQUENC
E NUMBER

PERIOD

NUMBER OF
LUBRICATION

LUBRICANT

POINTS

REF 1

REF 2

REF 3

QUANTITY

DRAIN FREQUENCY

Taprogge

Filter system for


CCW Exchanger

12/13/14 PCB15/16

AT

010

bearing of
backwash
rotor, worm
wheel of
reduction gear
(worm wheel
shaft/ worm
shaft )

ARAL Aralub
HLP 2

BP
Energrease
LS-EP 2

ESSO
Beacon EP 2

500 g

3Y

Taprogge

Filter system for


CCW Exchanger

12/13/14 PCB15/16

AT

010

bearing of
backwash
rotor, rolling
bearing
120/180 x 28
(cage)

ARAL Aralub
HLP 2

BP
Energrease
LS-EP 2

ESSO
Beacon EP 2

250 g

3Y (exchange)

Taprogge

Filter system for


CCW Exchanger

12/13/14 PCB15/16

001

Gear motor for


backwash rotor
(gear housing)

ARAL
Getriebel
EP 85 W-90

ARAL Degol
BG 150 / BG
220

BP Energol
GR-XP 150 /
220

700 ccm

3Y (exchange)

Taprogge

Filter system for


CCW Exchanger

12/13/14 PCB15/16

002

gear of partturn actuator of


discharge
valve (worm
wheel / worm
shaft / manual
drive worm /
planetary
gearing)

ARAL Aralub
FDP 00

CLS Grease

DEA
Glissando
6833 EP00

300 g

3Y (exchange)

Taprogge

Filter system for


CCW Exchanger

12/13/14 PCB15/16

002

switching and
signalling
device of partturn actuator
(cover of gear
housing)

ARAL Aralub
FDP 00

CLS Grease

DEA
Glissando
6833 EP00

5g

3Y (top up)

SHA 14 M --- C05 MM 100, Rev A. Page 177 of 361

10.09.2009

Schmidlin

Gller

07.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
APPROVED

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Title :

DATA SHEET Condenser Debris


Filter

Language
:E

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/DS/001

SHA 14 M --- C05 MM 100, Rev A. Page 178 of 361

DATA SHEET

ENERGY

Pow er Pl ants

CONDENSER DEBRIS FILTERS ND 84

Project : SHOAIBA III


1
2

CLIENT
NUMBER

3
4
5
6

TYPE

Conveyed fluid

Max operation temperature

Rated flow

Unit : 12/13/14

SAUDI ELECTRICITY COMPANY


SIX

FUNCTIONAL CODE
12/13/14PAB41AT010 /
12/13/14PAB42AT010
Mfr's REFERENCE
K2009/20/1367

MANUFACTURER
TAPROGGE GmbH
OPERATING CHARACTERISTICS
Seawater
50C
30010 m/h

10

Design pressure

11

Mesh aperture

7 bar gauge / Vacuum

12

Washing water consumption

13

Head loss clean

14

Inlet/outlet apertures - ND (1)

15

Drilling through flanges

16

Washing water discharge aperture - ND (1)

17

Electric power supplies

18

Motor power

19

Rotation speed of washing system

20

Capacity of the reducing gear oil casing

n.a.

21

Oil type

n.a.

22

Installation level

5 mm dia. with pitch 6 mm / 60


min. 900 m/h
0.73 mWG
2100 mm
AWWA C207 Cl D
DN 350 ANSI B16.5, 150 lbs
460 V / 60 Hz
3 Kw
6.rpm

n.a.

l
m

23
CONSTRUCTION

24

Type

25

Material
Grade

Standard

Mild steel

S235JR / rubberlined

EN 10025

26
27

Housing

28

Filter Element

Duplex Stainless Steel

1.4462

DIN EN
10088

29

Washing system

Duplex Stainless Steel

1.4462

DIN EN
10088

30

Lower bearings

31

Internal bolts and nuts

32

External bolts and nuts

33

Gaskets

PA 6 G for seawater
Duplex Stainless Steel

1.4462
A193B7 / A194Gr2M
equivalent A4-70 / A4

Asbestos free

34
WEIGHTS AND OVERALL DIMENSIONS

35
36

WEIGHT

37

In operating order

38

Empty

39

OVERALL DIMENSIONS

40

Length

See drawing SHA/14/M/---C05/GA/001

41

Width

See drawing SHA/14/M/---C05/GA/001

42

Height

See drawing SHA/14/M/---C05/GA/001

13,7 t
4t

43
44
45
46

OUTLINE AND LAYOUT DIAGRAM

47

(supporting and lifting included)

48
49
50
51

REMARKS
(1) nominal diameter

SHA 14 M --- C05 MM 100, Rev A. Page 179 of 361

Rubber

DIN EN
10088

29.07.2009

Schmidlin

Gller

27.07.2009

Schmidlin

Gller

17.07.2009

Schmidlin

Gller

15.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
Neugebauer
Neugebauer
APPROVED

Updated

FUS

Updated

FUS

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Title :

LV Motor DATA SHEET

Language
:E

Condenser Debris Filter

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/DS/002

SHA 14 M --- C05 MM 100, Rev A. Page 180 of 361

Rev. D

1
2

CLIENT
QUANTITY

3
4

MOTOR DESIGNATION RA 500/280


DRIVEN MACHINE Debris Filter (Condenser)

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

POWER SUPPLY NETWORK


Type
: alternating
Voltage between phases / variation
:460V +10-15%
Frequency / variation
:
60Hz +6-5%
Neutral
:
grounded

ENVIRONMENT
Installation area : non explosive explosive
Nature of service ambient conditions
:
Atmosphere
:
clean
Max - min - normal air temperature
:
55/9/30
Relative maximum humidity
: 100 %
Altitude
:6m
Particular risks
:
Seismicity
: UBC Zone 2A
MOTOR CHARACTERISTICS
Motor type
Location
Arrangement
Rated voltage
Rated frequency
Rated output
Synchronous speed
Slip (4/4 load)
Rated current
Starting current Id/In
Rated torque
Starting torque Cd/Cn
Max. torque Cmax/Cn
No load current

FUNCTIONAL CODE
12/13/14PAB41AT010 /
12/13/14PAB42AT010

Alstom
2 per unit

: asynchronous
:
inside
:
horizontal
: 460V
: 60Hz
: 3 kW
: 1800 rpm
: 82%
: 4,7 A
: 5,6
: 15 Nm
: 2,5
:3
: 6,2 A
2/4
3/4
4/4

MANUFACTURER
Rheingetriebe
CONSTRUCTION
Rotor
Stator winding
- class of insulation
- winding impregnation
- temperature rise
Type construction
Frame
dry
Coupling type
Bearings
- on shaft ends sides
- on opposite side or thrust
- lubrication type

Mfr's REFERENCE
K2009/20/1367

: class F
: varnish
:B
:
B
:
: F7
: roller bearing
: roller bearing
:

grease or oil flow or quantity per bearing : -l/mn


grease or oil viscosity
:
oil inlet/outlet temperature
:
-/
grease or oil change every
:-

Cooling
- type
- ventilating air flow
- cooling water pressure
- cooling water flow
- water inlet/outlet temp rise
- water inlet/outlet head losses
PAINTING

kg
-cSt
C

TEFC
:
:
:
:
:
:

/
/

m/h
bar abs.
m/h
C
Mwg

RAL 7037

MATERIALS

Stator winding
:
Stator bars
:
Efficiency
%
Frame
:
82,5
82
Power factor
Shaft
:
0,82
Cyclic duration factor
: n.a.
Insulation
:
Impregnation
:
Motor inertia
: 0,0047 kgm
Terminal box
:
Starting time
: < 6sec.
Rotor laminations
:
Number of successive startings
:3
:
Stator laminations
Max. permissible amplitudes of vibrations < 1 mm
Noise level 1 m from the motor surface :
<70 dB(A) (A)
WEIGTHS AND OVERALL DIMENSIONS
Protection class
: IP56
Rotation viewed from coupling end
Axis height
:
clockwise
Height
:
Stator winding coupling
:
star
Length
:
Width
:
Applicable standards
Shaft end diameter
:
- design
: IEC 60034
Net weight
:
- construction
: IEC 60034
- tests
: IEC 60034

Standard
VDE
VDE
VDE
VDE

n.a.
n.a.
VDE
VDE
VDE

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

SHA/14/M/---C05/DS/002

29.07.2009

en

2/2

SHA 14 M --- C05 MM 100, Rev A. Page 181 of 361

steel
cast +Al
steel
n.a.
n.a.
Al
steel
steel

85 mm
196 mm
372 mm
258 mm
20 mm
24 kg

Originator
ALSTOM 2006. All rights reserved.

Grade
copper

14.09.2009

Schmidlin

Gller

20.07.2009

Schmidlin

Gller

18.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
Neugebauer
APPROVED

Updated

FUS

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Title :

Valves DATA SHEET

Language
:E

Condenser Debris Filter

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 3

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/DS/003

SHA 14 M --- C05 MM 100, Rev A. Page 182 of 361

Rev. C

DATA SHEET
VALVES

ENERGY

Pow er Pl ants

Project : SHOAIBA Unit : 12/13/14


1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52

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

Originator

Identification number

Rev.

Date

Lang.

Sheet

ALSTOM
TAPROGGE

SHA/14/M/---C05/DS/003

14.09.2009

en

2/3

ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 183 of 361

Rev. C

DATA SHEET
VALVES

ENERGY

Pow er Pl ants

Project : SHOAIBA Unit : 12/13/14


1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52

DESIGNATION
12/13/14PAB41AA201
12/13/14PAB42AA201
IDENTIFIER
SUPPLIER
Mfr's REFERENCE
ND =
2 (DN50)
2 (DN50)
TAPROGGE
K2009/20/1367
ISO-PN ANSI B16.5 150lbs
/ SERIES =
CONSTRUCTION - CODES - STANDARDS
ANSI B 16-34
DIN
NFE
General constructive arrangements
Drain valve
- Body
ISO 5752
Cast
Forged
Fabricated
Die-worked
- Obturator
DIN 3202
- Body / bonnet junction
feather key
Bolted
Autoclave
Screwed & welded
- Weld end connection
Not applicable
Materials :
- housing
EN-JL-1040, DIN EN 1561
- diaphragm
EPDM
- switching shaft
1.4104, DIN EN 10088-1
- seal rings / gaskets
n.a.
- bolts
5.6, DIN ISO 8992
OPTIONS
Body :
Straight
Angle
Inclined
3-way
- Pipe connection :
O D x inlet / outlet thickness
DN50 ANSI B16.5, Class 150 lbs, R.F.
- Neck : Material :
inlet / outlet diameter
DN50
Control : Manual
Yes
No
Motor-driven : emerg. man. contr.
with withou without reducer
*
t
electric
pneumatic
hydraulic
- By-pass ND
n.a.
- Decompression ND
n.a.
- Over-pressure valve (>= 2500 Lbs)
*
n.a.
Stuffing-box :
Standard gasket
Gasket for vacuum
Water seal
Limit-switch on positions :
Closed
Intermediate
Open
Position Transmitter
No
Driving column Stem lengthening piece
No
Accesory for check valve
not applicable
Counter weight
Damper
Seat bore
-integral
Yes
-seat
350
Replacement Ring
Yes
Lining: Body/Obturator
NBR/no lining
Water seal
NBR
SERVO-MOTOR
pneumatic
Nature of fluide
Maximum pressure
6 bar abs. for motor
Temperature
Flow
50
C
1000
m3/h
Breakdown torque
*
520 Nm
Operation time
/ Rpm of stem
n.a.
s
/
Particular conditions :
Differential pressure allowing operation
10 bar
Torque required for operation
*
Manually operated
Setting of torque limiter
*
n.a.
Seat / obturator tightness : class / standard
Installation - orientation : by-pass / servo-motor
Drawing No
Weight of valve with fittings
*
10,3 kg
Fluid :seawater
Max. pressure : 10
bar G.
Max. temp. : 60
C
REMARKS : The lines marked with * will be completed by the supplier. The others must obligatorily be filled in by ALSTOM
if needed, completed by the supplier.

Originator

Identification number

Rev.

Date

Lang.

Sheet

ALSTOM
TAPROGGE

SHA/14/M/---C05/DS/003

14.09.2009

en

3/3

ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 184 of 361

18.05.2009

Schmidlin

Gller

Neugebauer

First issue

FUS

REV

DATE

PREPARED

CHECKED

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Title :

Pressure Transmitter DATA SHEET

Language
:E

Condenser Debris Filter

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

SHA/14/M/---C05/DS/004

Client Document No. :

SHA/14/M/---C05/ DS/004

SHA 14 M --- C05 MM 100, Rev A. Page 185 of 361

ENERGY

Pow er Pl ants

Project : SHOAIBA III

DATA SHEET
PRESSURE TRANSMITTER
Unit : 14,13,12

1
2
3
4
5
6

CLIENT

SAOUDI ELECTRICITY COMPANY

Quantity

Functional code (s)

14/13/12 PCB41CP010

14/13/12 PCB42CP010

Destination

Debris filter

Debris filter

MAKE

ROSEMOUNT-EMERSON

ROSEMOUNT-EMERSON

Type

1151 DP4

1151 DP4

MANUFACTURER
TAPROGGE GmbH

FUNCTIONAL CODE
14/13/12 PAB41/42CP010
Mfr's REFERENCE
K2009/20/1367

8
9
10
11
12
13
14
15
16
OPERATING CHARACTERISTICS

17
18

Nature of fluid

19

Nominal/maximum pressure

water

20

Nominal/maximum temperature

21

Density

22

water

bar abs.

5,5/16

50/70

5,5/16
50/70

appr. 1000kg/m

appr. 1000kg/m
370mbar

INSTRUMENT

23

Scale

bar abs.

370mbar

24

Measuring scale

bar abs.

-10 to 360 mbar

-10 to 360 mbar

25

Accuracy

0,1% of SPAN

0,1% of SPAN

26

Transmitter

Yes

Yes

27

Action

28

Signal/power supply characteristics

%
DIRECT / INDIRECT

29

4-20mA HART / 24V DC

4-20mA HART / 24V DC

(SMART TYPE)

(SMART TYPE)

CONSTRUCTION

30
31

Box

32

Protection class IP

33

Instrument connections

34

Coupling - dimensions

35

Location - standards

36

Connection

Yes / No

37

Expansion loop

38

Manifold

39

Drain trap

IP65

IP65

mm

DN3 Remote seal

DN3 Remote seal

mm

DN 3 Remote seal

DN 3 Remote seal

Yes / No

No

No

Yes / No

No

No

Yes / No

No

No

Electrical/process

40
41

MATERIALS

42

Gear chamber

1.4401/1.4404

1.4401/1.4404

43

Box

Aluminium

Aluminium

44

Equipment

2.4819

2.4819

45

Nut & bolts

SS316

SS316

DRAWINGS - NOTICES

K2009/20/1367-0501

K2009/20/1367-0501

46
47
48
49
50
51
52
53

REMARKS Local Indicator LCD Type = 0-100%


Label AISI 316
Transmitters with capillaries: capillary length 3 m, Flange ANSI RF, liquid fill with silicon oil

Issue
Date
Author
Checked by
Approved by

A
18.05.2009
Schmidlin
Gller
Neugebauer

N SHA/14/M/---/C05/DS/004

SHA 14 M --- C05 MM 100, Rev A. Page 186 of 361

04.08.2009

Schmidlin

Gller

18.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
APPROVED

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Title :

Actuator DATA SHEET

Language
:E

Condenser Debris Filter

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/DS/005

SHA 14 M --- C05 MM 100, Rev A. Page 187 of 361

Rev. B

Actuator
Series/Size
EBRO / EB12-DW
Spring Range
n.a.
Supply Pressure
3-8 bar
Action
0,7 s
Air failure
n.a.
Hand Wheel
n.a.
Pn.tubing Size/Mtl.
L-connection for air tube
Shut-off Pressure
6 bar
IBR
IBR for Pressure Parts
n.a.
Air Filter Regulator with Gauge
Make/Model
n.a.
Qty
Filter Size
Valve Positioner
Make/Model
local positioner by Ebro
Input Signal/Action
Certification
Cable Entry
Cable Gland
Limit Switch
Qty
n.a.
Specifications
Solenoid Valve
Qty
1
Supplier/type
Festo / NVF3

Originator

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

SHA/14/M/---C05/DS/005

04.08.2009

en

2/2

ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 188 of 361

02.06.2010

Schmidlin

Gller

22.10.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
APPROVED

Revised acc. to clients comments

FUS

First issue / Preliminary

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
MP

Title :

Operation & Maintenance Manual

Language
:E

for

Consortium Participant or Subcontractor Document No. : N/A

abcd

CCW Exhanger Debris Filter


No of
sheet : 89

Power Systems

Sheet :

Plants

Alstom document no :

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

Client Document No. :

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

SHA 14 M --- C05 MM 100, Rev A. Page 189 of 361

Rev. A

Maintenance manual number :

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

Equipment component code :

See equipment schedule

Equipment description :

Filter System

Subcontractor name :

Taprogge

Subcontractor document N. :

K2009/20/1368

List of contents

1.

