Operating Manual

AgipGas BV WESTERN LIBYA GAS PROJECT
AGBV Job No. AGBV Doc. No.

LIBYAN BRANCH 0177/NC/02 13595-M-N-0004-00
Snamprogetti Lummus Gas Ltd Plant CTR Job No. CTR Doc. No.
Snamprogetti MELLITAH PLANT
310300 51 33-PV-E-87725
ABB Lummus Malta

Location P1 A1 A2 A3 A4
GSPLAJ Sh. 1 of 58 Rev.
OVERALL
PACKAGE
OPERATING MANUAL
FOR
51-330-XX-001
52-330-XX-001
53-330-XX-001
A4 05.01.05 FINAL MKG

A3 19.11.04 F I N A L UMo
A2 29.10.04 Final UMo
A1 24.06.2004 For Information UMo
P1 17.05.2004 For Information UMo
Rev- Date Description Prep. Check. Appr. PMS AGBV
Review Appr.
File name: 13595G65MN000400_A3

This document is CONFIDENTIAL and the sole property of the AGIP GAS BV. It shall neither be shown to third parties nor used for other
purposes than those for which it has been issued/sent. Any unauthorized attempt to reproduce it, in any form, is strictly prohibited.
310300 51 33-PV-E-87725
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INDEX
1 INTRODUCTION ............................................................................................................................................4
2 BASIS OF DESIGN .........................................................................................................................................8

2.1 PRECOAT FILTER
2.2 CHARCOAL FILTER
2.3 CARTRIDGE FILTER
3 PACKAGE FUNCTIONAL DESCRIPTION...............................................................................................9

3.1 PRECOAT FILTER
3.2 CHARCOAL FILTER
3.3 CARTRIDGE FILTER
3.4 BASIC CONTROL CONCEPT
3.4.1 CYCLE OPERATION
3.4.2 AUTOMATIC/SEMIAUTOMATIC OPERATION & STEP ADVANCE
3.4.3 PLC OUTPUT CONFIGURATION
3.5 CALL OPERATOR ALARM
3.5.1 DEFINITION
3.5.2 GENERAL CALL OPERATOR ALARM
3.5.3 TABLE OF CALL OPERATOR ALARMS
3.6 NO CONFORMITY ALARM
3.6.1 DEFINITION
3.6.2 GENERAL NON-CONFORMITY ALARM
3.7 EQUPMENT CONTROL AND OPERATOR INPUTS
3.7.1 VALVES
3.7.1.1 ON/OFF VALVES
3.7.1.2 CONTROL VALVES
3.7.2 E-MOTOR ( PRECOAT- PUMP AND MIXER )
3.8 PACKAGE CONTROL AND OPERATOR INPUTS
3.8.1 DEFINITION
3.8.2 STOP PUSH BUTTON
3.8.3 EMERGENCY STOP PUSH BUTTON
3.8.4 START PUSH BUTTON
3.8.5 ADVANCE PUSH BUTTON
3.8.6 RESET PUSH BUTTON
3.8.7 AUTO/SEMI-A SELECTOR SWITTCH
3.8.8 LOCAL/REMOTE SELECTOR
3.8.9 ALARM ACKNOLEDGE
3.8.10 SERVICE MODE
3.9 OPERATOR PANEL PAGE DESCRIPTION
4 PREPARATION FOR INITIAL START-UP.............................................................................................20
4.1 SAFETY
4.2 START-UP OF FILTER SYSTEM
4.3 MAINTENANCE
4.4 FAILURES & BREAKDOWNS
4.5 PARTICULAR OPERATING PROCEDURES

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4.6 FILLING WITH FRESH CHARCOAL

4.7 CHARCOAL BAXKWASH PROCEDURE
4.8 INSERTING FRESH CARTRIDGES
5 START-UP ......................................................................................................................................................38
5.1 NORMAL START PROCEDURE ...................................................................................................................38
5.2 RESTART PROCEDURE ..............................................................................................................................39
6 NORMAL OPERATION ..............................................................................................................................40
6.1 GENERAL GUIDELINE ...............................................................................................................................40
6.2 DUAL FILTER "SWING" OPERATION
6.3 SEQUENCE DESCRIPTION
6.3.1 MAIN STEP 1 - STAND-BY
6.3.2 MAIN STEP 2 - FILL PRECOAT TANK
6.3.3 MAIN STEP 3 - ADD PRECOAT
6.3.4 MAIN STEP 4 - FILTER FILLING
6.3.5 MAIN STEP 5 - CLOTH CLEANING
6.3.6 MAIN STEP 6 - HOMEGENIZATION
6.3.7 MAIN STEP 7 - PRECOATING
6.3.8 MAIN STEP 8 - FILTRATION
6.3.9 MAIN STEP 9 - FILTER DRAINING
6.3.10 MAIN STEP 10 - CAKE DRYING
6.3.11 MAIN STEP 11 - VENT FILTER
6.3.12 MAIN STEP 12 - CAKE DISCHARGE
6.3.13 MAIN STEP 13 - DRAIN PRECOAT TANK TO FILTER
6.4 DESCRIPTION OF OPERATOR ACTION
6.5 NORMAL FUNDABAC© FILTRATION CYCLE ...............................................................................49
6.5.1 PRECOATING
6.5.2 CAKE REMOVAL
6.5.3 SWING OPERATION
6.6 PARTICULAR OPERATING PROCEDURE.......................................................................................51
6..6.1 CHARCOAL BACKWASHING PROCEDURE
6.6.1.1 DEFINITION
6.6.1.2 PREPARATION
6.6.1.3 BACKWASH PROCEDURE
6.6.2 CHARCOAL CHANGE
6.6.2.1 EMPYING OF CHARCOAL VESSEL
6.6.2.2 FILLING WITH FRESH CHARCOAL
6.6.3 PROCEDURE FOR CARTRIDGE CHANGE
6.6.3.1 REMOVAL OF CARTRIDGES
6.6.3.2 INSERTING FRESH CARTRIDGES
7 NORMAL SHUT DOWN PROCEDURE ...................................................................................................54