EQUIPMENT DESCRIPTION & OPERATING INSTRUCTIONS ..............................................................5


1.1. Task and function description of the TAPROGGE filter system ............................................................... 5
1.1.1.
Task of the TAPROGGE filter system ..........................................................................................................5
1.1.2.
Function description of the TAPROGGE filter system ................................................................................6
1.2. Description of the filter system .................................................................................................................. 10
1.2.1.
Assembly Debris Filter ................................................................................................................................10
1.2.1.1.
Debris Filter PR-BW 100 .......................................................................................................................10
1.2.1.2.
Differential pressure measuring system ...............................................................................................12
1.2.1.3.
Gear motor..............................................................................................................................................14
1.2.2.
Discharge valve ...........................................................................................................................................15
1.2.3.
Control ..........................................................................................................................................................16
1.3. Operating instructions................................................................................................................................ 19
1.3.1.
General .........................................................................................................................................................19
1.3.1.1.
Definition of basic position .....................................................................................................................20
1.3.2.
Description of operating modes ..................................................................................................................21
1.3.2.1.
Operating mode AUTOMATIC LOCAL .................................................................................................21
1.3.2.2.
Operating mode MANUAL .....................................................................................................................22
1.3.3.
Pre-commissioning settings and checks....................................................................................................23
1.3.3.1.
Testing and setting of the control panel ................................................................................................24
1.3.3.2.
Dry function test......................................................................................................................................26
1.3.3.3.
Commissioning of the actuators ............................................................................................................27
1.3.3.3.1. Part-turn actuator of discharge valve ...............................................................................................27
1.3.3.3.2. Gear motor for backwash rotor .........................................................................................................28
1.3.4.
Commissioning of the differential pressure measuring system ................................................................29
1.3.4.1.
Functional test of the control and setting of the limit values at the diff. press. measuring system ...30
1.3.4.2.
Filter system start-up..............................................................................................................................32
1.3.5.
Operation of the filter system ......................................................................................................................33
1.3.5.1.
Routine filter operation (AUTOMATIC): ................................................................................................33
1.3.5.2.
Filter backwash in the operating mode Automatic ...............................................................................34
1.3.5.2.1. Programme "filter backwash"............................................................................................................35
1.3.5.2.2. Programme "filter extended backwash" ...........................................................................................36
1.3.5.3.
Filter backwash in the operating mode MANUAL ................................................................................37
1.3.5.4.
Emergency operation (voltage breakdown) ..........................................................................................38
1.3.6.
Filter system shut-down ..............................................................................................................................39
1.3.7.
Measures to prevent corrosion due to stagnation .....................................................................................40
1.3.8.
Filter system restart after shut-down ..........................................................................................................41
1.3.9.
Operating Record ........................................................................................................................................42
1.3.10.
"Indication" and Operation"; Operator terminal screens ...........................................................................44
1.3.11.
Operational trouble-shooting.......................................................................................................................45
1.3.11.1. Backwash rotor fault...............................................................................................................................46

Originator

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

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

22.10.2009

en

2/89

ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 190 of 361

Rev. A
1.3.11.2. Fault of actuator of discharge valve ......................................................................................................47
1.3.11.3. Fault of differential pressure measuring system ..................................................................................49
1.3.11.4. p EXCESSIVE HIGH ...........................................................................................................................50
1.3.11.5. Voltage breakdown.................................................................................................................................51
1.3.11.6. PLC fault .................................................................................................................................................52
1.3.11.7. Battery low ..............................................................................................................................................53
2.
ENVIRONMENTAL, HEALTH AND SAFETY ............................................................................................54
3.
MAINTENANCE ...........................................................................................................................................55
3.1. Preventive maintenance ............................................................................................................................ 55
3.1.1.
PREVENTIVE MAINTENANCE INSTRUCTIONS ....................................................................................55
3.1.1.1.
Debris filter ..............................................................................................................................................56
3.1.1.1.1. Bearing assembly ..............................................................................................................................56
3.1.1.1.2. Backwash rotor ..................................................................................................................................65
3.1.1.2.
Differential pressure measuring system ...............................................................................................68
3.1.1.3.
Gear motor for backwash rotor .............................................................................................................71
3.1.1.4.
Part-turn actuator of the discharge valve ..............................................................................................72
3.1.1.5.
Valves......................................................................................................................................................74
3.1.1.5.1. Ball valve of discharge valve .............................................................................................................74
3.1.1.5.2. Isolation valves of differential pressure measuring system ............................................................75
3.1.1.5.3. Filter drain valve.................................................................................................................................76
3.1.1.6.
Control panel ..........................................................................................................................................77
3.1.2.
PREVENTIVE MAINTENANCE SCHEDULE ............................................................................................78
3.1.3.
LUBRICATION INSTRUCTIONS AND SCHEDULE .................................................................................81
3.1.4.
SPECIAL TOOLING AND HANDLING DEVICES .....................................................................................82
3.1.5.
STORAGE INSTRUCTIONS ......................................................................................................................83
3.1.6.
PRESERVATION INSTRUCTIONS ...........................................................................................................84
3.2. CORRECTIVE MAINTENANCE INSTRUCTIONS.................................................................................. 85
3.2.1.
Debris filter ...................................................................................................................................................85
3.2.2.
Differential pressure measuring system .....................................................................................................86
3.2.3.
Gear motor for backwash rotor ...................................................................................................................86
3.2.4.
Valves ...........................................................................................................................................................87
4.
ACCESSORIES ...........................................................................................................................................88
5.
DRAWING AND PART LISTS ....................................................................................................................89

Originator

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

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

22.10.2009

en

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ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 191 of 361

Rev. A
EQUIPMENT SCHEDULE
KKS No.

DESCRIPTION

REFERENCE PROCEDURE

EQUIPMENT
TYPE

PARTICIPANT
UNIT

SYSTEM

COMPONENT
FUNCTION

SEQUENCE
NUMBER

TAPROGGE

12/13/14

PCB15

AT

001

Debris filter PR-BW 100

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

TAPROGGE

12/13/14

PCB16

AT

001

Debris filter PR-BW 100

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

TAPROGGE

12/13/14

PCB15

CP

010

Diff. press. measuring system

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

TAPROGGE

12/13/14

PCB16

CP

010

Diff. press. measuring system

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

TAPROGGE

12/13/14

PCB15

AA

016

Discharge valve with actuator

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

TAPROGGE

12/13/14

PCB16

AA

016

Discharge valve with actuator

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

TAPROGGE

12/13/14

PCB15

GH

001

Control panel

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

TAPROGGE

12/13/14

PCB16

GH

001

Control panel

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

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SHA 14 M --- C05 MM 100, Rev A. Page 192 of 361

Rev. A

1.

EQUIPMENT DESCRIPTION & OPERATING INSTRUCTIONS

1.1.

Task and function description of the TAPROGGE filter system

1.1.1.

Task of the TAPROGGE filter system

A TAPROGGE debris filter is installed to prevent clogging of cooling tubes and all related problems.

Fig. 2-1: Schematic Arrangement


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

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SHA 14 M --- C05 MM 100, Rev A. Page 193 of 361

Rev. A

1.1.2.

Function description of the TAPROGGE filter system

Debris filter type PR-BW 100


1
2
3
4

Filter PR-BW 100


Differential pressure measuring system
Gear motor
Discharge valve

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SHA 14 M --- C05 MM 100, Rev A. Page 194 of 361

Rev. A

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

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SHA 14 M --- C05 MM 100, Rev A. Page 195 of 361

Rev. A

The special performance of the debris filter is based on the concept of

PRESSURE-RELIEVED BACKWASH (PR-BW)

The PR-BW procedure works as follows (see sketches on the following page):

During the backwash procedure, the backwash rotor is moving over the entire filter section. The
debris, which had been collected in that area of the filter section which is covered by the
backwash rotor, is relieved from flow pressure. Simultaneously, the flow direction in this area
reverses and the pressure-relieved debris is flushed away by the backwash flow of the filtered
water.

The PR-BW procedure easily handles all kind of debris, especially fibrous debris which is easily
removed from the filter section.

Since the area of the filter section covered by the backwash rotor is completely isolated from
the differential pressure of the cooling water during backwashing, the debris filter is fully
operational even if it is loaded with high amount of debris.

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SHA 14 M --- C05 MM 100, Rev A. Page 196 of 361

Rev. A

Pressure-relieved backwash (PR-BW procedure)


FILTRATION

water flow

fibres are retained


filter section
flow pressure forces fibres and debris onto
the filter section

PRESSURE-RELIEF

freeing and lifting of fibrous debris


the covering backwash rotor causes a
pressure-relieved area
backwash rotor

FILTER BACKWASH

flow pressure relief and initial flow reversal


produced by the opened discharge valve
help to untangle and flush out fibrous
debris from the filter section.

Backwash process

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SHA 14 M --- C05 MM 100, Rev A. Page 197 of 361

Rev. A

1.2.

Description of the filter system

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

1.2.1.

Assembly Debris Filter

1.2.1.1.

Debris Filter PR-BW 100

Debris filter type PR-BW 100


1/2
3
4
5
6

Filter housing
Bearing assembly
Backwash rotor
Filter section with wiper
Inspection hole

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SHA 14 M --- C05 MM 100, Rev A. Page 198 of 361

Rev. A

The filter housing 1 / 2

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

Bearing assembly

consists of a rotating hollow shaft with worm gear. The water is


discharged through the hollow shaft. The backwash rotor is actuated by
the gear motor which is mounted to the worm gear. The discharge valve
is fixed to the outlet flange of the bearing assembly.

The backwash rotor 4

consists of a funnel-shaped arm with rubber lips. This arm is connected


to the bearing assembly by a flange connection.

Filter section

weldless design; standard perforations typically start from 2 mm


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

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SHA 14 M --- C05 MM 100, Rev A. Page 199 of 361

Rev. A

1.2.1.2.

Differential pressure measuring system

Differential pressure measuring system


1
2
3
6
7
9

Differential pressure transmitter


Remote seal PLUS
Remote seal with capillary tube MINUS
Isolation valves
Measuring nozzles
Operator terminal

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SHA 14 M --- C05 MM 100, Rev A. Page 200 of 361

Rev. A

The differential pressure measuring system (p system) monitors the amount of debris on the
filter by constantly measuring the differential pressure (p).

Differential pressure transmitter 1

The differential pressure is electronically converted to a


signal.

Operator terminal 9

indicates: 


initiates:

limit value 1:
(test function)

the actual differential pressure


the programmed limit values

signalling upon reaching or falling below


the programmed limit values

IN-SERVICE MONITORING
The proper functioning of the measuring system is
electrically monitored constantly. In the event of a fault,
the differential pressure falls below limit value INSERVICE MONITORING and an alarm message will be
signalled by the control system.

limit value 2:
(service function)

FILTER BACKWASH
If debris accumulates on the filter section, the
differential pressure increases. If the limit value FILTER
BACKWASH is reached, the automatic control system
initiates filter backwash, until the differential pressure
falls below the pre-set limit value.

limit value 3:
(security function)

p EXCESSIVE HIGH
If the differential pressure continues to increase in spite
of the existent backwash and reaches the limit value p
EXCESSIVE HIGH, the automatic control system
continues filter backwash. Simultaneously, a signal and
an alarm message are indicated. The customer can
connect the potential free alarm from the control panel
to the control room.

Isolation valves 6

The differential pressure measuring system can be


isolated from the cooling water flow for maintenance
purposes by means of the isolation valves.

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SHA 14 M --- C05 MM 100, Rev A. Page 201 of 361

Rev. A

1.2.1.3.

Gear motor

The backwash rotor is operated by a special gear motor designed for 100 % continuous
operation.

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SHA 14 M --- C05 MM 100, Rev A. Page 202 of 361

Rev. A

1.2.2.

Discharge valve

The discharge valve in this filter system is a ball valve operated by a specially designed partturn actuator with short running time. In the open position, the valve allows an unrestricted flow
of the debris laden water.

The part-turn actuator is equipped with limit switches signalling the end positions to the control
panel. It is also equipped with torque limit switches protecting the valve as well as the actuator
against overload.

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SHA 14 M --- C05 MM 100, Rev A. Page 203 of 361

Rev. A

1.2.3.

Control
The control system serves to operate, control and monitor the filter system. The control is a
programmable logic controller (PLC). All control and monitoring functions required for automatic
operation (programmes) are stored in a single programme (EEPROM).
By means of a selector switch at the control panel the operating mode AUTOMATIC or
MANUAL is selected.
All further operations are effected via function keys at the operator terminal.

Operating mode AUTOMATIC

The control system monitors the filter system and initiates filter backwash in any of the following
cases:


p limit value FILTER BACKWASH

control command FILTER BACKWASH from control room

function key FILTER BACKWASH

function key FILTER EXTENDED BACKWASH

malfunction differential pressure measuring system (intermittent backwash every 3


minutes)

every 24 hours, initiated by a timer

Backwash
Backwash of the debris filter proceeds as follows:


The part-turn actuator opens the discharge valve

Simultaneously, the backwash rotor starts


The filter section is cleaned by backwashing. The debris is carried away through the
discharge pipe.

In the operating mode AUTOMATIC the actual differential pressure is processed by the
control system

After backwashing, the actual differential pressure is checked by the control system

If p < limit value FILTER BACKWASH, the backwash rotor stops and the discharge
valve closes

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SHA 14 M --- C05 MM 100, Rev A. Page 204 of 361

Rev. A

Operating mode MANUAL

Note:
The operating mode MANUAL is not permitted for routine filter operation and may be
selected for commissioning and in case of trouble in the operating mode AUTOMATIC
only!

All operations are initiated by the operating personnel by means of function keys at the operator
terminal.

Backwash
Filter backwash must be initiated if:


p limit value FILTER BACKWASH

p limit value p EXCESSIVE HIGH

Backwash of the debris filter shall be executed as follows:




Open the discharge valve

Start the backwash rotor


The filter section is cleaned by backwashing. The debris is carried away through the
discharge pipe.

Carefully check indication of differential pressure

If p < limit value FILTER BACKWASH:


stop the backwash rotor
close the discharge valve

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SHA 14 M --- C05 MM 100, Rev A. Page 205 of 361

Rev. A

Control panel

The control panel consists of all necessary devices for ...




...

control and operation of the filter system

...

transmission of control commands between the control room and control panel

...

control and power supply to the external electrical consumers

On the control panel front are:




main switch

selector switch for operating mode AUTOMATIC / MANUAL

signal lamp for indication of common alarm

operator terminal for


indication:

operation:

of the actual operational system status

of the actual differential pressure

individual alarms

running time meter of backwash rotor

limit values of the differential pressure measuring system

timers of control

information regarding trouble shooting

execution of all operations

setting of limit values

setting of timers

The control panel contains potential-free contacts which should be connected to the
control room by the customer.

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SHA 14 M --- C05 MM 100, Rev A. Page 206 of 361

Rev. A

1.3.

Operating instructions

1.3.1.

General

The filter system is automatically operated. The differential pressure measuring system
monitors debris accumulation on the filter section. When the differential pressure reaches the
pre-set limit value FILTER BACKWASH, the automatic control initiates the filter backwash.
If the automatic control failed, backwashing must be manually initiated upon reaching the limit
value FILTER BACKWASH.

Caution:
Operation of the cooling water circuit without the control panel switched on will lead to
mechanical damage of the filter.

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SHA 14 M --- C05 MM 100, Rev A. Page 207 of 361

Rev. A

1.3.1.1.

Definition of basic position

Operation starts from the basic position, which is defined as follows:

KKS *)

Component / subassembly

Status

12/13/14 PCB15 GH001 Control panel


12/13/14 PCB16 GH001

selector switch MANUAL /


AUTOMATIC
in position AUTOMATIC
main switch Q01 in position I

12/13/14 PCB15 AT001 Gear motor for backwash rotor


12/13/14 PCB16 AT001

OFF

12/13/14 PCB15 AA016 Discharge valve


12/13/14 PCB16 AA016

CLOSE

12/13/14 PCB15 AA301 Isolation valves of differential


12/13/14 PCB16 AA302 pressure measuring system

OPEN

*) see flow diagram SHA/14/M/---C05/FD/002

The filter system leaves the basic position under one of the following conditions:


p reaches the limit value FILTER BACKWASH

function key FILTER BACKWASH is pressed at the operator terminal

function key FILTER EXTENDED BACKWASH is pressed at the operator terminal

control command filter backwash is sent from the control room

filter backwash is initiated by timer

alarm message p SYSTEM DEFECT

Alarm messages are indicated at the control panel and at the control room

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SHA 14 M --- C05 MM 100, Rev A. Page 208 of 361

Rev. A

1.3.2.

Description of operating modes

1.3.2.1.

Operating mode AUTOMATIC LOCAL

In the operating mode AUTOMATIC LOCAL, all motor-operated components are actuated via
the control programmes. The isolation valves of the differential pressure measuring system
must be manually actuated. The operator terminal indicates the actual operating status of the
motor-operated components.
The accumulation of debris on the filter section causes an increasing differential pressure which
is constantly monitored by the differential pressure measuring system. During routine filter
operation the filter system is monitored by the differential pressure measuring system.
As a standard the debris filter must be backwashed once a day, unless operational experiences
require other backwash sequences. The debris filter can be backwashed by the function key
FILTER BACKWASH.
When the alarm p SYSTEM DEFECT is activated, a filter backwash cycle is initiated for a
pre-set duration (intermittent backwash).

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SHA 14 M --- C05 MM 100, Rev A. Page 209 of 361

Rev. A

1.3.2.2.

Operating mode MANUAL

In the operating mode MANUAL, all motor-operated components are individually actuated via
the appropriate function keys at the operator terminal. The actual operating status of the motoroperated components is indicated at the operator terminal.

The operating mode MANUAL is selected :

for commissioning

in the event of problems in the operating mode AUTOMATIC

Note:
The operating mode MANUAL is not permitted for routine filter operation!

In the operating mode MANUAL the differential pressure on the filter section is indicated.
However, the debris filter is not automatically backwashed upon reaching the limit value
FILTER BACKWASH.
Upon reaching the limit value FILTER BACKWASH, filter backwash must be manually initiated.
Upon reaching the limit value p EXCESSIVE HIGH, an alarm message is indicated at the
control panel and at the control room. The debris filter must be backwashed in the operating
mode MANUAL (for details see section 1.3.5.3). In operating mode MANUAL the filter
backwash programme will not be automatically initiated.

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SHA 14 M --- C05 MM 100, Rev A. Page 210 of 361

Rev. A

1.3.3.

Pre-commissioning settings and checks

Conditions:


All components are installed

All electrical connections have been made and checked to be in accordance with the
specified circuit diagram, operating voltage and frequency. For more information see
electrical documentation in section 5.

Verify rotating magnetic field of three-phase connection for clockwise rotation.

Cooling water line is not flooded

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SHA 14 M --- C05 MM 100, Rev A. Page 211 of 361

Rev. A

1.3.3.1.

Testing and setting of the control panel

Check the actual operating voltage; change transformer connection(s), if necessary

All manual motor starters in the position I

Connection of terminals checked

All fuses in working order

Insert main fuse F 01.

Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the


position MANUAL

Main switch Q01 in position

All miniature circuit breakers in the position ON

Connect voltage supply (green LED POWER lights up)

CPU must be in position RUN (green LED indicates RUN mode); green LED COMM 0
lights up.

Connect voltage supply (green LED POWER lights up)

CPU must be in position RUN (green LED indicates RUN mode)

Check lamp for proper functioning by push-button LAMP TEST

Preliminary programming of limit values at the operator terminal (see section 9), as
follows:

limit value FILTER BACKWASH


limit value p EXCESSIVE HIGH


p = 156 mbar
p = 200 mbar

Set the timers to the following values; after commissioning, record timer settings and
send one copy to TAPROGGE

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SHA 14 M --- C05 MM 100, Rev A. Page 212 of 361

Rev. A

Time Table

Timer
(adjustable
by function
key)

Denomination

Factory set
value

time filter backwash

30 sec.

time filter backwash after start filter backwash


from the control room

300 sec.

start filter backwash, if differential pressure


measuring system is defective

180 sec.

start filter backwash

Value after
commissioning

24 h

execution time check: running time of discharge


valve

30 sec.

time filter extended backwash

900 sec.

The following internal timers are already factory pre-set, alterations are not permitted:

Timer

Denomination

Value

iT

execution time check: test contact of differential pressure


measuring system

5 sec.

iT

delay time limit value filter backwash

5 sec.

iT

delay time limit value "p excessive high"

10 sec.

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SHA 14 M --- C05 MM 100, Rev A. Page 213 of 361

Rev. A

1.3.3.2.

Dry function test

Before flooding the filter system, the function of the backwash rotor and the discharge valve
must be checked.

Conditions:


the check must be performed without water in the filter system

selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in position


MANUAL

main switch Q01 in position I = ON

Discharge valve
The pneumatic actuator of the discharge valve has already been factory pre-adjusted.
The running times for the pneumatic actuator can be adjusted at the exhaust regulator with
sound absorber.

Backwash rotor

Warning:
During the following functional test do not reach into the filter housing.
Otherwise severe injury will result due to rotating parts!

Start the backwash rotor by the function key backwash rotor ON at the operator
terminal. The backwash rotor should now rotate. The proper rotation should be visually
checked through the inspection hole.

Close the inspection hole and tighten bolts.

Turn the backwash rotor off by pressing the function key backwash rotor OFF at the
operator terminal.

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SHA 14 M --- C05 MM 100, Rev A. Page 214 of 361

Rev. A

1.3.3.3.

Commissioning of the actuators

selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the position


MANUAL
main switch Q01 in the position I

1.3.3.3.1.