7.1 GENERAL GUIDELINE ...............................................................................................................................54
7.2 COMPLEETE CYCLE ..................................................................................................................................54
7.3 PREMATURE CYCLE TERMINATION ..........................................................................................................54
7.4 STOP THE PACKAGE .................................................................................................................................54
8 EMERGENCY SHUT DOWN PROCEDURE...........................................................................................55
8.1 GENERAL ..................................................................................................................................................55

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8.1.1 INSTRUMENT AIR FAILURE

8.1.2 ELECTRIC POWER FAILURE
8.2 STOP PUSH BUTTON
8.3 EMERGENCY STOP PUSH BUTTON
8.4 SHUTDOWN
8.4.1 REGULAR SHUTDOWN
8.4.2 EMERGENCY SHUTDOWN
8.4.3 EXTERNAL SHUTDOWN
9 TROUBLE SHOOTING ...............................................................................................................................57
10 REFERENCE DOCUMENTS..................................................................................................................58
10.1 PFD ..........................................................................................................................................................58
10.2 P&ID'S .....................................................................................................................................................58
10.3 ELECTRICAL LOAD SUMMARY .................................................................................................................58
10.4 EQUIPMENT SUMMARY .............................................................................................................................58
10.5 EQUIPMENT DATA SHEETS ........................................................................................................................58
10.6 INSTRUMENT DATA SHEETS FOR CONTROL VALVES, SAFETY VALVES .....................................................58
10.7 CAUSE & EFFECT DIAGRAMS, SPECIFICATION OF LOGIC SEQUENCES....................................................58
10.8 PACKAGE ASSEMBLY ................................................................................................................................58
10.9 PROCESS DOCUMENTS .............................................................................................................................58
10.10 OPERATOR PANEL DESCRIPTION
11 ANNEX........................................................................................................................................................58
11.1 FUNDABAC OPERATION MANUAL 13595-65-M-N-0002-00........................................................58
1 Introduction.
Oil and Gas processing industries are confronted with the removal of H2S, CO2 and other
contaminants from a gas stream. The general concept is an absorption followed by a
desorption through heating and depressurization. A straightforward method is to pass
Alkanolamines in the form of MEA, MDEA, DEA etc. through a scrubber to absorb the
disturbing substances and "sweeten" the sour gases.
Contamination
However, in circulating solvent systems, ingress of contaminants or degradation of the

solvent is often inevitable. Even if vapor losses are replenished, this does not purify the
solvent since contaminants tend to be non-volatile. Contaminant removal is always
necessary to maintain the purity of the solvent and to keep negative side effects under
control, such as corrosion and foaming.

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Corrosion
The scrubbing liquid in turn becomes fouled with corrosive contaminants, mainly sharp-
edged char, traces of iron sulfide and H2S, which have to be eliminated together with the
stripping process. If these solids are not removed, the protective layer of complex iron sulfide
on the reactor and pipe walls would be pierced and the amine-sulfur complexes would eat
through the walls very quickly.
Foaming
In gas treating, bubbles form in the solvent normally by the sour gas that is being scrubbed.
Foaming may cause severe problems such as cavitation damage, carryover of solution into
overhead systems or reduced gas purification.
Surface active contaminants identified as typical foamers for alkanolamine gas treating are:
• Finely divided small solid particles.

• Long-chain hydrocarbons close to saturation in the solvent
• Long-chain compounds such as proteins or other oxygenated polymers
Adding foam depressing agents to "fight the symptoms" has always been the measure of
choice. However, as more and more surfactants and particles are accumulated, more anti-
foam has to be added, which then can cause process upsets like reduced adsorption
efficiency of activated carbon or forming heat stable salts.
Common counter measures and their limits:
In the past various measures have been applied for amine purification with more or less
success and different disadvantages:
• bleeding off a solvent slip-steam is nowadays unacceptable because of the high loss
of solvent
• thimble methods like redistillation or reclaiming have high energy consumption and
are, in case of high efficient solvents like DEA, MDEA, very troublesome
• existing disposable bag or cartridge filtration systems are called upon to perform a job
beyond their capabilities, mainly due to quick clogging of the filter elements, high
input of manpower and expose of personal to hazardous substances
• permanent filtration systems like metal-leaf filters with back flush facilities are limited
in filter efficiency and require frequent manual cleaning
The FUNDABAC® way
In long pilot trails and in close cooperation with refinery experts DrM, Dr. Müller AG, have
developed a filtration process with respect to the specific requirements in Alkanolamine gas
treating plants.
FUNDABAC® filters use self-regenerating dynamic filtration elements which have proven
their excellent performance in over a thousand applications in various industries. Due to the
discharge of a dry filter cake, disposal costs are kept at a minimum and the loss of solvent is
almost zero. The completely enclosed system prevents operating personal from exposure to
the hazardous substances of the process.