Part-turn actuator of discharge valve

Check the moving direction of the part-turn actuator of ball valve:

Use the handwheel of the part-turn actuator in order to turn the ball valve into a position
between the final positions OPEN and CLOSE

Press the function key discharge valve CLOSE

Before reaching the final position CLOSE: stop the part-turn actuator by pressing the
function key STOP
If the ball valve does not move into the direction CLOSE (note mechanical position
indicator at the part-turn actuator), correct the wiring by changing two of three phases at
the terminal strip of the part-turn actuator.

Setting the limit switches of the part-turn actuator of ball valve

The torque limit switches have already been factory pre-set.

The travel limit switches must be set according to the manufacturers instructions (see
section 4 Part-turn actuator of discharge valve).

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SHA 14 M --- C05 MM 100, Rev A. Page 215 of 361

Rev. A

The assignment of limit switches to the moving direction of the ball valve into the final positions
OPEN / CLOSE depends on the rotation direction of the part-turn actuator:

Rotation direction of
part-turn actuator

Moving direction of
ball valve

Assignment of limit switches

CLOSE

torque limit switch and


travel limit switch
closing

counterclockwise

OPEN

torque limit switch and


travel limit switch
opening

clockwise

OPEN

torque limit switch and


travel limit switch
closing

CLOSE

torque limit switch and


travel limit switch
opening

clockwise

counterclockwise

Final positions CLOSE and OPEN




Turn the handwheel of the part-turn actuator into the final position CLOSE.

Set the travel limit switch for the position CLOSE.

Turn the handwheel of the part-turn actuator into the final position OPEN.

Set the travel limit switch for the position OPEN.

Press the function key discharge valve CLOSE.


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

Press the function key discharge valve OPEN.


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

Note:
The torque limit switches serve as an overload protection. If they are tripping,
an alarm message will be indicated (see section 5).

1.3.3.3.2.

Gear motor for backwash rotor

The gear motor has already been factory pre-adjusted.

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SHA 14 M --- C05 MM 100, Rev A. Page 216 of 361

Rev. A

1.3.4.

Commissioning of the differential pressure measuring system

Conditions :


Cooling water flow per filter as specified:



minimum

normal

maximum admissible

389 kg/s
499 kg/s
528 kg/s

Filter system in basic position (see section 1.3.1.1)

Isolation valves of differential pressure measuring system are open

Setting of the differential pressure transmitter and programming at the operator


terminal:
Zero point and measuring range of the differential pressure transmitter have already been set.
The limit values shall be programmed at the operator terminal by selecting the screen "Setting"
(see section 1.3.10).

Determination of pclean:


Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in position


AUTOMATIC LOCAL

Main switch Q01 at the control panel in the position I

Backwash the filter repeatedly by means of the function key FILTER BACKWASH.
Read the differential pressure directly after each filter backwash. The mean value is
determined as the differential pressure of the clean filter (pclean).

Programming of the limit values at the operator terminal:




limit value FILTER BACKWASH

p = pclean + 80 mbar (preliminary value)

limit value p EXCESSIVE HIGH

p = pclean + 160 mbar (preliminary value)

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SHA 14 M --- C05 MM 100, Rev A. Page 217 of 361

Rev. A

1.3.4.1.

Functional test of the control and setting of the limit values at the diff. press.
measuring system

Conditions :


Cooling water flow per filter as specified:



minimum

normal

maximum admissible

389 kg/s
499 kg/s
528 kg/s

Filter system in basic position (see section 1.3.1.1)

Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the


position AUTOMATIC LOCAL

Main switch Q01 at the control panel in position I

Check limit value FILTER BACKWASH




Programming of limit value FILTER BACKWASH at the operator terminal to a value <
pclean.

The programme "Filter backwash is initiated according to section 1.3.5.2.

Programming of limit value FILTER BACKWASH to the preliminary value (see section
1.3.4.3)
After the backwash procedure the differential pressure of the clean filter (pclean) will be
indicated (see section 1.3.4.3).

Check limit value p EXCESSIVE HIGH in the operating mode MANUAL




Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the


position MANUAL

Programming of limit value p EXCESSIVE HIGH at the operator terminal to a value <
pclean.

The following alarm messages are indicated:

individual alarm
(fault list at the operator terminal)
common alarm

at the control panel

at the control room

p EXCESSIVE HIGH

p EXCESSIVE HIGH

ALARM

common alarm

Programming of limit value p EXCESSIVE HIGH to the preliminary value (see section
1.3.4.3)

Reset the alarms by means of the push-button ALARM RESET according to section
1.3.11. If the alarm messages continue, trouble shooting must be carried out according
to the event messages of the operator terminal or section 1.3.11.

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SHA 14 M --- C05 MM 100, Rev A. Page 218 of 361

Rev. A

Check limit value p EXCESSIVE HIGH in the operating mode AUTOMATIC




Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the


position AUTOMATIC LOCAL

Programming of limit value p EXCESSIVE HIGH at the operator terminal to a value <
pclean.

The control initiates filter backwash according to section 1.3.5.2. Moreover, the following
alarm messages are indicated:

individual alarm
(fault list at the operator terminal)
common alarm

at the control panel

at the control room

p EXCESSIVE HIGH

p EXCESSIVE HIGH

ALARM

common alarm

Programming of limit value p EXCESSIVE HIGH to the preliminary value (see section
1.3.4.3)

Reset the alarms by means of the push-button ALARM RESET according to section
1.3.11. If the alarm messages continue, trouble shooting must be carried out according
to the event messages of the operator terminal or section 1.3.11.

Programming of the limit values at the operator terminal:




limit value FILTER BACKWASH

p = pclean + 80 mbar

limit value p EXCESSIVE HIGH

p = pclean + 160 mbar

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SHA 14 M --- C05 MM 100, Rev A. Page 219 of 361

Rev. A

1.3.4.2.

Filter system start-up

Cooling water flow per filter as specified:



minimum

normal

maximum admissible

389 kg/s
499 kg/s
528 kg/s

Selector switch MANUAL / AUTOMATIC LOCAL / AUTOMATIC REMOTE in the


position AUTOMATIC LOCAL

Main switch at the control panel in position I

The filter system is in the basic position (see section 1.3.1.1).

Filter backwash by the function key FILTER BACKWASH


Filter backwash according to section 1.3.5.2

The filter system is now ready for operation.

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SHA 14 M --- C05 MM 100, Rev A. Page 220 of 361

Rev. A

1.3.5.

Operation of the filter system

1.3.5.1.

Routine filter operation (AUTOMATIC):

In the basic position the debris filter separates debris from the cooling water

KKS*)

Component to be
operated
filter system

*)

Position

basic
position

12/13/14
PCB15
GH001
12/13/14
PCB16
GH001

control panel

12/13/14
PCB15
AT001
12/13/14
PCB16
AT001

gear motor for


backwash rotor

OFF

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016

discharge valve

CLOSE

12/13/14
PCB15
AA301
12/13/14
PCB16
AA302

isolation valves of
differential pressure
measuring system

OPEN

Action

Indication

according to section 1.3.1.1

p < limit value FILTER BACKWASH

selector switch MANUAL / AUTOMATIC LOCAL /


AUTOMATIC REMOTE in the position
AUTOMATIC LOCAL

backwash rotor OFF

discharge valve CLOSE

see flow diagram SHA/14/M/---C05/FD/002

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SHA 14 M --- C05 MM 100, Rev A. Page 221 of 361

Rev. A

1.3.5.2.

Filter backwash in the operating mode Automatic

Under the following operating conditions, the debris filter must be backwashed several
times as a precautionary measure:


during start of the cooling water pump

before start of another condenser / heat exchanger

before start of another cooling water pump

during or after cleaning work at the cooling water pipe or at the cooling water pump
sump

when high tide

Backwash of the debris filter can be accomplished as follows:




in the operating mode AUTOMATIC LOCAL:

repeatedly press the function key


FILTER EXTENDED BACKWASH at
the operator terminal

Before shutdown of the filter system the debris filter must be backwashed several times as
a precautionary measure:


in the operating mode AUTOMATIC LOCAL:

or

repeatedly press the function key


FILTER BACKWASH at the operator
terminal
by means of repeating the control
commands filter backwash from the
control room in AUTOMATIC
REMOTE

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SHA 14 M --- C05 MM 100, Rev A. Page 222 of 361

Rev. A

1.3.5.2.1.

KKS*)

Programme "filter backwash"

Component to be
operated

Position

Action

Indication

initiated by one of the following conditions:

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016

discharge valve

OPEN

12/13/14
PCB15
AT001
12/13/14
PCB16
AT001

gear motor for


backwash rotor

ON

p-indication reaches the limit value


FILTER BACKWASH

p limit value FILTER BACKWASH


FILTER BACKWASH

timer (recommended setting 24 h)

FILTER BACKWASH

function key FILTER BACKWASH

FILTER BACKWASH
discharge valve OPEN

backwash rotor ON

after the pre-set backwashing period:

*)

12/13/14
PCB15
AT001
12/13/14
PCB16
AT001

gear motor for


backwash rotor

OFF

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016

discharge valve

CLOSE

p < limit value FILTER BACKWASH


backwash rotor OFF

discharge valve CLOSE

see flow diagram SHA/14/M/---C05/FD/002

Even after the pre-set backwash period has elapsed, the filter will automatically continue backwashing until the
differential pressure measured across the filter section falls below the limit value FILTER BACKWASH. The
backwash rotor then stops and the discharge valve closes.

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SHA 14 M --- C05 MM 100, Rev A. Page 223 of 361

Rev. A

1.3.5.2.2.

KKS*)

Programme "filter extended backwash"

Component to be
operated

Position

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016

discharge valve

OPEN

12/13/14
PCB15
AT001
12/13/14
PCB16
AT001

gear motor for


backwash rotor

ON

Action

Indication

initiated by

p < limit value FILTER BACKWASH

- function key FILTER CONTINUOUS


BACKWASH

FILTER EXTENDED BACKWASH

- p reaches limit value p excessive high

FILTER EXTENDED BACKWASH


discharge valve OPEN

backwash rotor ON

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

*)

12/13/14
PCB15
AT001
12/13/14
PCB16
AT001

gear motor for


backwash rotor

OFF

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016

discharge valve

CLOSE

p < limit value FILTER BACKWASH


backwash rotor OFF

discharge valve CLOSE

see flow diagram SHA/14/M/---C05/FD/002

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SHA 14 M --- C05 MM 100, Rev A. Page 224 of 361

Rev. A

1.3.5.3.

KKS*)
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001

Component to be
operated

Position

control panel

Action

Indication

selector switch MANUAL / AUTOMATIC LOCAL


/ AUTOMATIC REMOTE in the position MANUAL

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016

discharge valve

OPEN

12/13/14
PCB15
AT001
12/13/14
PCB16
AT001

gear motor for


backwash rotor

ON

12/13/14
PCB15
AT001
12/13/14
PCB16
AT001

*)

Filter backwash in the operating mode MANUAL

gear motor for


backwash rotor

OFF

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016

discharge valve

CLOSE

12/13/14
PCB15
GH001
12/13/14
PCB16
GH001

control panel

p-indication reaches the limit value FILTER


BACKWASH

p limit value FILTER BACKWASH

function key discharge valve OPEN

discharge valve OPEN

function key backwash rotor ON

backwash rotor ON

after approximately 1 minute of backwash rotor


operation, check:

p < limit value FILTER BACKWASH

function key backwash rotor OFF

backwash rotor OFF

function key discharge valve CLOSE

discharge valve CLOSE

selector switch MANUAL / AUTOMATIC LOCAL


/ AUTOMATIC REMOTE in the position
AUTOMATIC LOCAL

see flow diagram SHA/14/M/---C05/FD/002

Note:
The operating mode MANUAL is not permitted for routine filter operation. It is only intended for
commissioning and in case of trouble in the operating mode AUTOMATIC!

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SHA 14 M --- C05 MM 100, Rev A. Page 225 of 361

Rev. A

1.3.5.4.

Emergency operation (voltage breakdown)

Caution:
If voltage does not return immediately, the following measures must be taken in order to avoid
damage of the filter.

KKS*)
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001

Component to be
operated

Position

control panel

discharge valve

Action

Indication

main switch Q01 in the position 0

OPEN

actuation by the part-turn actuator handwheel

mechanical position indicator at partturn indicator in the position OPEN

After removing the cover at the worm gear, attach


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

gear motor for


backwash rotor

verify return of voltage


12/13/14
PCB15
AA016
12/13/14
PCB16
AA016
12/13/14
PCB15
AT001
12/13/14
PCB16
AT001
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001

discharge valve

gear motor for


backwash rotor

CLOSE

actuation by the part-turn actuator handwheel

mechanical position indicator at partturn indicator in the position CLOSE

remove the handwheel


reinstall the worm gear cover

control panel

main switch Q01 in the position I

control panel

push-button LAMP TEST

control panel

Filter backwash:

lamp at the control panel lights while


pressing the push-button

selector switch MANUAL / AUTOMATIC


in the position AUTOMATIC
function key FILTER BACKWASH
check:
filter system

*)

p < limit value FILTER BACKWASH

continue routine filter operation according to


section 1.3.5.1

see flow diagram SHA/14/M/---C05/FD/002

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SHA 14 M --- C05 MM 100, Rev A. Page 226 of 361

Rev. A

1.3.6.

Filter system shut-down

KKS*)
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001

Component to be
operated

Position

selector switch MANUAL / AUTOMATIC LOCAL


/ AUTOMATIC REMOTE in the position
AUTOMATIC LOCAL

control panel

function key FILTER BACKWASH


or
control command FILTER BACKWASH
(from the control room)
discharge valve

OPEN

12/13/14
PCB15
AT001
12/13/14
PCB16
AT001

gear motor for


backwash rotor

ON

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016

Indication

Filter backwash:

12/13/14
PCB15
AA016
12/13/14
PCB16
AA016

12/13/14
PCB15
AT001
12/13/14
PCB16
AT001

Action

FILTER BACKWASH

discharge valve OPEN

backwash rotor ON

after the pre-set backwashing period:


gear motor for
backwash rotor

OFF

discharge valve

CLOSE

p < limit value FILTER BACKWASH


backwash rotor OFF

discharge valve CLOSE

check:
filter system

basic
position

p < limit value FILTER BACKWASH

according to section 1.3.1.1

after filter backwash:


cooling water pump
12/13/14
PCB15
GH001
12/13/14
PCB16
GH001

*)

control panel

OFF
selector switch MANUAL / AUTOMATIC LOCAL
/ AUTOMATIC REMOTE in the position MANUAL

see flow diagram SHA/14/M/---C05/FD/002

The filter system is now out of operation

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SHA 14 M --- C05 MM 100, Rev A. Page 227 of 361

Rev. A

1.3.7.

Measures to prevent corrosion due to stagnation

During prolonged shut-down periods the following must be strictly observed:

The corrosion resistance of stainless steel in aggressive water can be affected by the conditions
prevailing during shut-downs.

During shut-down periods, stagnant water, as well as evaporation of remaining water (e.g. drops),
is to be avoided.

The following measures are necessary to prevent corrosion damage :

Shut-downs up to 3 days:


Run the cooling water pump for a few minutes each day to circulate the cooling water and
to rinse deposits away.

If a high amount of debris is expected during operation of the cooling water pump turn the
main switch Q01 in the position I and backwash the debris filter according to section
1.3.5.3.

Shut-downs over 3 days require a dry conservation




Drain the TAPROGGE components

Clean the internals of the filter system with fresh water

Dry by natural aeration

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SHA 14 M --- C05 MM 100, Rev A. Page 228 of 361

Rev. A

1.3.8.

Filter system restart after shut-down

For shut-downs up to 3 days or maintenance of the debris filter


(with water in the filter system):


Functional test of control and


setting of the limit values at the
differential pressure measuring system

according to section 1.3.4.4

Filter system start-up

according to section 1.3.4.5

Resume routine filter operation

according to section 1.3.5.1

For shut-downs over 3 days or after maintenance of


the drained debris filter


Pre-commissioning settings and checks

according to section 1.3.3

Commissioning of the filter system

according to section 1.3.4

Resume of routine filter operation

according to section 1.3.5.1

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SHA 14 M --- C05 MM 100, Rev A. Page 229 of 361

Rev. A

1.3.9.

Operating Record

For documentation of the debris filter operation please use the attached form.

The documentation of the operational parameters of the TAPROGGE filter system on a regular
basis is helpful to evaluate special operational conditions, to optimize settings of the differential
pressure measuring system and timers and to trace the cause of damages.

We recommend recording the indicated differential pressure of the clean debris filter every 2
weeks and after each alarm p EXCESSIVE HIGH (potential-free contact)

We kindly ask you to have one completed copy of the form ready for information of the
TAPROGGE service department.

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SHA 14 M --- C05 MM 100, Rev A. Page 230 of 361

Rev. A

Operating Record

Date

Differential pressure
after the last filter
backwash (pclean)

Backwash rotor
operation hours

Remarks

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SHA 14 M --- C05 MM 100, Rev A. Page 231 of 361

Rev. A

1.3.10. "Indication" and Operation"; Operator terminal screens

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SHA 14 M --- C05 MM 100, Rev A. Page 232 of 361

Rev. A

1.3.11. Operational trouble-shooting

Note:
Alarm messages are indicated at the operator terminal of the control panel and at the control room
(common alarm) and can be reset in operating mode MANUAL* / AUTOMATIC* by means of the
push-button ALARM RESET. If operational trouble cannot be solved by following the procedures
described herein, or if alarm messages continue, kindly inform the TAPROGGE Service
Department. After trouble shooting, continue filter operation according to section 1.3.5.1.

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SHA 14 M --- C05 MM 100, Rev A. Page 233 of 361

Rev. A

1.3.11.1.

Backwash rotor fault

Indication at
operator terminal
manual motor starter
tripped

Potential-free
contact to
control room
common alarm

Probable cause

Remedy

manual motor starter


tripped

Reclose the manual motor starter. If the manual motor


starter trips again, electrically and mechanically check
the gear motor for backwash rotor according to section
4 "Gear motor for backwash rotor

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SHA 14 M --- C05 MM 100, Rev A. Page 234 of 361

Rev. A

1.3.11.2.

Fault of actuator of discharge valve

Indication at
operator terminal

Potential-free
contact to
control room

Probable cause

Remedy

motor starter tripped

common alarm

motor current
too high

Reclose the manual motor starter, if the manual motor


starter trips again, electrically and mechanically check
the part-turn actuator of the discharge valve according
to section 4 "Part-turn actuator of discharge valve".
Check motor current
Check setting of manual motor starter

motor temperature
too high

motor short or earthcircuit


malfunction both travel
limit switches actuated

not adjusted
defective cabling

running time exceeded

OPEN

CLOSE

restricted movability

Check cooling of motor


Check temperature of the part-turn actuator according
to section 4 "Part-turn actuator discharge valve"
Check cabling according to the electrical
documentation in section 5"
Check setting travel limit switches according to section
4 "Part-turn actuator of discharge valve"
Check the electrical connections
Check whether the discharge valve is difficult to move
or blocked by means of the actuator handwheel
Check the travel limit switches according to section 4
"Part-turn actuator of discharge valve"
Check the torque limit switch according to section 4
"Part-turn actuator of discharge valve"
Check running time of discharge valve according to
the time table, section 1.3.3.1
Check contacts of contactor
Check the electrical connections
Check cabling according to the electrical
documentation in section 5"

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SHA 14 M --- C05 MM 100, Rev A. Page 235 of 361

Rev. A

Indication at
operator terminal

Potential-free
contact to
control room

torque limit switches


tripped

OPEN

CLOSE

Probable cause

Remedy

restricted movability

Check whether the discharge valve is difficult to move


or blocked by means of the actuator handwheel
Check the travel limit switches according to section 4
"Part-turn actuator of discharge valve"
Check the torque limit switch according to section 4
"Part-turn actuator of discharge valve"
Check the electrical connections

cabling

Check cabling according to the electrical


documentation in section 5"

Caution:
If the discharge valve has not opened completely due to a defect of the part-turn actuator, the
discharge valve must be turned to the position OPEN by means of the part-turn actuator
handwheel.