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Filter cloths of different materials and mesh sizes are available in order to assure a clear
filtrate, even down to 0.5 µm particle size. Clogging or damaging of the filter medium is very
unlikely since a precoat can be applied if the nature of the solids handled calls for. Plants in
operation show a life expectancy of the cloth of several years.
Purified Gas Acid Gas
FUNDABAC® Filter
Fresh
Solvent
Cold Lean Solvent
Hot Rich Solvent
Regenerator
Absorber
Cooler
Flash Gas
Heat Cross
Exchanger
Raw Sour Gas

Circulation Reboiler
Flash Vessel
Pump
Basic Configuration for a sour gas purification unit utilizing a FUNDABAC ® Filter for removal of fine
solid particles from the cycle.
Thanks to modular construction, no moving parts and full automatic operation, investment
and run costs are kept low, maintenance costs have been reduced to almost zero.
Process Description
General
This skid mounted filter package is designed to remove all solid and dissolved contaminants
from a lean AMINE stream in a gas-processing unit. It contains two precoat filters
(FUNDABAC Type) one precoat preparation tank, two precoat circulation pumps, two
activated carbon adsorber and two cartridge filters for down stream polishing:

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Precoat Filter (Tag No. 51/52/53-330-CL-002A/B)

Charcoal Filter (Tag No. 51/52/53-330-CN-001A/B)
Cartridge Filter (Tag No. 51/52/53-330-CL-003A/B)
Lean MDEA solution from the base of the Amine Surge Tank is pumped by the Filtration
Feed Pump through the Precoat Filter for removal of particles, mainly iron sulfide. A
slipstream is taken off after the Precoat Filter and fed through the Charcoal Filter for removal
of hydrocarbons and through the Cartridge Filter for removal of any carbon fines, before
being returned to the Surge Tank.
NITROGEN
FIC
551
CARTRIDGE
FILTER
FIC
552
PRECOAT
PREPARATION
TANK
CL-003A/B
CJ-002
PRECOAT
PUMP PA-005A/B FILTRED AMINE
® CHARCOAL
FILTER
CN-001A/B
AMINE FEED

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2. BASIS OF DESIGN
2.1 Precoat Filter
The Amine filtration unit is equipped with two FUNDABAC® filter, (pressure candle type),
with filter elements fitted inside as well as one precoat tank. The filter design allows for a
max. cake thickness of 20 mm.
Flow through the filter elements is from outside to inside. Reverse flow is applied (Nitrogen
@ 2 bar g) to clean the filter cloths and discharge the cake. Filtered liquid is collected in a
center pipe inside the candle. The center pipe is threaded to the top support register.
The filter cloth (type B 11 MU 200) uses the mono-multifil seamless woven hose technology
that combines good filtration efficiency, mechanical strength as well as good clogging
resistance. Filter internals are stainless steel, the filter cloths are made from 100%
polypropylene.
Typical precoat filter data:

Filter cloth: B11 MU 200 (Polypropylene)
Filter cloth air permeability: 150 – 220 L/dm2*min @ 20 mm WC
Precoat type: Cellulose
Precoat loading: 1 kg / m2 filter area
Filter efficiency >99% @1 micron
The filter area should be sized to allow for flow rates of 1500 to 2000 L/h per m2 of filter area.
This will result in a filtration speed of 1.5 to 2.0 m/h what we recommend for this service.
For sizing we have taken an average figure in order to have sufficient safety margin or
reduce the precoat exchange frequency and/or to allow for solids load fluctuation in cases of
upset conditions of upstream process systems. The minimum life expectancy of the filter
cloth is 12 month.
Design Expect.
Filtration Filter Specific
Filter unit Fundabac® Type Flow Cake
Area Candle Flow Rate
Rate Volume
R-109-168- 1890
51-330-CL-002 109 m2 168 206 m3/h 1100 l
2500/T140Z L/h*m2
2.2 Charcoal Filters
The filtration unit is equipped with two carbon columns.
The diameter is sized to allow for flow rates of max. 15 m3/h per m2 cross sectional area.
The volume of the carbon bed should be the equivalent to the flow through the empty bed in
20 - 30 minutes. This will allow the solution to actually be in contact with the carbon for 10 -
15 minutes since there is about 50% void space between the carbon granules.
As far as the vessel height is concerned, sufficient space is needed to accommodate the
expansion of the carbon bed when back washing. Since the bed should be back washed at a

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flow rate that sufficiently expand the bed. The head space should be about 30% of the actual
carbon bed height.
UNIT cross carbon

Design Specific Flow carbon (T.L. -T.L.)
sectional bed
Flow Rate Rate volume
area height
51-330-CN-001 103 m3/h 7.74 m2 13.3 m3/h*m2 40 m3 5.1 m 7.5 m
2.3 Cartridge Filters
The Amine Cartridge Filters were sized to accommodate 24 cartridge elements.

Flow through the cartridge elements is from outside to inside. Reverse flow must be avoided
as it may damage the element. Filtered liquid is collected by a receptacle pipe inside the
cartridge which is connected to the support plate.
The element uses the compound radial pleat technology which allows high flow rates and low
pressure drops as well as a high dirt loading capacity. The cartridge has a double O-ring end
cap fitting. Apart from the O-rings the product is made from 100% polypropylene.
Typical cartridge element data:

Filter area: 20 m2 (per element)
Filter efficiency 100% at 25 micron
Loading capacity: 10 kg AC-Test dust
The filter is sized to allow for flow rates of 9 m3/h per cartridge. Our design meets the above
design figure and results in a well performing most economical solution.
The expected run life of the cartridge element is approx 6 months.
3 PACKAGE FUNCTIONAL DESCRIPTION
3.1Precoat Filter
The Amine Precoat Filter is designed to remove solid scale, manly iron sulfide, by a
mechanical filtration on precoat.
Before commencing filtration a precoat solution is made up in the precoat tank This is
circulated via precoat pump through the AMINE filters until a layer of precoat is built up on
the filter elements and the solution runs clear. Precoat material is tipped manually from bags
into the top of the precoat tank.
Filtered particles build up a cake on the filter elements until a limiting pressure drop is
reached. The filter is taken off-line for cleaning, draining and dry filter cake discharge to a
portable drum.
Flow through the Precoat Filter is controlled to maintain proper purification efficiency. For
fouling indication and monitoring a differential pressure transmitter is provided.