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SHA 14 M --- C05 MM 100, Rev A. Page 236 of 361

Rev. A

1.3.11.3.

Fault of differential pressure measuring system

The filter is running in "intermittent backwash", i.e. the filter is backwashing every 180
seconds.

Indication at
operator terminal

Potential-free
contact to
control room

p SYSTEM DEFECT

common alarm

Probable cause
no signal from
differential pressure
transmitter
measuring range fault

p below limit value


IN-SERVICEMONITORING for
more than 5 sec.
current loop of transmitter interrupted

Remedy
Check the electrical connections

Check the calibration of the differential pressure


transmitter according to section 4 "Differential
pressure transmitter"
Check cabling according to the electrical
documentation in section 5.

Check the differential pressure transmitter according


to section 4 "Differential pressure transmitter".
Check cabling according to the electrical
documentation in section 5.

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Rev.

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SHA 14 M --- C05 MM 100, Rev A. Page 237 of 361

Rev. A

1.3.11.4.

p EXCESSIVE HIGH

Indication at
operator terminal

Potential-free
contact to
control room

Probable cause

Remedy

p excessive high

common alarm

setting of limit values

Check setting of limit values according to section


1.3.4.4

p excessive high

extraordinary amount
of debris

Check the pre-screening system

cooling water flow


increased

Check setting of limit values according to section


1.3.4.4

change in load and


type of debris:
deviation from design
data

Inform the TAPROGGE Service Department

discharge flow fallen


below the design data

Inform the TAPROGGE Service Department

Verify that the


- discharge valve is fully opened
- backwash pipe is not clogged
cooling water flow rate
is less than the design 
data (insufficient
backwash)
sense of rotation
backwash rotor

Inform the TAPROGGE Service Department

Check the rotation direction: the plate indicating turning direction must correspond with the worm shaft
rotation (worm shaft rotation can be observed after
dismantling the cap located at the free end of bearing
housing)

Complete the operating record after each alarm p EXCESSIVE HIGH

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SHA 14 M --- C05 MM 100, Rev A. Page 238 of 361

Rev. A

1.3.11.5.

Voltage breakdown

Note:
In the event of voltage breakdown, run the filter system in emergency operation (see section
1.3.5.4).

Indication/Signal
at control panel

Potential-free
contact
to control room

no indication

common alarm

Probable cause

Remedy

no supply voltage to
the control panel

Check the main supply voltage


Clear any short-circuits

no control voltage

Check the manual motor starter of the control


voltage transformer
Check miniature circuit breaker(s)
Clear any short-circuits

Check miniature circuit breaker(s)


Clear any short-circuits

no auxiliary voltage

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SHA 14 M --- C05 MM 100, Rev A. Page 239 of 361

Rev. A

1.3.11.6.

PLC fault

Indication at
operator terminal
and CPU

Potential-free
contact to
control room

no indication

LED at CPU:
FLT

Probable cause

Remedy

common alarm

no auxiliary voltage

Replace fuse, check wiring according to the electrical


documentation in section 5 and section 4
"Programmable controller"

common alarm

CPU fault

Check hardware according


documentation in section 5

to

the

electrical

data bus fault

Check hardware according


documentation section 5

to

the

electrical

at operator terminal:
no active nodes found
on network

Compare error number, section 4, "Operator Terminal"

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SHA 14 M --- C05 MM 100, Rev A. Page 240 of 361

Rev. A

1.3.11.7.

Battery low

Indication at
operator terminal
and CPU

Potential-free
contact to
control room

battery low

common alarm

Probable cause

Remedy

battery of PLC has run Replace / add the battery of the CPU as soon as
out
possible
(see
also
manufacturer's
manual
"programmable logic controller")

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SHA 14 M --- C05 MM 100, Rev A. Page 241 of 361

Rev. A

2.

ENVIRONMENTAL, HEALTH AND SAFETY

The operating instructions contain basic information on erection, operation and maintenance. For
this reason it is essential that the operating instructions are carefully read before erection and
commissioning by both the installation personnel as well as those responsible for operation and
maintenance. The operation manual must always be available.

In order to prevent personal injury or property damage particular note must be taken of the
following:

the technical data and information as described in the operating instructions

accident prevention regulations

safety regulations of plant operator

electric protective measures acc. to local safety regulations

technical information on manufacturing plates

warning plates at components

regulations concerning environmental protection

all work on or near the system is to be done by qualified personnel

Moreover, the operating instructions contain safety notes which, if ignored, may cause
damage to persons, machinery or environment and which can be identified by the
following symbols:
Warning:

means that danger to life may result if corresponding measures are


not taken or ignored.

Caution:

means that personal injury or considerable material damage may


result if corresponding measures are not taken or ignored.

Note:

points out important information to which the readers specific


attention is drawn.

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SHA 14 M --- C05 MM 100, Rev A. Page 242 of 361

Rev. A

3.

MAINTENANCE
3.1. Preventive maintenance

3.1.1.

PREVENTIVE MAINTENANCE INSTRUCTIONS

In general the following must be observed during maintenance work:

Lightly grease metal parts before assembly.

In order to avoid crevice corrosion, the non-rubberlined sealing surfaces are to be


cleaned and completely covered with a permanently flexible sealing material during
maintenance work.

Only lubricate and grease o-rings with a silicone-based valve grease free of
hydrocarbons (see lubrication list)

Avoid excessive force, especially in case of rubberlined components

Pipes shall be connected stress-free. Take care of fixing points and expansion joints
to avoid unexpected forces at the components.

Restart the filter system according to section 1.3.8. after the maintenance work has been
completed.

If maintenance work cannot be performed according to the procedures described herein


kindly inform the TAPROGGE Service Department.

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SHA 14 M --- C05 MM 100, Rev A. Page 243 of 361

Rev. A

3.1.1.1.

3.1.1.1.1.

Debris filter

Bearing assembly

(see drawing K2009/20/1368-0503)

To replace wear parts the subassembly must be completely disassembled. We recommend to


have this work done by the TAPROGGE Service Department.

Warning:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and
make it safe. Ensure that the voltage supply to the electric actuators has been
interrupted. Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
has been drained. It is absolutely necessary to ensure that people are not exposed to
danger due to an inrush of water into the filter during maintenance work.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

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SHA 14 M --- C05 MM 100, Rev A. Page 244 of 361

Rev. A

Set of wear parts V1:

o-rings
1.3.37
1.3.66
1.3.74
1.3.75
gaskets
1.3.71
1.3.79
wipers
1.3.72
1.3.80
o-rings
1.3.81

Set of wear parts V2:

The replacement of

1.3.82
wiper
1.3.26
o-ring
1.3.37
guide ring
1.3.38
wiper
1.3.16
o-ring
1.3.77
tab washer
1.3.78

is described in section 3.1.1.1.2


Set of wear parts V4:

lubricant for
1.3.64
worm wheel and bearings

For assembly, you will need securing for bolts and nuts (Loctite 242) 1.3.62, securing for bolts
and nuts (Loctite 270) 1.3.63 and permanently elastic sealing material 1.3.69.
Worn-out internal sealing (1.3.71, 1.3.74, 1.3.75, 1.3.79, 1.3.81, 1.3.82) can be immediately
detected by leaks from the open bottom drain hole in seal supports 1.3.3 and 1.3.70 or 1.3.4
and 1.3.73.
The bearing assembly is protected towards the worm wheel shaft by additional sealings,
permitting a temporary continuation of filter operation. However, the sets of wear parts V1, V2
and V4 (see also section 3.2.1) must be replaced by the next opportunity.

Dismantling


Disconnect the discharge pipe.

Loosen hexagon socket head cap screws 1.3.43 and remove the seal support 12 1.3.4
with all assembled components.

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SHA 14 M --- C05 MM 100, Rev A. Page 245 of 361

Rev. A

Loosen the hexagon socket head cap screw 1.3.58, remove the o-ring 1.3.66 and seal
support 9 1.3.73.

Replace o-rings 1.3.66, 1.3.74 and 1.3.75 as well as gaskets 1.3.79 and wipers 1.3.80
(Note: insert wear parts after greasing with silicone grease GX 1).

Install the seal support 9 1.3.73 with assembled o-rings 1.3.74 / 1.3.75 as well as gasket
1.3.79 and wiper 1.3.80 into the seal support 12 1.3.4 with the o-ring 1.3.66 and
hexagon socket head cap screw 1.3.58.

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SHA 14 M --- C05 MM 100, Rev A. Page 246 of 361

Rev. A

Replace the wiper 1.3.26.

Loosen hexagon nut 1.3.46 and carefully support the hollow shaft 1.3.1 with the
backwash rotor in the filter housing. The corrosion protection of the filter housing
(rubberlining, coating) must not be damaged.

Note:
If the upper half of the filter housing has been disassembled (see section
3.1.1.1.2 Replacement of wear parts of backwash rotor) the hollow shaft 1.3.1
must be prevented from sliding out.


Screw the bow of the safety device for mounting (special tool is provided within the
scope of supply) to nut 1.3.9 by means of hexagon bolts.

Loosen slotted round nut 1.3.32 by means of hook wrench (special tool within scope of
supply) and remove together with distance ring 1.3.15 and tab washer 1.3.33.

Pull off the housing 1.3.2 complete with the worm gear and gear motor.

Remove the parallel keys 1.3.25, guide rings 1.3.38 and loosen hexagon socket head
cap screws 1.3.36.

Carefully remove the seal support 11 1.3.3 with o-ring 1.3.37.

Dismantle the seal support 10 1.3.70 with o-rings 1.3.81, 1.3.82, gasket 1.3.71 and
wiper 1.3.72.

Dismantle bush 1.3.8 with guide rings 1.3.38.

Replace gaskets 1.3.71 and wiper 1.3.72 as well as o-rings 1.3.81, 1.3.82 and guide
rings 1.3.38.

Replace the o-ring 1.3.37; grease the new o-ring with silicone grease GX 1 before
installation.

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SHA 14 M --- C05 MM 100, Rev A. Page 247 of 361

Rev. A

Assembly

Apply the permanently elastic sealing material 1.3.69 to the medium touched contact
surfaces of positions 1.3.1, 1.3.8, 1.3.58.

Mount bush 1.3.8 with guide rings 1.3.38.

Slip mounting device (enclosed in the set of special tools) onto the hollow shaft 1.3.1
and completely install the seal support 11 1.3.3 with seal support 10 1.3.70 and o-ring
1.3.37; carefully avoid any skewing!

Note:
The bores of the housing 1.3.2 and the seal supports 1.3.3 / 1.3.70 and 1.3.4 /
1.3.73 must be mounted in true alignment. The bottom drain holes must be
open.


Tighten the hexagon socket head cap screws 1.3.36.

Remove the mounting device and insert parallel keys 1.3.25.

Mount the housing 1.3.2 with the complete worm gear and fix with hexagon nuts 1.3.46.

Install the distance ring 1.3.15, tighten the slotted round nut 1.3.32 and secure with tab
washer 1.3.33.

Remove bow of the safety device for mounting.

Carefully position the fully assembled seal support 12 1.3.4.

Tighten the hexagon socket head cap screws 1.3.43.

Flange-mount the discharge pipe; ensure that the wiper 1.3.26 is fitted correctly !

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SHA 14 M --- C05 MM 100, Rev A. Page 248 of 361

Rev. A

Replacement of:

worm wheel shaft


worm shaft
groove ball bearing
angular ball bearing

1.3.6
1.3.7
1.3.28/1.3.29
1.3.54

For assembly, you will need securing for bolts and nuts (Loctite 242) 1.3.62.
The parts above mentioned are not wear parts. If replacement becomes necessary,
please proceed as follows:

Please ensure the following:

heat the bearings with suitable heaters before assembly


maximum temperatures
position 1.3.28 approximately 80 C (176 F)
position 1.3.29 approximately 70 C (158 F)

do not damage the seal contact surfaces on the hollow shaft

the bottom drain holes must be open

Dismantling


Disconnect the discharge pipe.

Loosen hexagon socket head cap screws 1.3.43 and remove seal support 12 1.3.4 with
all assembled components.

Loosen hexagon nut 1.3.46 and carefully support the hollow shaft 1.3.1 with the
backwash rotor in the filter housing. The corrosion protection of the filter housing
(rubberlining, coating) must not be damaged.

Note:
If the upper half of the filter housing has been disassembled (see section
3.1.1.1.2 "Replacement of wear parts of backwash rotor") the hollow shaft
1.3.1 must be prevented from sliding out.

Screw the bow of the safety device for mounting (special tool is provided within the
scope of supply) to nut 1.3.9 by means of hexagon bolts.

Loosen slotted round nut 1.3.32 by means of hook wrench (special tool within scope of
supply) and remove together with distance ring 1.3.15 and tab washer 1.3.33.

Pull off the housing 1.3.2 complete with the worm gear and gear motor.

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SHA 14 M --- C05 MM 100, Rev A. Page 249 of 361

Rev. A

At the motor-actuated side:




Loosen hexagon nut 1.3.50 of the threaded pin 1.3.56.

Remove the gear motor.

Remove the lantern 1.3.18 and the coupling.

At the non-actuated side:




Loosen the hexagon bolt 1.3.23 and remove the cap 1.3.24.

Loosen the hexagon nut 1.3.50.

Remove the bearing support 4 1.3.20 by means of jacking screws.

Remove the retaining ring 1.3.40 and the supporting ring 1.3.22 and remove the groove
ball bearing 1.3.29 (free bearing side).

Loosen the hexagon nut 1.3.50 on the fixed bearing side and remove the stud 1.3.49
and threaded pin 1.3.56.

Remove the worm shaft 1.3.7 with the bearing support 3 1.3.19 by tipping and turning
(fixed bearing side).

Loosen hexagon socket head cap screw 1.3.21 and remove the cover 1.3.5.

Remove the worm shaft 1.3.7 with the angular ball bearing 1.3.54 from the bearing
support 3 1.3.19.

Loosen the tab washer 1.3.48 and the slotted round nut 1.3.41 by using the hook wrench
(special tool provided within the scope of supply) and remove the ring 1.3.14 and the
Nilos ring 1.3.55.

Remove the angular ball bearing 1.3.54, remove the Nilos ring 1.3.55 (note: only use
new Nilos rings for assembly).

Remove the retaining rings 1.3.34, 1.3.35 and the shim ring 1.3.60.

Push the worm wheel shaft 1.3.6 with the groove ball bearing 1.3.28, the supporting ring
1.3.13 and the shim ring 1.3.61 out of the housing 1.3.2 towards the fixed bearing side.

Remove the groove ball bearing 1.3.28 (free bearing) from the housing.

Remove the groove ball bearing 1.3.28 (fixed bearing), shim ring 1.3.61 and the
supporting ring 1.3.13.

Check the bearing and bearing seating.

Check the worm wheel shaft 1.3.6 and the worm shaft 1.3.7 for wear and replace, if
necessary.

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SHA 14 M --- C05 MM 100, Rev A. Page 250 of 361

Rev. A

Assembly

Note:
Secure positions 1.3.21, 1.3.49, 1.3.50 and 1.3.56 (except counter nuts) with
securing for bolts and nuts 1.3.62.

Fit the supporting ring 1.3.13 and the shim ring 1.3.61 to the worm wheel shaft 1.3.6.

Fix the groove ball bearing 1.3.28 at the fixed bearing side; adjust with shim rings 1.3.60
and secure with the retaining ring 1.3.35.

Mount the worm wheel shaft 1.3.6 with the fully assembled groove ball bearing 1.3.28
into the housing 1.3.2.

Insert the retaining ring 1.3.34.

Add grease G 7 (1.3.64) - approximately 400 g.

Mount the groove ball bearing 1.3.28 to the free bearing side.

Mount the Nilos ring 1.3.55 and the angular ball bearing 1.3.54 (fixed bearing side) to
the worm shaft 1.3.7; apply the Nilos ring 1.3.55, ring 1.3.14 and tab washer 1.3.48,
tighten and secure with the slotted round nut 1.3.41.

Mount the bearing support 3 1.3.19 and fix the cover 1.3.5 with the hexagon socket head
cap screws 1.3.21.

Spread grease G 7 (approximately 100 g) on the worm shaft.

Insert the worm shaft 1.3.7 with the fully assembled angular ball bearing 1.3.54 by
tipping and turning into the housing 1.3.2.

According to position of the gear motor the bearing support 3 1.3.19 is mounted to the
housing 1.3.2 with studs 1.3.49, threaded pin 1.3.56 and hexagon nuts 1.3.50 or with
studs 1.3.49 and hexagon nuts 1.3.50.

Mount the groove ball bearing 1.3.29 and fix it with the supporting ring 1.3.22 and
retaining ring 1.3.40.

Mount the bearing support 4 1.3.20 with stud 1.3.49 and hexagon nut 1.3.50 or with
stud 1.3.49, threaded pin 1.3.56 and hexagon nut 1.3.50.

Set the flank clearance by positioning the bearing supports 3 1.3.19 and 4 1.3.20.

Tighten the hexagon nuts 1.3.50 with the required tightening torque.

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SHA 14 M --- C05 MM 100, Rev A. Page 251 of 361

Rev. A

At the non-actuated side:




Fix the cap 1.3.24 with hexagon bolt 1.3.23.

At the motor-actuated side:




Install and secure the coupling.

Install the lantern 1.3.18 and the gear motor.

Mount the housing 1.3.2 with the complete worm gear and fix with hexagon nuts 1.3.46.

Install the distance ring 1.3.15, tighten the slotted round nut 1.3.32 and secure with tab
washer 1.3.33.

Remove bow of the safety device for mounting.

Carefully position the fully assembled seal support 12 1.3.4 (bottom drain hole must be
open)

Tighten the hexagon socket head cap screws 1.3.43.

Flange-mount the discharge pipe; ensure that the wiper 1.3.26 is fitted correctly!

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SHA 14 M --- C05 MM 100, Rev A. Page 252 of 361

Rev. A

3.1.1.1.2.

Backwash rotor

(see drawing K2009/20/1368-0503)

Warning:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and make
it safe. Ensure that the voltage supply to the electric actuators has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter has
been drained. It is absolutely necessary to ensure that people are not exposed to danger
due to an inrush of water into the filter during maintenance work.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

The filter housing must be removed for the replacement of wear parts. We recommend this
work to be performed by the TAPROGGE Service Department.