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Operation of the precoat filtration cycle is fully automatic and controlled by the plant PCS
system. Due to the provided high automation level, operator intervention is reduced to
manual tipping of precoat material and initiation of the filtration precoat cycle.
3.2 Charcoal Filters
The Charcoal Filter is designed to remove dissolved organic impurities, mainly hydrocarbons,
by adsorption to granular activated carbon (GAC). Adsorption of such compounds takes
place on the large “inner” surface area of the activated carbon (approx. 650 m2/g) appearing
as a finely divided system of capillaries and pores. Driven by diffusion transport mechanism
the activated carbon slowly becomes loaded with adsorbed impurities until a saturation is
reached. Now the carbon cannot adsorb more contaminants and must be exchanged.
The expected run life of the carbon fill is approx. 6 months subject to level of contaminants.
Fluctuation of the flow is expected to be minor as the pressure drop across the carbon filter is
approximately constant. Adsorption mechanism being of microscopic nature will hardly affect
the carbon bed permeability.
The filtered AMINE solution from Fundabac filter enters via inlet valve into the top part of the
carbon filter. Liquid is distributed and slowly streams through the carbon bed. Purified liquid
leaves the carbon filter through the bottom valve and enters into the cartridge filter. Carbon
fines carried over from the carbon filters are caught on the surface of the cartridge and clean
AMINE solution is returned from the bottom part of the cartridge vessel to the main steam.
In case of reduced filtration efficiency of the upstream precoat filter (i.e. damage of filter
media) the carbon bed may become fouled with suspended solids. For fouling indication a
differential pressure device is provided (PDT-5012).
If a differential pressure across the carbon of 1.0 bar is reached a CALL OPERATER ALARM
will be given and the filtration must be terminated manually. In such a case a back wash of
the carbon bed is required, respectively the bed must be exchanged if saturated (refer also to
the installation & maintenance manual).
However, this limit is an amine process requirement and not a limitation set by the filtration
plant. Filtration may proceed up to at least 2 bar differential pressure (at design flow rate).
IMPORTANT:
The carbon filter is fitted with a rupture disc that protects the carbon bed support against
damage from excessive differential pressure (3.0 bar burst pressure). However, such
differential pressure will only damage the rupture disc itself, housing and carbon bed support
facilities are not affected as they allow for higher pressure drops. Excessive differential
pressure causing the rupture disk to burst may occur under extreme conditions only such as
fire exposure or severe fouling of the carbon bed (i.e. complete blocking). If such conditions
occurred the rupture disk must be replaced.

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3.3 Cartridge Filters
The Amine Cartridge Filters were sized to accommodate 24 cartridge elements.

Flow through the cartridge elements is from outside to inside. Reverse flow must be avoided
as it may damage the element. Filtered liquid is collected by a receptacle pipe inside the
cartridge which is connected to the support plate.
The element uses the compound radial pleat technology which allows high flow rates and low
pressure drops as well as a high dirt loading capacity. The cartridge has a double O-ring end
cap fitting. Apart from the O-rings the product is made from 100% polypropylene.
Typical cartridge element data:

Filter area: 20 m2 (per element)
Filter efficiency 100% at 25 micron
Loading capacity: 10 kg AC-Test dust
The filter is sized to allow for flow rates of 9 m3/h per cartridge. Our design meets the above
design figure and results in a well performing most economical solution.
The expected run life of the cartridge element is approx 6 months.
3.4 BASIC CONTROL CONCEPT
3.4.1 Cycle Operation
The filtration precoat cycle is a successive sequence of 98 individual steps (Sub Steps 01 ~
98) to perform 13 main operations (Main Steps).
The Control Logic for automatic operation is implemented into the PLC. The PLC advances
successively through a Step Sequence, checking the OUTPUT CONFIGURATION and the
input conditions (ADVANCE CONDITIONS) for each Sup Step for conformity (refer to Control
Logic Diagram).
After completion of a full filtration cycle the PLC Logic is ready for a new one. As manual
operations are required at the beginning of each cycle (i.e. loading of precoat material)
initiation of the filtration cycle is always by an operator command.
3.4.2 AUTOMATIC/SEMI-AUTOMATIC OPERATION & STEP ADVANCE
A fully automatic as well as a Semi-Automatic execution of the above described filtration

cycle is possible (see para. 7 – Package Control and Operator Inputs).
In Automatic operation mode automatic Step Advance is foreseen. If the Advance

Conditions are met the PLC enters the next step of the filtration cycle.
Possible Advance Conditions are TIMER, INSTRUMENT STATUS and PROCESS FLAGS
they are defined in to the Control Logic Diagram.
CONFORMITY checks are compulsory and must be satisfied in each step.

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In Semi-Automatic operation step advance from the program logic is not possible. The
ADVANCE Push Button (HS-553A/B) is used instead to force the PLC to the next step.
TIMER or Instrument Status as well as CONFORMITY checks are by-passed.
However, alarms and warnings will appear as defined
3.4.3 PLC Output Configuration
The PLC output configuration defines the status of valves (i.e. OPEN or CLOSED) and
motors (i.e. RUNNING or OFF) according to the requirement of the filtration process. The
output configuration for each step is defined in the Control Logic Diagram.
Outputs will be activated by the START (HS-551A/B) command or may be inhibited by the
STOP (HS-552A/B) or EMERGENCY STOP (HS-558) push button.
Inhibited outputs represent the SAFETY CONFIGURATION (see para. 7 – Package Control
and Operator Inputs).
Note 1:
Output configuration is identically for AUTOMATIC and SEMI-AUTOMATIC operation.
Note 2:
Timer are started at the moment the NON CONFORMITY check is satisfied (i.e. from the
moment the valve limit switches conform with the outputs to the solenoid valves).
In steps where instruments and timers are involved, the instrument check is activated at the
moment the NON CONFORMITY check is satisfied and the timer is elapsed.
3.5 CALL OPERATOR ALARM (C.O.)
3.5.1 Definition
To ensure safe and convenient operation of the filtration plant a CALL OPERATOR Alarm
(C.O.) has been foreseen. A C.O. Alarm does not require immediate intervention nor it refers
to a failure or a hazardous situation (as the NON CONFORMITY Alarm (N.C.) does).
However, it indicates that a (regular) manual action or intervention is required by the plant
operating or maintenance personnel within a suitable time. A “suitable time” – in this concern
– is depending on the type of action required, and must be evaluated by the operating
personnel.
3.5.2 General CALL OPERATOR Alarm (UA-555A/B)
One common alarm per filtration package
A visual check of status information provided on the corresponding DCS-VDU will enable site
personnel to identify the affected equipment. Always, the appearance of the CALL
OPERATOR Alarm refers to one or more single CALL OPERATOR Alarms witch are listed in
the table below.
The CALL OPERATOR Alarm is active until the required action has been taken and the
required action is confirmed by operator input or the source of the alrm was removed.