Wear parts of bearing:

wiper
o-rings
tab washer

1.3.16
1.3.77
1.3.78

Loosen the tab washers 1.3.78 and hexagon nuts 1.3.50 and remove together with
washers 1.3.51

Remove the shim rings 1.3.10 (if any), o-ring support 1.3.76, wiper 1.3.16, spacer 1.3.17
and o-rings 1.3.77 and lay the backwash rotor down in the filter section

Replace the wiper 1.3.16, tab washer 1.3.78 and o-rings 1.3.77

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SHA 14 M --- C05 MM 100, Rev A. Page 253 of 361

Rev. A

Set of wear parts V3:

rubber lip 1
1.4.1.2
rubber lip 2
1.4.1.3
domed cap nut
1.4.1.7
slide washer
rubber lip 3
1.4.16
rubber lip 4
1.4.17
rubber lip 5
1.4.18
rubber lip 6
1.4.19
o-ring
1.4.20
o-ring
1.4.21
o-ring
1.4.22

1.4.9

For assembly of the backwash rotor, you will need securing for bolts and nuts 1.4.1.9 and
1.4.33 (Loctite 242).
(see drawing K2009/20/1368-0503)

Loosen and remove the domed cap nut 1.4.1.7 with washers 1.4.1.6 and hexagon bolt
1.4.29, replace the domed cap nuts

Take out the sheets 1.4.1.4, 1.4.1.5, 1.4.14, 1.4.15 and the rubber lips 1.4.1.2, 1.4.1.3,
1.4.16, 1.4.17, 1.4.18 and 1.4.19, replace the rubber lips

Loosely screw the rubber lips and sheets with the domed cap nuts 1.4.1.7 and hexagon
bolts 1.4.29

Note:
In the rotation direction the rubber lip 1.4.1.3 on the leading edge gives a
clearance of a few millimetres to the filter section. The rubber lip 1.4.1.2 on the
trailing edge, as well as rubber lips 1.4.16, 1.4.17, 1.4.18 and 1.4.19, must sit
close to the filter section!

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SHA 14 M --- C05 MM 100, Rev A. Page 254 of 361

Rev. A

Replacement of the o-rings 1.4.20, 1.4.21, 1.4.22 and the slide washer 1.4.9:










loosen the hexagon bolts 1.4.23 and remove with washers 1.4.30, 1.4.11,
rotor 1.4.4, shim rings 1.4.10 and parallel key 1.4.13
loosen the hexagon bolts 1.4.24, 1.4.25 and remove the washer 1.4.12
remove the arm 1.4.1.1 of the backwash rotor
loosen the hexagon bolts 1.4.26 at the rotor support 1.4.2
remove the rotor support 1.4.2
remove the pusher shaft 1.4.3, o-ring 1.4.20 and 1.4.21 and gasket 1.4.8
remove the slide washer 1.4.9 and bush 1.4.5
remove the o-ring 1.4.22 from the shielding 1.4.6
replace the o-rings 1.4.20, 1.4.21, 1.4.22 and slide washer 1.4.9

Secure the screws with securing for bolts and nuts 1.4.1.9 while reassembling in reverse
order

Mount the component parts of the bearing, fix with the hexagon nuts 1.3.50 and the tab
washers 1.3.78 and secure with securing for bolts and nuts 1.3.63

Apply the sealing material 1.3.69 to the medium touched contact surfaces of the
positions 1.3.9, 1.3.10, 1.3.17 and 1.3.27

Adjust the rubber lips, tighten the domed cap nuts 1.4.1.7 and hexagon bolts 1.4.29 and
secure with securing for bolts and nuts 1.4.1.9.

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SHA 14 M --- C05 MM 100, Rev A. Page 255 of 361

Rev. A

3.1.1.2.

Differential pressure measuring system

(see drawing K2009/20/1368-0501)

Caution:
As long as the differential pressure measuring system is out of order the debris
accumulated on the filter section cannot be monitored.
Therefore the filter shall be backwashed continuously while performing the following
work in the operating mode MANUAL (see section 1.3.5.3).
After the work has been completed, resume the operating mode AUTOMATIC.

Check tightness of the differential pressure measuring system as follows:


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


If the p indication decreases:


check PLUS side of the differential pressure measuring system for leakage and repair it
accordingly.

If the p indication increases:


check MINUS side of the differential pressure measuring system for leakage and repair
it accordingly.

If it may become necessary to replace parts or the complete isolation, see section
3.1.1.5.2 as well as section 4.

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SHA 14 M --- C05 MM 100, Rev A. Page 256 of 361

Rev. A

Cleaning of the differential pressure measuring system

Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and make
it safe. Ensure that the voltage supply to the electric consumers has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
must be drained.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

Close and lock the isolation valves of the differential pressure measuring system.

Remove differential pressure transmitter with remote seal / remote seal with capillary
tube. Take care, that the measuring diaphragm will not be damaged.

Caution:
Do not use the capillary tube for carrying and do not bend it. Do not loosen the
connection between capillary tube and remote seal. Deposits may not be removed using
sharp objects.

Clean the isolation valves of the differential pressure measuring system and the
diaphragm of the differential pressure transmitter.

Clean the sealing between remote seal and isolating valve

Assemble differential pressure transmitter and remote seal, tighten bolts crosswise.

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SHA 14 M --- C05 MM 100, Rev A. Page 257 of 361

Rev. A

Calibration of the differential pressure measuring system

Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and make
it safe. Ensure that the voltage supply to the electric consumers has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
must be drained.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

Close and lock the isolation valves of the differential pressure measuring system.

Remove differential pressure transmitter with remote seal / remote seal with capillary
tube. Take care, that the diaphragm will not be damaged.

Caution:
Do not use the capillary tube for carrying and do not bend it. Do not loosen the
connection between capillary tube and remote seal. Deposits may not be removed using
sharp objects.

Calibration according to manufacturer's instructions "Differential pressure transmitter",


section 4.

Assemble differential pressure transmitter and remote seal, tighten bolts crosswise.

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SHA 14 M --- C05 MM 100, Rev A. Page 258 of 361

Rev. A

3.1.1.3.

Gear motor for backwash rotor

Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and
make it safe. Ensure that the voltage supply to the electric consumers has been
interrupted. Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
must be drained because the debris accumulation at the filter section cannot be
monitored or discharged.
After the work is completed, restart the filter system according to section 1.3.8 of
these operating instructions.

Repairs according to the manufacturers instructions (see section 4: Gear motor for backwash
rotor).

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SHA 14 M --- C05 MM 100, Rev A. Page 259 of 361

Rev. A

3.1.1.4.

Part-turn actuator of the discharge valve

(see drawing K2009/20/1368-0502)


The part-turn actuator has no wear parts and should be completely replaced in case of defect.

Caution:
As long as the discharge valve is closed the debris accumulated cannot be removed.
Therefore the filter shall be backwashed in the operating mode MANUAL before
starting maintenance work. During replacement of actuator the differential pressure
must not reach the limit value p EXCESSIVE HIGH.

Replacement of the part-turn actuator with built-in ball valve

Backwash the filter according to section 1.3.5.3 in the operating mode MANUAL,
actuate the discharge valve by the handwheel of the defective part-turn actuator

Check the position CLOSE of the ball valve; final position is indicated at the control
panel

Interrupt the voltage supply to the filter system; put the main switch Q01 in the position
OFF

Unplug part-turn actuator

Loosen the screw connection and remove the part-turn actuator together with the
coupling from the lantern of the ball valve.

Turn the spare part-turn actuator to the position CLOSE by means of the handwheel.
Verify 90 movement of pointer at the window of the mechanical position indicator,
indicating the proper function of the travel limit switches of the part-turn actuator

Verify that the ball valve is in the position CLOSE (marking at stem vertical to flow
direction)

Put the spare part-turn actuator (in position CLOSE) with the built-in coupling onto the
lantern of ball valve

Mount the part-turn actuator to the lantern of ball valve by means of the screw
connection following the manufacturers instructions

Set the mechanical position indicator at the part-turn actuator to the position CLOSE

Plug in part-turn actuator

Connect voltage supply to filter system: put the main switch Q01 in the position ON

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SHA 14 M --- C05 MM 100, Rev A. Page 260 of 361

Rev. A

Check of limit switches at the part-turn actuator of discharge valve


After replacing the part-turn actuator, the setting of the limit switches (travel limit switches and
torque limit switches) must be checked and corrected according to the rating plate on the partturn actuator, if necessary (see section 4 Part-turn actuator of discharge valve).


Put the selector switch MANUAL / AUTOMATIC at the control panel in the position
MANUAL

Move the part-turn actuator by means of the handwheel


Upon reaching the final position OPEN or CLOSE the part-turn actuator shuts off via the
corresponding travel limit switch. The final positions are signalled to the control panel by
these travel limit switches.

Note:
The torque limit switches serve as overload protection. In case of tripping,
see section 1.3.11.

Check the moving direction of the part-turn actuator




Put the selector switch MANUAL / AUTOMATIC at the control panel in the position
MANUAL

Use the handwheel of the part-turn actuator to turn the discharge valve into a position
between the final positions OPEN and CLOSE

Press the function key discharge valve CLOSE to move the part-turn actuator

Before reaching the final position CLOSE, stop the part-turn actuator by pressing the
function key discharge valve STOP

Check the moving direction (towards CLOSE) by means of the mechanical position
indicator on the part-turn actuator.
The mechanical position indicator on the part-turn actuator must correspond with the
selected moving direction. Otherwise the moving direction of the part-turn actuator must
be corrected according to section 4 Part-turn actuator of discharge valve.

Put the selector switch MANUAL / AUTOMATIC at the control panel in the operating
mode AUTOMATIC

Initiate a filter backwash by pressing the function key FILTER BACKWASH

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SHA 14 M --- C05 MM 100, Rev A. Page 261 of 361

Rev. A

3.1.1.5.

3.1.1.5.1.

Valves

Ball valve of discharge valve

(see drawing K2009/20/1368-0502)

Warning:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and
make it safe. Ensure that the voltage supply to the electric actuators has been
interrupted. Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
has been drained. It is absolutely necessary to ensure that people are not exposed to
danger due to an inrush of water during maintenance work.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

To replace wear parts or make repairs on the valves, please proceed as follows:

Remove the part-turn actuator

Drain the discharge pipe

Remove the valve from the discharge pipe

Replace the wear parts (section 3.2.4) or perform repairs according to section 4 Ball
valve

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SHA 14 M --- C05 MM 100, Rev A. Page 262 of 361

Rev. A

3.1.1.5.2.

Isolation valves of differential pressure measuring system

(see drawing K2009/20/1368-0501)

Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and make
it safe. Ensure that the voltage supply to the electric actuators has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
must be drained.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

Replace the wear parts (section 3.2.4) or perform repairs according to section 4 Diaphragm
valve

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SHA 14 M --- C05 MM 100, Rev A. Page 263 of 361

Rev. A

3.1.1.5.3.

Filter drain valve

Warning:
Before starting work, shut down the filter system (see section 4.6), isolate it and make
it safe. Ensure that the voltage supply to the electric actuators has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the main cooling water flow must be shut off and locked and the filter
has been drained.
After the work is completed, restart the filter system according to section 4.8 of these
operating instructions.

Replace the wear parts or perform repairs according to manufacturers instructions, section 9
"Ball valve"

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SHA 14 M --- C05 MM 100, Rev A. Page 264 of 361

Rev. A

3.1.1.6.

Control panel

Caution:
Before starting work, shut down the filter system (see section 1.3.6), isolate it and make
it safe. Ensure that the voltage supply to the electric actuators has been interrupted.
Voltage-carrying adjoining parts must be covered or kept separate.
To begin work, the filter must run in emergency actuation according to section 1.3.5.4.
After the work is completed, restart the filter system according to section 1.3.8 of these
operating instructions.

The control panel contains no wear parts. Signal lamps are spare parts and are included in the
control panel.
For repairs of the electrotechnical components see the electrical documentation, section 5 and
the manufacturers' instructions, section 4.

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SHA 14 M --- C05 MM 100, Rev A. Page 265 of 361

Rev. A

3.1.2.

PREVENTIVE MAINTENANCE SCHEDULE

DESCRIPTION
ITEM No.
PARTICIPANT

UNIT

SYSTEM

COMPONENT

SEQUENCE

FUNCTION

NUMBER

PERIO
D

ACTION

SPARES
REQUIREMENT

REFERENCE PROCEDURE

TAPROGGE

12/13/14

PCB15/1
6

AT

001

filter housing
(Debris filter)

coating of housing, external damage,


signs of corrosion

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

TAPROGGE

12/13/14

PCB15/1
6

AT

001

sealings (Debris
filter)

tightness of flange connections

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

TAPROGGE

12/13/14

PCB15/1
6

AT

001

bearing
assembly
(Debris filter)

tightness of bearing assembly


(check by means of drain hole at
bearing housing), tightening of screw
connections, quiet running of worm
gear

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

TAPROGGE

12/13/14

PCB15/1
6

AT

001

backwash rotor
(Debris filter)

movability : filter backwash in the


operating mode MANUAL (section
1.3.5.3) differential pressure must
drop

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

TAPROGGE

12/13/14

PCB15/1
6

AT

001

backwash rotor
(Debris filter)

movability : check direction of rotation


of backwash rotor

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

TAPROGGE

12/13/14

PCB15/1
6

AT

001

backwash rotor
and filter section
(Debris filter)

3Y

cleanliness, fastening of internals,


condition of rubber lips, rubberlining
of internal filter housing

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

TAPROGGE

12/13/14

PCB15/1
6

AT

001

drain valve
(Debris filter)

Movability of actuation

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

TAPROGGE

12/13/14

PCB15/1
6

AT

001

drain valve
(Debris filter)

tightening of flange connections

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

TAPROGGE

12/13/14

PCB15/1
6

AT

001

drain valve
(Debris filter)

coating, external damage, signs of


corrosion, internals

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

TAPROGGE

12/13/14

PCB15/1
6

CP

010

entire differential
pressure
measuring
system

proper function, tightness

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

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SHA 14 M --- C05 MM 100, Rev A. Page 266 of 361

Rev. A

DESCRIPTION

PERIO
D

entire differential
pressure
measuring
system
entire differential
pressure
measuring
system
isolation valves
(Differential
pressure
measuring
system)
isolation valves
(Differential
pressure
measuring
system)
isolation valves
(Differential
pressure
measuring
system)
remote seals /
remote seals
with capillary
tubes
(Differential
pressure
measuring
system)
electric motor
(Gear motor for
backwash rotor)

6M

electric motor
(Gear motor for
backwash rotor)

ITEM No.
PARTICIPANT

UNIT

SYSTEM

COMPONENT

SEQUENCE

FUNCTION

NUMBER

TAPROGGE

12/13/14

PCB15/1
6

CP

010

TAPROGGE

12/13/14

PCB15/1
6

CP

010

TAPROGGE

12/13/14

PCB15/1
6

CP

010

TAPROGGE

12/13/14

PCB15/1
6

CP

010

TAPROGGE

12/13/14

PCB15/1
6

CP

010

TAPROGGE

12/13/14

PCB15/1
6

CP

010

TAPROGGE

12/13/14

PCB15/1
6

AT

001

TAPROGGE

12/13/14

PCB15/1
6

AT

001

ACTION

SPARES
REQUIREMENT

REFERENCE PROCEDURE

cleaning of differential pressure


measuring system

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

calibration of differential pressure


measuring system

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

coating, external damage, signs of


corrosion, internals

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

movability of actuation

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

tightness of flange connections

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

fastening, tightness

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

coating, cleanliness, external


damage, quiet running, compare
setting current of manual motor
starter with nominal current of motor
proper cable connection

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

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SHA 14 M --- C05 MM 100, Rev A. Page 267 of 361

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

Rev. A

DESCRIPTION

PERIO
D

spur gear (Gear


motor for
backwash rotor)
ball valve
(Discharge
valve)
ball valve
(Discharge
valve)
part-turn
actuator
(Discharge
valve)
part-turn
actuator
(Discharge
valve)

cleanliness, quiet running, tightness,


coating

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

coating, external damage, signs of


corrosion, internals

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

movability of actuation, tightness of


flange connections

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

coating, external damage, tightness,


cleanliness

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

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

3Y

operability and movability (by


handwheel), proper cable connection,
tightening of fastening screws
between actuator and valve,
adjustments: limit stops + limit
switches + mechanical position
indicator
wear of worm gear and planetary
gearing

ITEM No.
PARTICIPANT

UNIT

SYSTEM

COMPONENT

SEQUENCE

FUNCTION

NUMBER

TAPROGGE

12/13/14

PCB15/1
6

AT

001

TAPROGGE

12/13/14

PCB15/1
6

AA

016

TAPROGGE

12/13/14

PCB15/1
6

AA

016

TAPROGGE

12/13/14

PCB15/1
6

AA

016

TAPROGGE

12/13/14

PCB15/1
6

AA

016

TAPROGGE

12/13/14

PCB15/1
6

AA

016

TAPROGGE

12/13/14

PCB15/1
6

AA

016

TAPROGGE

12/13/14

GH

001

TAPROGGE

12/13/14

PCB15/1
6
PCB15/1
6

part-turn
actuator
(Discharge
valve)
switching and
signalling device
(Discharge
valve)
control panel

GH

001

control panel

TAPROGGE

12/13/14

GH

001

control panel

2Y

TAPROGGE

12/13/14

PCB15/1
6
PCB15/1
6

GH

001

control panel

7Y

ACTION

SPARES
REQUIREMENT

operability

lamp for common alarm (by the


function key on control panel door)
external damage, cleanliness,
terminal connections, check
adjustable times, proper function of
control (in the operating mode
AUTOMATIC)
replace / add battery of PLC

REFERENCE PROCEDURE

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

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

replace battery of the Operator


Terminal / real-time clock module

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SHA 14 M --- C05 MM 100, Rev A. Page 268 of 361

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

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

Rev. A

3.1.3.
PARTICIPANT

LUBRICATION INSTRUCTIONS AND SCHEDULE


EQUIPMENT

ITEM No.
UNIT

Taprogge

Taprogge

Taprogge

SYSTEM

worm wheel of 12/13/14 PCB15/16


reduction gear
(bearing of
backwash rotor)
rolling bearing 12/13/14 PCB15/16
120/180 x 28
(bearing of
backwash rotor)
Gear motor for 12/13/14 PCB15/16
backwash rotor

PARTS TO BE
LUBRICATED
COMPONENT
FUNCTION

SEQUENCE
NUMBER

AT

010

AT

AT

PERIO
D

NUMBER OF
LUBRICATION

LUBRICANT

QUANTITY

DRAIN
FREQUENCY

POINTS

REF 1

REF 2

REF 3

worm wheel shaft/


worm shaft

ARAL Degol
GS220

BP Enersyn
SG-XP220

Mobil
Glygoyle
HE460

500 g

3Y

010

cage

ARAL Degol
GS220

BP Enersyn
SG-XP220

Mobil
Glygoyle
HE460

250 g

3Y (exchange)

010

gear housing

ARAL Degol
GS220

BP Enersyn
SG-XP220

Mobil
Glygoyle
HE460

700 ccm

3Y (exchange)

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SHA 14 M --- C05 MM 100, Rev A. Page 269 of 361

Rev. A

3.1.4.

SPECIAL TOOLING AND HANDLING DEVICES

Tools for Maintenance

Part name

Material

handwheel AL-315-K28-D

Al

mounting device

steel

hook wrench HN 18

steel

hook wrench NN 7

steel

safety device for mounting

1.4541

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SHA 14 M --- C05 MM 100, Rev A. Page 270 of 361

Rev. A

3.1.5.

STORAGE INSTRUCTIONS

Storage of parts

Caution:
The packing is prepared for a life of 6 or 24 months.
A storage below 5 C (41 F), in particular of rubberlined parts, is not admissible.
The packing is not suitable for outdoor storage.
Parts which cannot be immediately installed shall be stored in dry and lockable rooms.