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3.5.3 Table of CALL OPERATOR Alarms
Single N.C.
No. Source Description Action required (manual)
Alarm
Sub Step 10
UA-555
– Control Logic Add Precoat Material (Note1)

reached
Sub Step 42 Start Regeneration of Filter
– Control Logic
reached (Note1)
Sub Step 98
– Control Logic Remove Cake from Drum (Note1)
reached
High pressure CN-
PDAH-552 PDT-552 back wash or carbon change
001
High pressure CL-
PDAH-553 PDT-553 cartridge change
003
Note 1:
To satisfy this CALL OPERATOR Alarm the START push button is used.
It is to be pressed after the necessary action has been taken
3.6 NON CONFORMITY ALARM (N.C.)

3.6.1 Definition
To avoid hazardous situations with possible damage of equipment and/or danger to health a
NON CONFORMITY Alarm (N.C.) has been foreseen.
WARNING
A NON CONFORMITY Alarm does require immediate attention or intervention and it refers to
a faulty operation, failure of equipment or a hazardous situation.
However, in case of a NON CONFORMITY automatic intervention takes place to prevent

damage and/or danger to health that may be caused by faulty operation, failure of equipment
or a hazardous situation (refer also to Description of Global Interlocks).
The appearance of a NON CONFORMITY Alarm implies that immediate corrective action or
intervention are required by the plant operating personnel. A “corrective action or
intervention” – in this concern – is depending on the type of NON CONFORMITY, and must
be evaluated by the operating personnel.

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3.6.2 General NON CONFORMITY Alarm (UA-556A and UA-556B)
One common alarm per filtration package
A visual check of status information provided on the DCS-VDU will enable site personnel to
identify the affected equipment. The appearance of the general N.C. Alarm refers always to
one or more single NON CONFORMITY Alarms.
Remark:
Appearance of an Instrument Alarm (i.e. the alarm set point is reached) does not necessarily
imply that a NON CONFORMITY occurred. Further conditions must be met to generate a
N.C. Alarm (see table of N.C. Alarms). Therefore each Instrument Alarm has a
corresponding NON CONFORMITY Alarm indication.
Example:
Instrument: LT-553 (Level Transmitter in Tank VA-009)
Switch point (Status): LLH-553 (High level in Tank VA-009)
Instrument Alarm: LAH-553 (Alarm level high in Tank VA-009)
Single N.C. Alarm: L-UA-553 (Step 3 ALARM-Time elapsed)
General N.C. ALARM UA-556 (General non conformity)
The alarm is active until the required action has been taken, the source for the NON
CONFORMITY is removed and the Alarm Ackn. has been pressed.
3.7 EQUIPMENT CONTROL AND OPERATOR INPUTS
3.7.1 Valves
All limit switches of the valves are connected to inputs on the PLC via the valve position
indicators on the video display. The signals are then processed and checked for their
conformity with the valve outputs. In case of a discrepancy a NON CONFORMITY ALARM is
produced (refer also to NON CONFORMITY Alarm description as above).
All pneumatically actuated valves have a local visual position Indicator. Process ON-OFF
valves are equipped with a local PUSH-TO-CLOSE button which is installed close to the
valve.
In case of power failure, all signals to the valves are inhibited which corresponds to the
STOP mode (SAFETY CONFIGURATION). In this configuration, all valves are closed. Some
liquid remains trapped between the register valves and the valves on the inlet/outlet lines.
In case of instrument air failure fail close valves close which corresponds to the STOP mode
(SAFETY CONFIGURATION).
Fail lock valves will remain in the actual position, but can be closed due to the instrument air
tank.

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3.7.1.1 ON/OFF Valves
All actuated ON/OFF valves can be operated manually from the PLC-VDU by the following
facilities:
Auto/Manual Selector Switch (HSUVxxx)

OPEN/CLOSE
If the AUTO/MANUAL selector is on AUTO position the valve position is as defined by the
Control Logic OUTPUT CONFIGURATION. The corresponding OPEN/ CLOSE command is
not active. This is the normal position for automatic operation of the filtration package.
When the AUTO/MANUAL selector is on MANUAL position then the Control Logic cannot
take control of the valve. The valve can now be opened or closed by the OPEN/CLOSE
command. Manual valve operation is only possible in Semi-Automatic control mode and is
mainly used for maintenance or test duties.
3.7.1.2 Control Valves
Controlled valves are linked to software PID Controller in the PLC. A controlled valve is
permanent doing what the controller output requires.
The controller can be operated from the PLC-VDU by the following facilities:
AUTO/MANUAL Selector (FIC-xxx-MA)

Output over ride (FIC-xxx-OUT)
Set point (FIC-xxx-SP)
If the AUTO/MANUAL selector switch is on AUTO the valve position is as defined by the
Control Logic OUTPUT CONFIGURATION. This is the normal position for an automatic
operation of the filtration package.
The Control Logic Diagram can require a controlled set point (SP from SEQUENCE) or a
fixed output to the Valve (% defined in SEQUENCE)
When the AUTO/MANUAL selector is on MANUAL position then the valve can be operated
by the output over ride. Manual valve operation is mainly used for tuning, maintenance or
test duties. The Control Logic can force a valve in manual mode to set a desired position.
The corresponding controller is marked with "M" so the Manual Mode is clear visible.
Unlike the On/OFF valves manual operation of a controller is possible in AUTO mode of the
sequence.
WARNING
Global Interlocks may be active when operating the valves manually at the corresponding
Manual Control Terminals.
Possible hazardous situation, spillage of Amine solution or damage to filter internals if miss-
used.