Delivery

covered with foil in


boxes or on pallets

Inspection

packing

Frequency of
inspections
every 3 months

provide packing (not


splash-proof) with waterrepellent covering
close or repair damaged
packing

(maximum storage 6
months)
in sealed vinyl cover in
boxes

Remarks

packing

every 6 months

(maximum storage 24
months)

provide packing (not


splash-proof) with waterrepellent covering
in case of open packing:
reseal cover

moisture indicator
(if applicable)

every 6 months

desiccant

every 6 months

check moisture indicator

renew desiccant

Note:
Parts which are not sealed in vinyl cover shall be removed from packing and stored in
dry rooms. If parts cannot be stored as indicated please inform the TAPROGGE Service
Department.

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SHA 14 M --- C05 MM 100, Rev A. Page 271 of 361

Rev. A

Disposal of packing material

Note:
Our products are protected for the transport ex works by environmentally friendly
materials (wood, cardboard, paper and PE foil) which can easily be separated and
recycled according to local regulations.

3.1.6.

PRESERVATION INSTRUCTIONS

See sections 1.3.6 and 1.3.7.

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SHA 14 M --- C05 MM 100, Rev A. Page 272 of 361

Rev. A

3.2. CORRECTIVE MAINTENANCE INSTRUCTIONS

Wear part

3.2.1.

Drawing no.

Position

Replacement frequency

Debris filter

(12/13/14PCB15AT010 / 12/13/14PCB16AT010)

Bearing assembly 2.3


Set of wear parts V1:
o-ring
o-ring
gasket
wiper
o-ring
o-ring
gasket
wiper
o-ring
o-ring
Set of wear parts V2:
wiper
wiper
o-ring
guide ring
o-ring
tab washer
Set of wear parts V4:
lubricant for worm wheel and
bearings

K2009/20/1368-0503

1.3.37
1.3.66
1.3.71
1.3.72
1.3.74
1.3.75
1.3.79
1.3.80
1.3.81
1.3.82

every 3 years or in case of


leakages from the drain hole.
In order to check sealing of
bearing assembly see section
3.1.1.1.1

1.3.16
1.3.26
1.3.37
1.3.38
1.3.77
1.3.78
1.3.64

Backwash rotor
Set of wear parts V3:
rubber lip 1
rubber lip 2
domed cap nut
slide washer
rubber lip 3
rubber lip 4
rubber lip 5
rubber lip 6
o-ring
o-ring
o-ring
*

K2009/20/1368-0503

1.4.1.2
1.4.1.3
1.4.1.7
1.4.9
1.4.16
1.4.17
1.4.18
1.4.19
1.4.20
1.4.21
1.4.22

every 3 years

During replacing wear parts of filter please record the reading of the running time meter of
backwash rotor as an additional information (see operating record section 1.3.9)

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SHA 14 M --- C05 MM 100, Rev A. Page 273 of 361

Rev. A

Wear part

3.2.2.

Drawing no.

Position

Replacement frequency

Differential pressure measuring system

(12/13/14PCB15CP010 / 12/13/14PCB16CP010)

none

3.2.3.

Gear motor for backwash rotor

(12/13/14PCB15AT001 / 12/13/14PCB16AT001)

none

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SHA 14 M --- C05 MM 100, Rev A. Page 274 of 361

Rev. A

Wear part

3.2.4.

Drawing no.

Position

Replacement frequency

Valves

(12/13/14PCB15AA016 / 12/13/14PCB16AA016)
Ball valve
see manufacturer's instructions

(12/13/14PCB15AA301/302 & 12/13/14PCB16AA301/302)


Diaphragm valve
diaphragm

see section 4

443

every 5 years

Note:
See disassembled material to a sound disposal or to separate recycling according to
materials. Observe the national regulations for waste disposal.
After the end of the service life, old rubberlined system parts can be recycled easily via
valuable metal recycling companies (smelting).

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SHA 14 M --- C05 MM 100, Rev A. Page 275 of 361

Rev. A

4.

ACCESSORIES
KKS

MATERIAL / TYPE

SUPPLIER

12/13/14PCB15CP010
12/13/14PCB16CP010

Differential pressure transmitter / 1151 DP 4 S

Emerson

12/13/14PCB15CP010
12/13/14PCB16CP010

Remote seal / 1199

Emerson

12/13/14PCB15AT001
12/13/14PCB16AT001

Gear motor for backwash rotor / SK 02

Getriebebau Nord

12/13/14PCB15AA016
12/13/14PCB16AA016

Part turn actuator of discharge valve / SG 07.1

AUMA

12/13/14PCB15AA016
12/13/14PCB16AA016

Ball valve

Brooksbank

12/13/14PCB15AA301/302
12/13/14PCB16AA301/302

Diaphragm valve / SISTO KB

KSB

12/13/14PCB15/16GH001

Programmable logic controller / FlexxLogix 5434

Allen Bradley

12/13/14PCB15/16GH001

Operator Terminal / PV 600

Allen Bradley

12/13/14PCB15/16GH001

Analogue data repeater / IM31-12Ex-I

Turck

12/13/14PCB15/16GH001

Isolating switching amplifier / IM1-12Ex-R

Turck

Originator

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

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

22.10.2009

en

88/89

ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 276 of 361

Rev. A

5. DRAWING AND PART LISTS


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

Taprogge Index no.


K2009/20/1368-0001
K2009/20/1368-0505
K2009/20/1368-0503
1/20/0111-0016
1/20/0112-0005
K2009/20/1368-0501
K2009/20/1368-0502

SHA/14/M/---C05/WD/002

K2009/20/1368-1000

SHA/14/M/---C05/DS/011
SHA/14/M/---C05/DS/012
SHA/14/M/---C05/DS/013
SHA/14/M/---C05/DS/014
SHA/14/M/---C05/DS/015

Title
Flow Diagram
Assembly debris filter
Debris filter PR-BW 100
Filter section
Inspection hole
Differential pressure measuring system
Discharge valve
Electrical documentation of control
panel
Data sheet CCW Exchanger Debris
filter
Data sheet LV Motor CCW Exchanger
Debris filter
Data sheet Valves CCW Exchanger
Debris filter
Data sheet Pr. Transmitter CCW
Exchanger Debris filter
Data sheet Actuator CCW Exchanger
Debris filter

Originator

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

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

22.10.2009

en

89/89

ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 277 of 361

16.09.2009

Schmidlin

Gller

Neugebauer

First issue

FUS

REV

DATE

PREPARED

CHECKED

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DD

Title :

Sectional drawing of CCW Exchanger


Debris Filter with parts list

Language
:E

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 8

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/DD/002

SHA 14 M --- C05 MM 100, Rev A. Page 278 of 361

Stand/Status: 15.03.2005
Erstellt/prepared: 16.09.2009/w

Blatt/Sheet: 1/4

TL2009201368.xls

TEILELISTE / PARTS LIST


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

Dokumenten-Nr. / Document No.


entstanden aus / originating from:
zugehrige Zeichnung / relevant drawing:
entstanden aus / originating from:

Pos.
Pos.

Part name

Benennung

Stk
No

QA2009/20/1368-0020
4/20/0150-0112

K2009/20/1368-0503
1/20/0150-0005

Sach-Nr.
Ident-No.

Bemerkungen
Remarks

FILTER

FILTER

V1-V4 = Verschleiteil-Stze

1.1

FILTERGEHUSE 1

FILTER HOUSING 1

R1-R6 = Reserveteil-Stze

1.2

FILTERGEHUSE 2

FILTER HOUSING 2

LAGERUNG
Hohlwelle
Gehuse
Dichtungstrger 11
Dichtungstrger 12
Deckel
Schneckenradwelle
Schneckenwelle
Buchse
Mutter
Pascheibe
Sttzscheibe
Ring
Distanzring
Abstreifer
Distanzscheibe
Laterne
Lagertrger 3
Lagertrger 4
Zylinderschraube
Sttzscheibe
Sechskantschraube
Haube
Pafeder
Abstreifer

BEARING ASSEMBLY
Hollow shaft
Housing
Seal support 11
Seal support 12
Cover
Worm wheel shaft
Worm shaft
Bush
Nut
Adjusting washer
Supporting ring
Ring
Distance ring
Wiper
Spacer
Lantern
Bearing support 3
Bearing support 4

= Sets of wear parts

= Sets of spare parts

1.3
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.3.6
1.3.7
1.3.8
1.3.9
1.3.10
1.3.13
1.3.14
1.3.15
1.3.16
1.3.17
1.3.18
1.3.19
1.3.20
1.3.21
1.3.22
1.3.23
1.3.24
1.3.25
1.3.26
1.3.27
1.3.28
1.3.29
1.3.32
1.3.33
1.3.34
1.3.35
1.3.36
1.3.37

1
1
1
1
1
1
1 R1
1 R1
1
1
1
1 R2
1
1
1 V2
1
1
1
1
4
1 R3
2
1
2 R1
1 V2
1 Satz/
set
2 R2
1 R3
1 R2
1 R2
1 R2
1 R2
2
1 V1

Pascheibe
Rillenkugellager
Rillenkugellager
Wellenmutter
Sicherungsblech
Sicherungsring
Sicherungsring
Zylinderschraube
O-Ring

Hexagon socket head cap screw

Supporting ring
Hexagon bolt
Cap
Parallel key
Wiper
Adjusting washer
Groove ball bearing
Groove ball bearing
Slotted round nut
Tab washer
Retaining ring
Retaining ring
Hexagon socket head cap screw

O-ring

V2

1.3.38
1.3.39
1.3.40
1.3.41
1.3.42
1.3.43
1.3.44
1.3.45

2 V2 Fhrungsring
8
Stiftschraube
1 R3 Sicherungsring
1 R3 Wellenmutter
2
Pafeder
16
Zylinderschraube
16
Scheibe
16
Scheibe

R = Reserveteil/Spare part
V = Verschleiteil/Wear part

Guide ring
Stud
Retaining ring
Slotted round nut
Parallel key
Hexagon socket head cap screw

Washer
Washer

SHA 14 M --- C05 MM 100, Rev A. Page 279 of 361

Stand/Status: 15.03.2005
Erstellt/prepared: 16.09.2009/w

Blatt/Sheet: 2/4

TL2009201368.xls

TEILELISTE / PARTS LIST


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

Dokumenten-Nr. / Document No.


entstanden aus / originating from:
zugehrige Zeichnung / relevant drawing:
entstanden aus / originating from:

Pos.
Pos.
1.3.46
1.3.47
1.3.48
1.3.49
1.3.50
1.3.51
1.3.52
1.3.53
1.3.54
1.3.55
1.3.56
1.3.58
1.3.60
1.3.61
1.3.62
1.3.63
1.3.64

Benennung

Stk
No
16
16
1
10
36
26
2
14
2
2
4
8
5
5

R3

R3
R3

R2
R2

Sechskantmutter
Stiftschraube
Sicherungsblech
Stiftschraube
Sechskantmutter
Scheibe
Scheibe
Gewindestift
Schrgkugellager
NILOS-Ring
Gewindebolzen
Zylinderschraube
Pascheibe
Pascheibe
Schraubensicherung
Schraubensicherung

RCKSPLROTOR
Rcksplrotor
Arm
Gummilippe 1
Gummilippe 2
Blech 1
Blech 2
Scheibe
Hutmutter
Sttzblech

BACKWASH ROTOR
Backwash rotor
Arm
Rubber lip 1
Rubber lip 2
Sheet 1
Sheet 2
Washer
Domed cap nut
Supporting plate

radsatz und Lager


1 V1 O-Ring
1
Drehrichtungsanzeige,

1.3.68

1.3.69
1.3.70
1.3.71
1.3.72
1.3.73
1.3.74
1.3.75
1.3.76
1.3.77
1.3.78
1.3.79
1.3.80
1.3.81
1.3.82

1
1
1
1
1
1
1
2
4
1
1
1
2

1.4
1.4.1
1.4.1.1
1.4.1.2
1.4.1.3
1.4.1.4
1.4.1.5
1.4.1.6
1.4.1.7
1.4.1.8

1
1
1
1
1
2
2
38
14
1

V1
V1
V2
V2
V1
V1
V1
V1

V3
V3

V3

Hexagon socket head cap screw

rechts
Drehrichtungsanzeige,
links
Dichtungsmasse
Dichtungstrger 10
Dichtung
Abstreifer
Dichtungstrger 9
O-Ring
O-Ring
O-Ringtrger
O-Ring
Sicherungsblech
Dichtung
Abstreifer
O-Ring
O-Ring

1.3.66
1.3.67

V1

Hexagon nut
Stud
Tab washer
Stud
Hexagon nut
Washer
Washer
Hexagon socket set screw
Angular ball bearing
NILOS ring
Threaded pin
Shim ring
Shim ring
Securing for bolts and nuts
Securing for bolts and nuts
Lubricant for worm wheel
and bearings
O-ring
Indication turning direction,
right
Indication turning direction,
left
Sealing material
Seal support 10
Gasket
Wiper
Seal support 9
O-ring
O-ring
O-ring support
O-ring
Tab washer
Gasket
Wiper
O-ring
O-ring

V4 Schmiermittel fr Schnecken-

V1

Part name

R = Reserveteil/Spare part
V = Verschleiteil/Wear part

SHA 14 M --- C05 MM 100, Rev A. Page 280 of 361

QA2009/20/1368-0020
4/20/0150-0112

K2009/20/1368-0503
1/20/0150-0005

Sach-Nr.
Ident-No.

Bemerkungen
Remarks

Stand/Status: 15.03.2005
Erstellt/prepared: 16.09.2009/w

Blatt/Sheet: 3/4

TL2009201368.xls

TEILELISTE / PARTS LIST


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

Dokumenten-Nr. / Document No.


entstanden aus / originating from:
zugehrige Zeichnung / relevant drawing:
entstanden aus / originating from:

Pos.
Pos.

1.4.1.9
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
1.4.7
1.4.8
1.4.9
1.4.10
1.4.11
1.4.12
1.4.13
1.4.14
1.4.15
1.4.16
1.4.17
1.4.18
1.4.19
1.4.20
1.4.21
1.4.22
1.4.23
1.4.24
1.4.25
1.4.26
1.4.27
1.4.28
1.4.29
1.4.30
1.4.31
1.4.32
1.4.33

Part name

Benennung

Stk
No

1
1
1
1
1
1
1
1
1
5
1
1
1
2
2
1
1
1
1
1
1
1
1
1
4
14
3
3
28
6
1
14
1

V3

V3
V3
V3
V3
V3
V3
V3

Schraubensicherung
Rotorsttze
Mitnehmerwelle
Rotor
Buchse
Abdeckung
Scheibe
Dichtung
Gleitscheibe
Pascheibe
Scheibe
Scheibe
Pafeder
Blech 6
Blech 7
Gummilippe 3
Gummilippe 4
Gummilippe 5
Gummilippe 6
O-Ring
O-Ring
O-Ring
Sechskantschraube
Sechskantschraube
Sechskantschraube
Sechskantschraube
Sechskantschraube
Sechskantmutter
Sechskantschraube
Scheibe
Scheibe
Scheibe
Schraubensicherung

Securing for bolts and nuts


Rotor support
Pusher shaft
Rotor
Bush
Shielding
Washer
Gasket
Slide washer
Shim ring
Washer
Washer
Parallel key
Sheet 6
Sheet 7
Rubber lip 3
Rubber lip 4
Rubber lip 5
Rubber lip 6
O-Ring
O-Ring
O-Ring
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon nut
Hexagon bolt
Washer
Washer
Washer
Securing for bolts and nuts

FILTER SECTION
Filter element C
Wiper

1.5
1.5.1
1.5.2
1.5.3
1.5.4

1
1
1
4
1

FILTEREINSATZ
Filterelement C
Abstreifer
Senkschraube
Schraubensicherung

1.6

INSPEKTIONSFFNUNG

INSPECTION HOLE

1.7

SCHILDER

PLATES

1.8
1.9
1.10
1.16

28
24
52
1

Sechskantschraube
Sechskantmutter
Scheibe
Blindflansch

Hexagon bolt
Hexagon nut
Washer
Blind flange

R = Reserveteil/Spare part
V = Verschleiteil/Wear part

Slotted countersunk flat head screw

Securing for bolts and nuts

SHA 14 M --- C05 MM 100, Rev A. Page 281 of 361

QA2009/20/1368-0020
4/20/0150-0112

K2009/20/1368-0503
1/20/0150-0005

Sach-Nr.
Ident-No.

Bemerkungen
Remarks

Stand/Status: 15.03.2005
Erstellt/prepared: 16.09.2009/w

Blatt/Sheet: 4/4

TL2009201368.xls

TEILELISTE / PARTS LIST


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

Dokumenten-Nr. / Document No.


entstanden aus / originating from:
zugehrige Zeichnung / relevant drawing:
entstanden aus / originating from:

Pos.
Pos.
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.26
1.27
1.28
1.29

Part name

Benennung

Stk
No

4
Sechskantschraube
4
Sechskantmutter
4
Scheibe
1 R4 Dichtung
12
Stiftschraube
12
Sechskantmutter
12
Scheibe
1
Dichtung
2 R4 Dichtung
4
Ringmutter
1
Warnschild

1.30

Sttzring

3.

1 R6 GETRIEBEMOTOR FR

RCKSPLROTOR

QA2009/20/1368-0020
4/20/0150-0112

K2009/20/1368-0503
1/20/0150-0005

Sach-Nr.
Ident-No.

Bemerkungen
Remarks

Hexagon bolt
Hexagon nut
Washer
Gasket
Stud
Hexagon nut
Washer
Gasket
Gasket
Lifting eye nut
Warning plate
Supporting ring
GEAR MOTOR FOR
BACKWASH ROTOR

5.

1 R5 KUPPLUNG

COUPLING

6.

2 R5 Gewindestift

Hexagon socket set screw

7.

Stiftschraube

Stud

8.

Sechskantmutter

Hexagon nut

9.

Scheibe

Washer

fr DIN/BS/JIS/AFNOR
Stutzen DN 3 = DN 80

R = Reserveteil/Spare part
V = Verschleiteil/Wear part

SHA 14 M --- C05 MM 100, Rev A. Page 282 of 361

Stand/Status: 15.03.2005
Erstellt/prepared: 16.09.2009/w

TL2009201368.xls

Blatt/Sheet: 1/1

TEILELISTE / PARTS LIST


DIFFERENZDRUCK-MESYSTEM /
DIFFERENTIAL PRESSURE MEASURING SYSTEM
Dokumenten-Nr. / Document No.

QA2009/20/1368-0021
4/00/0983-0926

entstanden aus / originating from:


zugehrige Zeichnung / relevant drawing:

K2008/20/1368-0501
1/15/0005-0285

entstanden aus / originating from:

Pos.
Pos.

Benennung

Stk

Sach-Nr.
Ident-No.

DIFFERENZDRUCKMESYSTEM
Emerson-MD03
1

Part name

No

Bemerkungen
Remarks

DIFFERENTIAL PRESSURE
MEASURING SYSTEM
Emerson-MD03

1 R Differenzdrucktransmitter
Typ Rosemount 1151 DP4

Differential pressure transmitter


type Rosemount 1151 DP4

Druckmittler

Remote seal

Druckmittler

Remote seal

Kapillarrohr

Capillary tube

2 R Membranschieber
1 V Membrane

Diaphragm valve
Diaphragm

2 R Dichtung

Gasket

Sechskantschraube

Hexagon bolt

Sechskantmutter

Hexagon nut

16

Scheibe

Washer

eingestellter Mebereich /
adjusted measuring range
- 10 - + 360 mbar

R = Reserveteil/Spare part
V = Verschleiteil/Wear part

SHA 14 M --- C05 MM 100, Rev A. Page 283 of 361

in Pos. 5 enthalten/included in pos. 5

SHA 14 M --- C05 MM 100, Rev A. Page 284 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 285 of 361

27.07.2009

Schmidlin

Gller

10.07.2009

Schmidlin

Gller

03.07.2009

Schmidlin

Gller

11.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
Neugebauer
Neugebauer

Revised according to customer comments

FUS

Revised according to customer comments

FUS

Revised according to customer comments

FUS

First issue

FUS

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
EL

Title :

CCW Exchanger Debris Filter

Language
:E

Electrical Load List

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

SHA/14/M/---C05/EL/002

Client Document No. :

SHA/14/M/---C05/ EL/002

SHA 14 M --- C05 MM 100, Rev A. Page 286 of 361

ELECTRICAL LOAD LIST - C05


R
E
V

Functional number
of the electrical
auxiliary

Unit

System

Equipment

Designation
of the driven machine
or of the electrical auxiliary

Load
type

Rated
volt.
V

Voltage

Consumer
type

Nature

Red
und
ancy
(Y/N)

Std
Inter
face
(Y/N)

Rated

Rated
power
factor

power

Rated
eff.

SC
/
FLC

Star
ting
time
(s)

kW/
kVA

Load
conn
diag

Local
Fuse
(A)

Loc.

Load
Term
panel

D
u
t
y
(1)

Feeding
Cubicle

Mechanical absorbed power


During
Stop of
the Unit

At Startup of the
Unit

During
normal
running

D
I
E
S
E
L

U
P
S

SIGNAL EXCHG WITH


DCS FOR INDICATION /
Supplied internally via
control panel
Supplied internally via
control panel

IFU
D

12/13/14PCB15AT010

12/13/14 PCB15

AT010

12/13/14PCB15AA016

12/13/14 PCB15

AA016

AUX CW DEBRIS FILTER 1 MOTOR


AUX CW DEBRIS FILTER 1 DISCHARGE
IFU
VALVE

12/13/14PCB15GH001

12/13/14 PCB15

GH001

CONTROL PANEL

12/13/14PCB15GH001B

12/13/14 PCB15

GH001B

CONTROL PANEL UPS

12/13/14PCB15GH001C

12/13/14 PCB15

GH001C

CONTROL PANEL UPS

IFU
IFU
IFU

460 AC TRI 60 Hz

0,75 kw

B63/400

14PCB15GS100

460 AC TRI 60 Hz

0,16 kw

B63/400

14PCB15GS100

460 AC TRI 60 Hz

2 kw

B63/400

14PCB15GS100

120 AC MONO 60 Hz L

0,25 kw

B63/400

14PCB15GS100

120 AC MONO 60 Hz L

0,25 kw

B63/400

14PCB15GS100

To be supplied by client
X

To be supplied by client

To be supplied by client
SIGNAL EXCHG WITH
DCS FOR INDICATION /
Supplied internally via
control panel
Supplied internally via
control panel

IFU
D

12/13/14PCB16AT010

12/13/14 PCB16

AT010

12/13/14PCB16AA016

12/13/14 PCB16

AA016

AUX CW DEBRIS FILTER 2 MOTOR


AUX CW DEBRIS FILTER 2 DISCHARGE
IFU
VALVE

12/13/14PCB16GH001

12/13/14 PCB16

GH001

CONTROL PANEL

12/13/14PCB16GH001B

12/13/14 PCB16

GH001B

CONTROL PANEL UPS

12/13/14PCB16GH001C

12/13/14 PCB16

GH001C

CONTROL PANEL UPS

IFU
IFU
IFU

460 AC TRI 60 Hz

0,75 kw

B63/400

14PCB16GS100

460 AC TRI 60 Hz

0,16 kw

B63/400

14PCB16GS100

460 AC TRI 60 Hz

2 kw

B63/400

14PCB16GS100

120 AC MONO 60 Hz L

0,25 kw

B63/400

14PCB16GS100

120 AC MONO 60 Hz L

0,25 kw

B63/400

14PCB16GS100

SHA 14 M --- C05 MM 100, Rev A. Page 287 of 361

Comments

To be supplied by client
X

To be supplied by client

To be supplied by client

Scope

Package
no.

C05
C05
C05
C05
C05

C05
C05
C05
C05
C05

010

010

010

010

SHA 14 M --- C05 MM 100, Rev A. Page 288 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 289 of 361

16.09.2009

Schmidlin

Gller

08.09.2009

Schmidlin

Gller

19.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
Neugebauer
APPROVED

Updated

FUS

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
IO

Title :

CCW Exchanger Debris Filter

Language
:E

Signal Exchange List

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/IO/002

SHA 14 M --- C05 MM 100, Rev A. Page 290 of 361

signals
s - Instrumentation Setpoint - Debris Filters 12/13/14PCB15AT010 & 12/13/14PCB16AT010
List for iinput/output
nput/output signal

R
e
v

Sensor / Signal number

Service description

Typical
connection
diagram

I/O
information
for the DCS

Measurement
range
(mbar)
Min.

12 PCB15

EA101

DF1 ALARM

BI

yes

12 PCB15

EA102

DF1 FLUSHING

BI

yes

12 PCB15

EA103

DF1 ON

BI

12 PCB15

EA104

DF1 OFF

13 PCB15

EA101

DF2 ALARM

13 PCB15

EA102

13 PCB15

13 PCB15

A
A

Set
point
(mbar)

Process
unit

Event &
Alarm
coding

Signal
user

specif

Max.

EC1

C05

EC0

C05

yes

EC0

C05

BI

yes

EC0

C05

BI

yes

EC1

C05

DF2 FLUSHING

BI

yes

EC0

C05

EA103

DF2 ON

BI

yes

EC0

C05

EA104

DF2 OFF

BI

yes

EC0

C05

14 PCB15

EA101

DF3 ALARM

BI

yes

EC1

C05

14 PCB15

EA102

DF3 FLUSHING

BI

yes

EC0

C05

14 PCB15

EA103

DF3 ON

BI

yes

EC0

C05

14 PCB15

EA104

DF3 OFF

BI

yes

EC0

C05

12 PCB16

EA101

DF4 ALARM

BI

yes

EC1

C05

12 PCB16

EA102

DF4 FLUSHING

BI

yes

EC0

C05

12 PCB16

EA103

DF4 ON

BI

yes

EC0

C05

12 PCB16

EA104

DF4 OFF

BI

yes

EC0

C05

13 PCB16

EA101

DF5 ALARM

BI

yes

EC1

C05

13 PCB16

EA102

DF5 FLUSHING

BI

yes

EC0

C05

13 PCB16

EA103

DF5 ON

BI

yes

EC0

C05

14 PCB16

EA104

DF5 OFF

BI

yes

EC0

C05

14 PCB16

EA101

DF6 ALARM

BI

yes

EC1

C05

14 PCB16

EA102

DF6 FLUSHING

BI

yes

EC0

C05

14 PCB16

EA103

DF6 ON

BI

yes

EC0

C05

14 PCB16

EA104

DF6 OFF

BI

yes

EC0

C05

-10

-10

-10

-10

-10

-10

360

360

360

360

360

360

120

120

120

120

120

120

SHA 14 M --- C05 MM 100, Rev A. Page 291 of 361

Comment

08.09.2009

Schmidlin

Gller

26.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
APPROVED

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

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PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems

Scale :

SUBCONTRACTOR

N/A

Format :
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Title :

Language
:E
Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
LC

Cable Schedule
CCW Exchanger Debris Filter

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

SHA/14/M/---C05/LC/002

Client Document No. :

SHA/14/M/---C05/ LC/002

SHA 14 M --- C05 MM 100, Rev A. Page 292 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 293 of 361

22.06.2010

Schmidlin

Gller

01.06.2010

Schmidlin

Gller

18.05.2010

Schmidlin

Gller

19.02.2010

Schmidlin

Gller

30.11.2009

Schmidlin

Gller

02.09.2009

Schmidlin

Gller

28.08.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
Neugebauer
Neugebauer
Neugebauer
Neugebauer
Neugebauer

Integration of clients comments

FUS

Integration of clients comments

FUS

Integration of clients comments

FUS

Integration of clients comments

FUS

Integration of clients comments

FUS

Integration of clients comments

FUS

First issue

FUS

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

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Format :
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Project :

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IS
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Doc Type :
WD

Title :

Electrical and Control Cabinet /

Language
:E

Wiring Diagram

Consortium Participant or Subcontractor Document No. : N/A

abcd

for CCW Exchanger Debris Filter


No of
sheet : 40

Power Systems

Sheet :

Plants

1/40

Alstom document no :

SHA/14/M/---C05/WD/002

Client Document No. :

SHA/14/M/---C05/ WD/002

SHA 14 M --- C05 MM 100, Rev A. Page 294 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 295 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 296 of 361

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SHA 14 M --- C05 MM 100, Rev A. Page 331 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 332 of 361

SHA 14 M --- C05 MM 100, Rev A. Page 333 of 361

03.07.2009

Schmidlin

Gller

13.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
APPROVED

Second issue

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DM

Title :

CCW Exchanger Debris Filter

Language
:E

System Description

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 17

Power Systems

Sheet :

Plants

1
Alstom document no :

Client Document No. :

SHA/14/M/---C05/DM/002

SHA 14 M --- C05 MM 100, Rev A. Page 334 of 361

Table of Contents
1.

TASK AND FUNCTION DESCRIPTION OF THE TAPROGGE FILTER SYSTEM ........................................................3


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

2
SHA 14 M --- C05 MM 100, Rev A. Page 335 of 361

1. TASK AND FUNCTION DESCRIPTION OF THE TAPROGGE FILTER SYSTEM

1.1.

Task of the TAPROGGE filter system


A TAPROGGE debris filter is installed to prevent clogging of cooling tubes and all related problems.

Fig. 2-1: Schematic Arrangement


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

3
SHA 14 M --- C05 MM 100, Rev A. Page 336 of 361

1.2.

Function description of the TAPROGGE filter system

Fig. 2-2: Debris filter type PR-BW 100


1
2
3
4

Filter PR-BW 100


Differential pressure measuring system
Gear motor
Discharge valve

4
SHA 14 M --- C05 MM 100, Rev A. Page 337 of 361

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

5
SHA 14 M --- C05 MM 100, Rev A. Page 338 of 361

The special performance of the debris filter is based on the concept of

PRESSURE-RELIEVED BACKWASH (PR-BW)

The PR-BW procedure works as follows (see sketches on the following page):

During the backwash procedure, the backwash rotor is moving over the entire filter section. The
debris, which had been collected in that area of the filter section which is covered by the
backwash rotor, is relieved from flow pressure. Simultaneously, the flow direction in this area
reverses and the pressure-relieved debris is flushed away by the backwash flow of the filtered
water.

The PR-BW procedure easily handles all kind of debris, especially fibrous debris which is easily
removed from the filter section.

Since the area of the filter section covered by the backwash rotor is completely isolated from the
differential pressure of the cooling water during backwashing, the debris filter is fully operational
even if it is loaded with high amount of debris.

6
SHA 14 M --- C05 MM 100, Rev A. Page 339 of 361

Pressure-relieved backwash (PR-BW procedure)


FILTRATION

water flow

fibres are retained


filter section
flow pressure forces fibres and debris onto
the filter section

PRESSURE-RELIEF

freeing and lifting of fibrous debris


the covering backwash rotor causes a
pressure-relieved area
backwash rotor

FILTER BACKWASH

flow pressure relief and initial flow reversal


produced by the opened discharge valve
help to untangle and flush out fibrous
debris from the filter section.

Fig. 2-3: Backwash process

7
SHA 14 M --- C05 MM 100, Rev A. Page 340 of 361

2. DESCRIPTION OF THE FILTER SYSTEM


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

2.1.

Assembly Debris Filter

2.1.1.

Debris Filter PR-BW 100

Fig. 2-4: Debris filter type PR-BW 100


1/2
3
4
5
6

Filter housing
Bearing assembly
Backwash rotor
Filter section with wiper
Inspection hole

8
SHA 14 M --- C05 MM 100, Rev A. Page 341 of 361

The filter housing 1 / 2

consists of two hemispheres, one carrying the cooling water inlet,


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

Bearing assembly 3

consists of a rotating hollow shaft with worm gear. The


water is discharged through the hollow shaft. The backwash
rotor is actuated by the gear motor which is mounted to the worm
gear. The discharge valve is fixed to the outlet flange of the
bearing assembly

The backwash rotor 4 consists of a funnel-shaped arm with rubber lips. This arm is
connected to the bearing assembly by a flange connection.

Filter section

weldless design; standard perforations typically start from 2


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

9
SHA 14 M --- C05 MM 100, Rev A. Page 342 of 361

2.1.2.

Differential pressure measuring system

Fig. 2-5: Differential pressure measuring system


1
2
3
6
7
9

Differential pressure transmitter


Remote seal PLUS
Remote seal with capillary tube MINUS
Isolation valves
Measuring nozzles
Operator panel

10
SHA 14 M --- C05 MM 100, Rev A. Page 343 of 361

The differential pressure measuring system (p system) monitors the amount of debris on the filter
by constantly measuring the differential pressure (p).

Differential pressure transmitter 1

The differential pressure is electronically converted to a signal.

Operator panel 9

indicates:




the actual differential pressure


the programmed limit values

initiates:

signalling upon reaching or falling below


the programmed limit values

limit value 1:
(test function)

IN-SERVICE MONITORING
The proper functioning of the measuring system is electrically
monitored constantly. In the event of a fault, the differential
pressure falls below limit value IN-SERVICE MONITORING and
an alarm message will be signalled by the control system.

limit value 2:
(service function)

FILTER BACKWASH
If debris accumulates on the filter section, the differential
pressure increases. If the limit value FILTER BACKWASH is
reached, the automatic control system initiates filter
backwash, until the differential pressure falls below the pre-set
limit value.

limit value 3:
(security function)

p EXCESSIVE HIGH
If the differential pressure continues to increase in spite of the
existent backwash and reaches the limit value p EXCESSIVE
HIGH, the automatic control system continues filter backwash.
Simultaneously, a signal and an alarm message are indicated.
The customer can connect the potential free alarm from the
control panel to the control room.

11
SHA 14 M --- C05 MM 100, Rev A. Page 344 of 361

Isolation valves 6

The differential pressure measuring system can be isolated


from the cooling water flow for maintenance purposes by
means of the isolation valves.

12
SHA 14 M --- C05 MM 100, Rev A. Page 345 of 361

2.1.3.

Gear motor

The backwash rotor is operated by a special gear motor designed for 100 % continuous operation.

13
SHA 14 M --- C05 MM 100, Rev A. Page 346 of 361

2.2.

Discharge valve
The discharge valve in this filter system is a ball valve operated by a specially designed part-turn
actuator with short running time. In the open position, the valve allows an unrestricted flow of the
debris laden water.

The part-turn actuator is equipped with limit switches signalling the end positions to the control
panel. It is also equipped with torque limit switches protecting the valve as well as the actuator
against overload.

14
SHA 14 M --- C05 MM 100, Rev A. Page 347 of 361

2.3.

Control
The control system serves to operate, control and monitor the filter system. The control is a
programmable logic controller (PLC). All control and monitoring functions required for automatic
operation (programmes) are stored in a single programme (Flashcard).
By means of a selector switch at the control panel the operating mode AUTOMATIC or MANUAL is
selected.
All further operations are effected via function keys at the operator panel.

Operating mode AUTOMATIC

The control system monitors the filter system and initiates filter backwash in any of the following
cases:


p limit value FILTER BACKWASH

control command FILTER BACKWASH from control room

function key FILTER BACKWASH

function key FILTER CONTINUOUS BACKWASH

malfunction differential pressure measuring system (intermittent backwash every 3 minutes)

function key p SYSTEM FLUSH

every 24 hours, initiated by a timer

Backwash
Backwash of the debris filter proceeds as follows:


The part-turn actuator opens the discharge valve

Simultaneously, the backwash rotor starts


The filter section is cleaned by backwashing. The debris is carried away through the
discharge pipe.

In the operating mode AUTOMATIC the actual differential pressure is processed by the
control system

After backwashing, the actual differential pressure is checked by the control system

If p < limit value FILTER BACKWASH, the backwash rotor stops and the discharge valve
closes

15
SHA 14 M --- C05 MM 100, Rev A. Page 348 of 361

Operating mode MANUAL

Note:
The operating mode MANUAL is not permitted for routine filter operation and
may be selected for commissioning and in case of trouble in the operating
mode AUTOMATIC only!

All operations are initiated by the operating personnel by means of function keys at the operator
panel.

Backwash
Filter backwash must be initiated if:


p limit value FILTER BACKWASH

p limit value p EXCESSIVE HIGH

Backwash of the debris filter shall be executed as follows:




Open the discharge valve

Start the backwash rotor


The filter section is cleaned by backwashing. The debris is carried away through the
discharge pipe.

Carefully check indication of differential pressure

If p < limit value FILTER BACKWASH:


stop the backwash rotor
close the discharge valve

16
SHA 14 M --- C05 MM 100, Rev A. Page 349 of 361

Control panel

The control panel consists of all necessary devices for ...




...

control and operation of the filter system

...

transmission of control commands between the control room and control panel

...

control and power supply to the external electrical consumers

On the control panel front are:




main switch

selector switch for operating mode AUTOMATIC / MANUAL

signal lamp for indication of common alarm

operator panel for


indication:

operation:

of the actual operational system status

of the actual differential pressure

individual alarms

running time meter of backwash rotor

limit values of the differential pressure measuring system

timers of control

information regarding trouble shooting

alternative language

execution of all operations

setting of limit values

setting of timers

selection of language

The control panel contains potential-free contacts which should be connected to the control room
by the customer.

17
SHA 14 M --- C05 MM 100, Rev A. Page 350 of 361

10.09.2009

Schmidlin

Gller

07.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
APPROVED

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Title :

DATA SHEET CCW Exchanger


Debris Filter

Language
:E

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/DS/011

SHA 14 M --- C05 MM 100, Rev A. Page 351 of 361

DATA SHEET

ENERGY

Pow er Pl ants

EXCHANGER DEBRIS FILTERS ND 20

Project : SHOAIBA III


1
2

CLIENT
NUMBER

3
4
5
6

TYPE

Conveyed fluid

Max operation temperature

Rated flow

Unit : 12/13/14

SAUDI ELECTRICITY COMPANY


SIX

FUNCTIONAL CODE
12/13/14PCB15AT010 /
12/13/14PCB16AT010
Mfr's REFERENCE
K2009/20/1368

MANUFACTURER
TAPROGGE GmbH
OPERATING CHARACTERISTICS
Seawater
50C
1580 m/h

10

Design pressure

11

Mesh aperture

10 bar gauge / Vacuum

12

Washing water consumption

13

Head loss clean

14

Inlet/outlet apertures - ND (1)

15

Drilling through flanges

16

Washing water discharge aperture - ND (1)

17

Electric power supplies

18

Motor power

19

Rotation speed of washing system

20

Capacity of the reducing gear oil casing

n.a.

21

Oil type

n.a.