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3.7.2 E-Motors (Precoat Pump and Mixer)
START HSYY-XXX-1
from the PLC only a programmed start by logic sequence is possible.
The pump is running as long as the Start input is high.
RUNNING ULYY-XXX-1
The motor status is send from the MCC to PLC. It is processed and checked for conformity
with.
COMMAND FAILURE UAYY-XXX-2

In case of a discrepancy between Control Logic output and motor status, after elapsing of the
defined timer a NON CONFORMITY ALARM is produced (refer also to NON CONFORMITY
Alarm).
In case of power failure, all motors stop which corresponds to the STOP mode (SAFETY
CONFIGURATION).
NOTAVIABLE UAYY-XXX-3
is indicating a motor which is not ready for operation, the main stand by switch will be
changed if the "main" motor returns a "NOT AVIABLE" signal.
LOCAL REMOTE SELECTOR HSYY-XXX-4

Motors have local control stations with START, STOP and EMERGENCY STOP push
buttons which are installed close to the motor.
Those functions are direct linked to the MCC and are only active if on the PLC LOCAL
REMOTE SELECTOR is in LOCAL position
All motors can be operated manually only in the field
In REMOTE position the Motor are controlled by the MCC. PLC does send a series of signals
to the MCC. So the required motors can be started as defined in the CONTROL LOGIC
DIAGRAM.
MAIN / STAND BY HSYY-XXX-5

Is PLC internal selector defining which pump motor (A or B) has to start if the control logic
requires the precoat pump running
Trip XY-YY-XXX
To trip a motor the PLC is sending a individual trip signal to the MCC.
3.8 PACKAGE CONTROL AND OPERATOR INPUTS
3.8.1Definition
All PLC inputs are possible from DCS or VDU. The normal operation will be done from DCS,
the VDU inputs are not active.
However for Commissioning, Start Up and Trouble Shooting a VDU operation permission
(HS-561-A) will activate the inputs from the VDU.

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In principle, the PLC program (Control Logic) advances automatically through the filtration
precoat cycle as detailed in the Process Description and shown on the Control Logic
Diagram.
However, there are a number of operator inputs from the Local Control Station (LCS), the
Touch screen of the PLC(VDU) or the DCS to take control of the process. These are
described below.
3.8.2 STOP Push Button (HS-552A/B)
The STOP push button is used to:

inhibit all PLC outputs to the corresponding filtration package (SAFETY CONFIGURATION)
stop the automatic operation of the corresponding filter in case of emergency
Once the STOP push button was pressed the PLC enters into the STOP mode (SAFETY
CONFIGURATION) but keeps the actual step active. All actuated valves are closed and
motors are switched off. To re-enter into the RUN mode, the START push button has to be
pressed.
Note 1: The local STOP push button on the package LCS is not active if the local
LOCAL/REMOTE selector switch is on REMOTE position.
Note 2: The ADVANCE push button remains active when in STOP mode. This allows an
operator to advance the program to a certain step with all outputs inhibited (SAFETY
CONFIGURATION). This may be useful under special circumstances, i.e. to repeat steps
manually or for test duties.
IMPORTANT:
The STOP push button must be used with caution, considering the possible irreversible
effects on the filter cake (cake slippage).
3.8.3 EMERGENCY STOP Push Button (HS-558 only on LCS)
The local STOP push button on the package LCS is not active if the local LOCAL/REMOTE
selector is on REMOTE position. In case of an emergency the local EMERGENCY STOP
must be used instead.
The EMERGENCY STOP push button is red, of mushroom type and stay-put. It is to be reset
by twisting the mushroom head.
3.8.4 START Push Button (HS-551-A/B)
The START push button is used:

to activate all outputs to the corresponding filtration package after STOP or EMERGENCY
STOP has been pressed
to re-start the automatic operation of the corresponding filtration after STOP or
EMERGENCY STOP has been pressed
to confirm a required manual action from the operator after a call operator alarm. The
automatic operation of the corresponding filtration will continue

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Once the START push button has been pressed the PLC activates the individual step output
configuration as defined in the Control Logic Diagram (RUN Mode).
As soon as the outputs are activated the corresponding operation indicator

will change to RUN. However, when the outputs are inhibited the signal will change to STOP.
3.8.5 ADVANCE Push Button (HS-553-B/A)
The ADVANCE push button is used:

to ADVANCE the Control Sequence to the next step in SEMI-A Mode.
The ADVANCE function is only active in SEMI-A operation mode.
Note: The ADVANCE P.B. remains active in STOP (SAFETY CONFIGURATION) mode.
This allows to advance the sequence to a certain step with all outputs inhibited It can be
used i.e. to repeat steps manually or for test duties.
While the PLC is in STOP mode, the sub step counter can be set with a numeric input. This
allows a fast access to all steps (i.e. repeating a previous step).
3.8.6 RESET Push Button (HS-554-A/B)
The RESET push button is used to set the Control Logic Sequence to Main Step A
(Sub Step 1) – Stand-by position
The RESET function is only active in SEMI-A operation mode.
3.8.7 AUTO/SEMI-A Selector Switch (HS-559-A/B)
If the AUTO/SEMI-A selector switch is on AUTO position the PLC proceeds through the
control sequence as defined. All input conditions for the actual step are active as well as all
interlocks. In steps where timers are involved these are running. The ADVANCE function and
RESET push button are not active.
When switched to SEMI-A position timers are interrupted and all input conditions are by-
passed. Advance to the next step are only possible by means of the ADVANCE PUSH
button. However, all interlocks and the step output configuration remain active as defined in
the Logic sequence
3.8.8 LOCAL/REMOTE Selector (HS-560)
In REMOTE position, AUTOMATIC/SEMI-A operation will be conducted from DCS-VDU.