22

Installation level

3 mm
min. 50 m/h
0.8 mWG
500 mm
ANSI B16.5
DN 150 ANSI B16.5, 150 lbs
460 V/60 Hz
0,75 Kw
2.rpm

n.a.

l
m

23
CONSTRUCTION

24

Type

25

Material
Grade

Standard

Mild steel

S235JR / rubberlined

EN 10025
DIN EN
10088
DIN EN
10088

26
27

Housing

28

Filter Element

Duplex Stainless Steel

1.4462

29

Washing system

Duplex Stainless Steel

1.4462

30

Lower bearings

31

Internal bolts and nuts

32

External bolts and nuts

33

Gaskets

PA 6 G for seawater
Duplex Stainless Steel

1.4462
A193B7 / A194Gr2M
equivalent A4-70 / A4

Asbestos free

34
WEIGHTS AND OVERALL DIMENSIONS

35
36

WEIGHT

37

In operating order

1,7 t

38

Empty

1,1 t

39

OVERALL DIMENSIONS

40

Length

See drawing SHA/14/M/---C05/GA/002

41

Width

See drawing SHA/14/M/---C05/GA/002

42

Height

See drawing SHA/14/M/---C05/GA/002

43
44
45
46

OUTLINE AND LAYOUT DIAGRAM

47

(supporting and lifting included)

48
49
50
51

REMARKS
(1) nominal diameter

SHA 14 M --- C05 MM 100, Rev A. Page 352 of 361

Rubber

DIN EN
10088

10.09.2009

Schmidlin

Gller

20.07.2009

Schmidlin

Gller

18.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
Neugebauer
APPROVED

Updated

FUS

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Title :

Valves DATA SHEET

Language
:E

CCW Exchanger Debris Filter

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 3

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/DS/013

SHA 14 M --- C05 MM 100, Rev A. Page 353 of 361

Rev. C

DATA SHEET
VALVES

ENERGY

Pow er Pl ants

Project : SHOAIBA Unit : 12/13/14


1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52

DESIGNATION
12/13/14PCB15AA016
12/13/14PCB16AA016
IDENTIFIER
SUPPLIER
Mfr's REFERENCE
ND =
DN150
DN150
TAPROGGE
K2009/20/1368
ISO-PN ANSI B16.5 150lbs
/ SERIES =
CONSTRUCTION - CODES - STANDARDS
ANSI B 16-34
DIN
NFE
General constructive arrangements
Ball valve
- Body
ISO 5752
Cast
Forged
Fabricated
Die-worked
- Obturator
ANSI B16.10
- Body / bonnet junction
feather key
Bolted
Autoclave
Screwed & welded
- Weld end connection
Not applicable
Materials :
- housing
BS 1504 318 C17 ST.ST.
- ball
904L ST.ST.
- switching shaft
904L ST.ST.
- seat rings / gaskets
PTFE (TFM1600) / graphite
- bolts
A 193 B8M CL2 / A 194 8M
OPTIONS
Body :
Straight
Angle
Inclined
3-way
- Pipe connection :
O D x inlet / outlet thickness
DN150 ANSI B16.5, Class 150 lbs, R.F.
- Neck : Material :
inlet / outlet diameter
DN150
Control : Manual
Yes
No
Motor-driven : emerg. man. contr.
with withou without reducer
*
t
electric
pneumatic
hydraulic
- By-pass ND
n.a.
- Decompression ND
n.a.
- Over-pressure valve (>= 2500 Lbs)
*
n.a.
Stuffing-box :
Standard gasket
Gasket for vacuum
Water seal
Limit-switch on positions :
Open
Closed
Intermediate
Position Transmitter
No
Driving column Stem lengthening piece
No
Accesory for check valve
not applicable
Counter weight
Damper
Seat bore
-integral
Yes
-seat
150
Replacement Ring
Yes
Lining: Body/Obturator
NBR/no lining
Water seal
NBR
SERVO-MOTOR
electric
Nature of fluide
Maximum pressure
6 bar abs. for motor
Temperature
Flow
50
C
50
m3/h
Breakdown torque
*
135 Nm
Operation time
/ Rpm of stem
n.a.
s
/
Particular conditions :
Differential pressure allowing operation
6 bar
Torque required for operation
*
135 Nm
Setting of torque limiter
*
n.a.
Seat / obturator tightness : class / standard
Installation - orientation : by-pass / servo-motor
Drawing No
Weight of valve with fittings
*
26,5 kg
Fluid :seawater
Max. pressure : 10
bar G.
Max. temp. : 60
C
REMARKS : The lines marked with * will be completed by the supplier. The others must obligatorily be filled in by ALSTOM
if needed, completed by the supplier. Length of the valve 151/2

Originator

Identification number

Rev.

Date

Lang.

Sheet

ALSTOM
TAPROGGE

SHA/14/M/---C05/DS/013

10.09.2009

en

2/3

ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 354 of 361

Rev. C

DATA SHEET
VALVES

ENERGY

Pow er Pl ants

Project : SHOAIBA Unit : 12/13/14


1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52

DESIGNATION
12/13/14PCB15AA201
12/13/14PCB16AA201
IDENTIFIER
SUPPLIER
Mfr's REFERENCE
ND =
DN50
DN50
TAPROGGE
K2009/20/1368
ISO-PN ANSI B16.5 150lbs
/ SERIES =
CONSTRUCTION - CODES - STANDARDS
ANSI B 16-34
DIN
NFE
General constructive arrangements
Drain valve
- Body
ISO 5752
Cast
Forged
Fabricated
Die-worked
- Obturator
ANSI B16.10
- Body / bonnet junction
feather key
Bolted
Autoclave
Screwed & welded
- Weld end connection
Not applicable
Materials :
- housing
BS 1504 318 C17 ST.ST.
- ball
BS 1504 318 C17 ST.ST.
- switching shaft
904L ST.ST.
- seat rings / gaskets
PTFE (TFM1600) / graphite
- bolts
A 193 B8M CL2 / A 194 8M
OPTIONS
Body :
Straight
Angle
Inclined
3-way
- Pipe connection :
O D x inlet / outlet thickness
DN50 ANSI B16.5, Class 150 lbs, R.F.
- Neck : Material :
inlet / outlet diameter
DN50
Control : Manual
Yes
No
Motor-driven : emerg. man. contr.
with withou without reducer
*
t
electric
pneumatic
hydraulic
- By-pass ND
n.a.
- Decompression ND
n.a.
- Over-pressure valve (>= 2500 Lbs)
*
n.a.
Stuffing-box :
Standard gasket
Gasket for vacuum
Water seal
Limit-switch on positions :
Closed
Intermediate
Open
Position Transmitter
No
Driving column Stem lengthening piece
No
Accesory for check valve
not applicable
Counter weight
Damper
Seat bore
-integral
Yes
-seat
150
Replacement Ring
Yes
Lining: Body/Obturator
NBR/no lining
Water seal
NBR
SERVO-MOTOR
electric
Nature of fluide
Maximum pressure
6 bar abs. for motor
Temperature
Flow
50
C
50
m3/h
Breakdown torque
*
135 Nm
Operation time
/ Rpm of stem
n.a.
s
/
Particular conditions :
Differential pressure allowing operation
15 bar
Torque required for operation
*
41 Nm
Setting of torque limiter
*
n.a.
Seat / obturator tightness : class / standard
Installation - orientation : by-pass / servo-motor
Drawing No
Weight of valve with fittings
*
11 kg
Fluid :seawater
Max. pressure : 10
bar G.
Max. temp. : 60
C
REMARKS : The lines marked with * will be completed by the supplier. The others must obligatorily be filled in by ALSTOM
if needed, completed by the supplier. Length of the valve 7

Originator

Identification number

Rev.

Date

Lang.

Sheet

ALSTOM
TAPROGGE

SHA/14/M/---C05/DS/013

10.09.2009

en

3/3

ALSTOM 2006. All rights reserved.


SHA 14 M --- C05 MM 100, Rev A. Page 355 of 361

29.07.2009

Schmidlin

Gller

27.07.2009

Schmidlin

Gller

20.07.2009

Schmidlin

Gller

18.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
Neugebauer
Neugebauer
APPROVED

Updated

FUS

Updated

FUS

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Title :

LV Motor DATA SHEET

Language
:E

CCW Exchanger Debris Filter

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

Client Document No. :

SHA/14/M/---C05/DS/012

SHA 14 M --- C05 MM 100, Rev A. Page 356 of 361

Rev. D

1
2

CLIENT
QUANTITY

3
4

MOTOR DESIGNATION SK02F-IEC-80L/4


DRIVEN MACHINE Debris Filter (Exchanger)

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

POWER SUPPLY NETWORK


Type
: alternating
Voltage between phases / variation
:460V +10-15%
Frequency / variation
:
60Hz +6-5%
Neutral
:
grounded

ENVIRONMENT
Installation area : non explosive explosive
Nature of service ambient conditions
:
Atmosphere
:
clean
Max - min - normal air temperature
:
55/9/30
Relative maximum humidity
: 100 %
Altitude
:6m
Particular risks
:
Seismicity
: UBC Zone 2A
MOTOR CHARACTERISTICS
Motor type
Location
Arrangement
Rated voltage
Rated frequency
Rated output
Synchronous speed
Slip (4/4 load)
Rated current
Starting current Id/In
Rated torque
Starting torque Cd/Cn
Max. torque Cmax/Cn
No load current

FUNCTIONAL CODE
12/13/14PCB15AT010 /
12/13/14PCB16AT010

Alstom
2 per unit

: asynchronous
:
inside
:
horizontal
: 460V
: 60Hz
: 0,75 kW
: 1800 rpm
: 74 %
: 1,95 A
:6
: 5,1 Nm
: 2,5
: 2,6
:5A
2/4
3/4
4/4
74
74
74

MANUFACTURER
NORD
CONSTRUCTION
Rotor
Stator winding
- class of insulation
- winding impregnation
- temperature rise
Type construction
Frame
dry
Coupling type
Bearings
- on shaft ends sides
- on opposite side or thrust
- lubrication type

Mfr's REFERENCE
K2009/20/1368

: class F
: varnish
:B
:
B
:
: F7
: roller bearing
: roller bearing
:

grease or oil flow or quantity per bearing : -l/mn


grease or oil viscosity
:
oil inlet/outlet temperature
:
-/
grease or oil change every
:-

Cooling
- type
- ventilating air flow
- cooling water pressure
- cooling water flow
- water inlet/outlet temp rise
- water inlet/outlet head losses
PAINTING

kg
-cSt
C

TEFC
:
:
:
:
:
:

/
/

m/h
bar abs.
m/h
C
Mwg

RAL 7037

MATERIALS

Stator winding
:
Stator bars
:
Efficiency
%
Frame
:
Power factor
Shaft
:
0,8
0,8
0,8
Cyclic duration factor
: n.a.
Insulation
:
Impregnation
:
Motor inertia
: 0,0053 kgm
Terminal box
:
Starting time (Un)
: < 6 sec. (460 V)
Rotor laminations
:
Number of successive startings
:3
:
Stator laminations
Max. permissible amplitudes of vibrations < 1 mm
Noise level 1 m from the motor surface :
<70 dB(A) (A)
WEIGTHS AND OVERALL DIMENSIONS
Protection class
: IP56
Rotation viewed from coupling end
Axis height
:
clockwise
Height
:
Stator winding coupling
:
star
Length
:
Width
:
Applicable standards
Shaft end diameter
:
- design
: IEC 60034
Net weight
:
- construction
: IEC 60034
- tests
: IEC 60034

Standard
VDE
VDE
VDE
VDE

n.a.
n.a.
VDE
VDE
VDE

Identification number

Rev.

Date

Lang.

Sheet

TAPROGGE

SHA/14/M/---C05/DS/012

29.07.2009

en

2/2

SHA 14 M --- C05 MM 100, Rev A. Page 357 of 361

steel
cast +Al
steel
n.a.
n.a.
Al
steel
steel

140 mm
279 mm
318 mm
166 mm
25 mm
18 kg

Originator
ALSTOM 2006. All rights reserved.

Grade
copper

06.05.2009

Schmidlin

Gller

21.04.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer

Revised according to customer comments

FUS

First issue

FUS

APPROVED

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Title :

DATA SHEET PRESSURE


TRANSMITTER

Language
:E

Consortium Participant or Subcontractor Document No. : N/A

abcd

No of
sheet : 2

Power Systems

Sheet :

Plants

Alstom document no :

SHA/14/M/---C05/DS/014

Client Document No. :

SHA/14/M/---C05/ DS/014

SHA 14 M --- C05 MM 100, Rev A. Page 358 of 361

ENERGY

Pow er Pl ants

Project : SHOAIBA III

DATA SHEET
PRESSURE TRANSMITTER
Unit : 14,13,12

1
2
3
4
5
6

CLIENT

SAOUDI ELECTRICITY COMPANY

Quantity

Functional code (s)

14/13/12 PCB15CP010

14/13/12 PCB16CP010

Destination

Debris filter

Debris filter

MAKE

ROSEMOUNT-EMERSON

ROSEMOUNT-EMERSON

Type

1151 DP4

1151 DP4

MANUFACTURER
TAPROGGE GmbH

FUNCTIONAL CODE
14/13/12 PCB15/16CP010
Mfr's REFERENCE
K2009/20/1368

8
9
10
11
12
13
14
15
16
OPERATING CHARACTERISTICS

17
18

Nature of fluid

19

Nominal/maximum pressure

water

20

Nominal/maximum temperature

21

Density

22

water

bar abs.

5,5/16

50/70

5,5/16
50/70

appr. 1000kg/m

appr. 1000kg/m
370mbar

INSTRUMENT

23

Scale

bar abs.

370mbar

24

Measuring scale

bar abs.

-10 to 360 mbar

-10 to 360 mbar

25

Accuracy

0,1% of SPAN

0,1% of SPAN

26

Transmitter

Yes

Yes

27

Action

28

Signal/power supply characteristics

%
DIRECT / INDIRECT

29

4-20mA HART / 24V DC

4-20mA HART / 24V DC

(SMART TYPE)

(SMART TYPE)

CONSTRUCTION

30
31

Box

32

Protection class IP

33

Instrument connections

34

Coupling - dimensions

35

Location - standards

36

Connection

Yes / No

37

Expansion loop

38

Manifold

39

Drain trap

IP65

IP65

mm

DN3 Remote seal

DN3 Remote seal

mm

DN 3 Remote seal

DN 3 Remote seal

Yes / No

No

No

Yes / No

No

No

Yes / No

No

No

Electrical/process

40
41

MATERIALS

42

Gear chamber

1.4401/1.4404

1.4401/1.4404

43

Box

Aluminium

Aluminium

44

Equipment

2.4819

2.4819

45

Nut & bolts

SS316

SS316

DRAWINGS - NOTICES

K2009/20/1367-0501

K2009/20/1367-0501

46
47
48
49
50
51
52
53

REMARKS Local Indicator LCD Type = 0-100%


Label AISI 316
Transmitters with capillaries: capillary length 3 m, Flange ANSI RF, liquid fill with silicon oil

Issue
Date
Author
Checked by
Approved by

21.04.2009

06.05.2009

Schmidlin

Schmidlin

Gller

Gller

Neugebauer

Neugebauer

N SHA/14/M/---/C05/DS/014

SHA 14 M --- C05 MM 100, Rev A. Page 359 of 361

20.07.2009

Schmidlin

Gller

19.05.2009

Schmidlin

Gller

REV

DATE

PREPARED

CHECKED

Neugebauer
Neugebauer
APPROVED

Updated

FUS

First issue

FUS

MODIFICATIONS

STATUS

CLIENT

PROJECT

SHOAIBA POWER PLANT STAGE III


CONTRACT No. 20821102/00
CONSULTANT

CONTRACTOR

abcd
Power Systems
Scale :

SUBCONTRACTOR

N/A

Format :
A4

Ta p r o g g e
G e s e l l s c h a f t mb H
58292 Wetter
Te l e f o n + 4 9 2 3 3 5 7 6 2 - 0

Project :

SHA

IS
N/A

KKS
N/A

Doc Type :
DS

Consortium Participant or Subcontractor Document No. : N/A

abcd

Title :

Actuator DATA SHEET

Language
:E

CCW Exchanger Debris Filter


No of
sheet : 2

Power Systems

Sheet :

Plants

1
Alstom document no :

Client Document No. :

SHA/14/M/---C05/DS/015

SHA 14 M --- C05 MM 100, Rev A. Page 360 of 361

Rev. B

FUNCTIONAL CODE
12/13/14PCB15M002 /
12/13/14PCB16M002

1
2

CLIENT
QUANTITY

3
4

MOTOR DESIGNATION AUMA SG 07.1-32


DRIVEN MACHINE

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

POWER SUPPLY NETWORK


Type
: alternating
Voltage between phases / variation
:460V +10-15%
Frequency / variation
:
60Hz +6-5%
Neutral
:
grounded

ENVIRONMENT
Installation area : non explosive explosive
Nature of service ambient conditions
:
Atmosphere
:
clean
Max - min - normal air temperature
:
55/9/30
Relative maximum humidity
: 100 %
Altitude
:6m
Particular risks
:
Seismicity
: UBC Zone 2A
MOTOR CHARACTERISTICS
Motor type
Location
Arrangement
Rated voltage
Rated frequency
Rated output
Synchronous speed
Slip (4/4 load)
Rated current
Starting current Id/In
Rated torque
Starting torque Cd/Cn
Max. torque Cmax/Cn
No load current

: asynchronous
:
inside
:
horizontal
: 460V
: 60Hz
: 0,08 kW
: 1800 rpm
: 59 %
: 0,55 A
: 1,64
: 135 Nm
:3
: 2,1
: 3,3 A
2/4
3/4
4/4

MANUFACTURER
AUMA
CONSTRUCTION
Rotor
Stator winding
- class of insulation
- winding impregnation
- temperature rise
Type construction
Frame
dry
Coupling type
Bearings
- on shaft ends sides
- on opposite side or thrust
- lubrication type

Mfr's REFERENCE
K2009/20/1368

: class F
: varnish
:B
:
B
:
: F7
: roller bearing
: roller bearing
:

grease or oil flow or quantity per bearing : -l/mn


grease or oil viscosity
:
oil inlet/outlet temperature
:
-/
grease or oil change every
:-

Cooling
- type
- ventilating air flow
- cooling water pressure
- cooling water flow
- water inlet/outlet temp rise
- water inlet/outlet head losses
PAINTING

kg
-cSt
C

no cooling
:
:
:
:
:
:

m/h
bar abs.
m/h
/
C
/
Mwg
Manufacturer Standard

MATERIALS

Stator winding
:
Stator bars
:
Efficiency
%
Frame
:
59
59
Power factor
Shaft
:
60
60
Cyclic duration factor
: n.a.
Insulation
:
Impregnation
:
Motor inertia
: 0,005 kgm
Terminal box
:
Starting time
: < 6sec.
Rotor laminations
:
Number of successive startings
:3
:
Stator laminations
Max. permissible amplitudes of vibrations < 1 mm
Noise level 1 m from the motor surface :
<65 dB(A) (A)
WEIGTHS AND OVERALL DIMENSIONS
Protection class
: IP67
Rotation viewed from coupling end
Axis height
:
clockwise
Height
:
Stator winding coupling
:
star
Length
:
Width
:
Applicable standards
Shaft end diameter
:
- design
: IEC 60034
Net weight
:
- construction
: IEC 60034
- tests
: IEC 60034

Standard
VDE
VDE
VDE
VDE

n.a.
n.a.
VDE
VDE
VDE

Originator

Identification number

Rev.

Date

Lang.

Sheet

SHA/14/M/---C05/DS/015

20.07.2009

en

2/2

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

steel
cast +Al
steel
n.a.
n.a.
Al
steel
steel

50 mm
275 mm
450 mm
250 mm
40 mm
18 kg

ALSTOM
TAPROGGE
ALSTOM 2006. All rights reserved.

Grade
copper