In LOCAL position control of the filtration package from the LCS is possible. This position
corresponds to the SEMI-A position of the AUTO/ SEMI-A switch provided on the DCS-VDU.
When HS is switched to REMOTE position, then all inputs on the LCS (except EMERGENCY
STOP) are deactivated and changes have to take place on the DCS-VDU.
If the LOCAL/REMOTE selector is in LOCAL position then all manual inputs from the DCS-
VDU are deactivated and changes have to take place on the LCS.

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In local mode, Automat operation is not possible.
Schematic view of inter-link between the two switches:
HS-560 HS-559-A/B
1 Local operation
from LCS in field Manual inputs from
0 0 VDU/DCS
1 Automat operation
3.8.9 ALARM ACKNOWLEDGE (HS-555-A/B)
This push button is used to acknowledge a NON CONFORMITY Alarm. If pressed the
corresponding alarm lamp (on DCS-VDU and LCS) changes from blinking to a steady signal.
The steady signal remains until the NON CONFORMITY is removed. Please refer also to
paragraph "Call Operator Alarms” and “Non Conformity Alarms" as above.
General Logic Diagram of HS- Functions
N.C. Alarm S Gen. N.C. Alarm
Alarm ACKN R
START S Field Outputs

According Sequence
STOP R Logic Diagram
Valve conformity A
N A
Other conformity D Step timer
N
Instrument Advance Conditions
D Advance to
AUTO O the next Step
R
SEMI-A A
N
ADVANCE D
A Reset the
RESET N Sequence
D to Step “1”

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3.8.10 SERVICE MODE (HS-557-A/B)
This selector is used to perform the Backwash and cake recovery procedures.
If pressed the package operation mode changes from normal to Service mode.
In SERVICE MODE the PLC will execute only steps from the sequence that are marked with
a check for the SERVICE FLAG. This function allows to bypass certain process parts
(typically Filtration) in automatic operation mode.
3.9 OPERATOR PANEL PAGE DESCRIPTION
Operation of the PLC-Touch panel is described in detail in: 13595-65-P-N-0002-00 see

attachment 10.11
4 PREPARATION FOR INITIAL START-UP
Erection, mounting and preparation for initial start-up shall be done strictly according the DrM
standard Manual.
4.1 SAFETY
4.1.1 Range of application of the installation
The filtration installation has been designed for the exclusive ®use of the removal of solids
from fluids by filtration. Any other application of the FUNDABAC equipment does not comply
with the designed ® and destined purpose of this process equipment. It is not permitted to use
the FUNDABAC Filter for any other purposes!
The process-fluid system, describing all components is fully defined in the relevant purchase
order.
The process is only partly known to the DrM, Dr. Mueller AG Corporation. The buyer
therefore bears full responsibility for
• The full safety of the articulation of the process steps.

• The use of each medium in the process
• All applied process parameters, such as temperatures and pressures.
The use of the filtration equipment not covered by application specifications causes the
cessation of ®all warranties given by DrM, Dr. Mueller AG Corporation. Known misuse of our
FUNDABAC Filter Equipment: no such misuse is known to the DrM, Dr.Mueller AG Corp.
4.1.2 Emergency Stop Switches
Such switches must be located in such a manner that all qualified personnel has immediate
access to stop all operations in case of various sudden troubles, such as leakages, rising
pressure, etc.

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4.1.3 Safety-Protection Equipment

If the installation was ordered and delivered without such components, it is the responsibility
of the buyer to provide such safety control instrumentation which complies with the relevant
regulations obtaining in the country from which the equipment was ordered and to which it
was delivered.
4.1.4 Integration of the FUNDABAC Installation into the buyers’ process

The points-of-interface with the up-and-downstream installations must be® defined by the
buyer. The connections for these points of interface on the FUNDABAC installation on
delivery are not designed to comply with the safety requirements as they obtain in the
country of delivery. The responsibility for such designs and construction for compliance rests
with the buyer.
4.1.5 Qualifications of Personnel

The buyer is responsible for the qualifications of the personnel charged with operating the
purchased equipment; they must be able to operate the equipment professionally. Faults in
operating the equipment absolves the DrM Corporation from damages arising from such
faulty operations.
4.1.5.1 Training of Personnel

DrM offers to train the operating personnel for erecting, rigging, assembly and operation of
the equipment. The fully qualified DrM staff for such training will also advise on operating
process procedures.
4.1.6 Welding on pressure-coded and stamped FUNDABAC Equipment

It is forbidden to make any changes on pressure-coded and stamped vessels.
WARNING! Any change performed on a pressure-coded and stamped vessel

can lead to loss of hardness of the steel. Danger of bursting the vessel is quite possible and
this can lead to very serious injury! A vessel that has beensubjected to such changes
inherently loses operatingsafety and permission to operate is voided. The provided
installation has been stamped according to the official pressure code issued by the
regulatory authority: any changes to be performed on the vessel require official permission
by that regulatory authority.
4.2 Start-Up of the filter System
Start-up of the Filter System
4.2.1 Transportation
4.2.1.1 Manufacturer --> Construction site

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4.2.1.1.1 Industrial Production Installations

The Filter vessel is shipped in the horizontal lying position on a flat car (or, with appropriate
support construction). The usual mode of transportation is by truck, resp. lorry. All internal
components, i.e. candles, registers, filter-cloths, are packed separately in a crate, which is
part of the shipment. When the installation is delivered, care must be taken that all
components are carefully unloaded and equally carefully stored. Damage due to rough,
unprofessional handling cancels all claims for compensation. Please realize, that hard rubber
lined vessels should not be transported at below freezing temperatures, as this may cause
the lining to crack.
4.2.1.1.2 Test / Pilot plants

These smaller installations are shipped in special wooden crates, in the horizontal position,
by truck-lorry. All components belonging to such pilot-plants are also packed in the same
wooden crates. Larger, skid-mounted plants are shipped in their horizontal or vertical
position, depending on their size and total height. Components belonging to the installation
are packed in a separate crate, which is also part of such a shipment. When such an
installation is delivered, attention must be paid, that all crates and components are carefully
unpacked and inspected for any damage incurred during shipment. Every item must be
safely stored. The buyer is liable for any damage incurred.
4.2.1.2 At Construction or Plant Site
4.2.1.2.1 Industrial installations
When the filter vessel is rigged, the following points must be carefully observed:
• A suitable passage must be found or established that leads from the receiving
platform to the erection site, i.e. adequately sized doorways, paths, roof-ope-nings,
etc.
• The lifting lugs on the vessel-cover are the lifting points at which the crane raises the
EMPTY vessel! At the erection sight the rigging equipment, i.e. cranes or lifts have to
be fixed in such a manner, so as to permit vertical adjustment in the raised position!
• CAUTION!
The lifting lugs on the cover are dimensioned for the empty-weight of the vessel!
• The filter vessel must be rigged in its vertical position without damaging any of
the side nozzles especially on the cone and the bottom flange.
• Once the filter vessel has reached its planned location, erection devices must
be firmly mounted at the planned points of support, e.g. mounting brackets,
etc.

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• Often, filter vessels are delivered with transporting gaskets to safe the usually
more expensive operating gaskets. In such a case a notice is attached to the
filter vessel. This gasket may not be appropriate for the required duty and
must be replaced before start-up.
4.2.1.2.2 Pilot Plants
When you rig and erect a pilot plant, you must observethe following directives:
• Arrange for clear passage from the shipping platform to the operating site with
sufficient clearance throughout. The lifting point and center of gravity in such
installations is the filter vessel.
• It is strictly forbidden to use the piping for lifting and moving these pilot plants.
Cranes and lifts used to take the pilot plant out of the crate MUST keep the plant in the
HORIZONTAL POSITION. Only AFTER that move can you turn the pilot plant into its vertical
position. The fully piped-up plant comes with casters for rest and for moving it. Other
accessories for the plant must only be removed from the crate AFTER the pilot plant has
been lifted out.
• The lifting points of the large skid-mounted installations are at the upper portion of the
skid-frame, i.e. ABOVE the centers of gravity! Cranes and lifts must only raise the equipment
at these lifting points and at the frame itself (very few lifting lugs are provided on these skids).
IT IS STRICTLY FORBIDDEN TO LIFT THE EQUIPMENT AT ANY OTHER POINTS, e.g.

PIPING, etc.

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• Installing the pilot plant must be carried out with the utmost care. Avoid all
damages, especially to instrument and fittings, such as valves, drives, controls, measuring
instruments, pressure reducers, etc.The operator-buyer is liable for all such damages.
• Generally, these pilot and other skid-mounted plants are operated either manually or
automatically. They are piped up accordingly and are ready simply to be connected to the in-
and-outlet lines (product, compressed air,power, etc.) corresponding to the supplied
flowsheet.
4.2.1.3 Lifting lugs on filter cover
WARNING: These lugs are dimensioned for the empty filter unless otherwise
noted on the equipment. It is strictly prohibited to lift filter filled with liquid (or out-fitted with
the internal components).
4.2.1.4 Cranes or lifting rigging equipment

You are only permitted to operate with adequately sized and undamaged cranes and lifting
devices. They must be certified for the given weights to be handled and they must comply
with the relevant safety regulations that obtain in the country concerned. Compliance with
above is the buyer’s responsibility.
WARNING! Inadequately sized and/or damaged cranes and lifting devices may
fail or actually break down under load. This is likely to produce fatal accidents. The above
discussed undamaged rigging equipment must meet the weight capacities given by the
dimensional weight specifications stated in the addendum on the concerned filtration
equipment.
The buyer is solely responsible for compliance of the rigging equipment with all local
regulations unless such equipment has been supplied by DrM.
4.2.2 Storage of filter components, resp. spare parts
4.2.2.1 Storage facility

The internals of the filter, as well as other accessory components (e.g. nuts and
bolts, electrical and electronic control components, etc.) must be stored carefully,
in a clean location fully protected against inclement weather conditions.
Filter elements - candles, must be stored on absolutely flat floors, shelves, or racks,
for their entire length (risk of deformation).
STOP! Candles made of plastic materials may be deformed even when stored hori-
zontally for several years. If such lengthy periods are envisaged, such candles must
be stored suspended vertically.

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4.2.2.2 Environmental, resp. climatic conditions

Storage warehouses must be dry and not be subject to extreme climatic conditions. Direct
sunshine, as well as ice should be avoided (This applies to all filters and their spare parts).
Coatings and linings are rendered brittle at low outside temperatures; they arelikely to tear or
burst and plastic components may become deformed.
4.2.3 Preparation for erection-rigging
4.2.3.1 Room requirement
4.2.3.1.1 Assembly
Make certain that enough room is available at site for assembly, i.e. positioning of filter
vessel cover, work-place floor panel for candles and assembly of filter hose-cloths, crates for
parts, etc.
4.2.3.1.2 Operation start-up

Pay attention to easy accessibility to all fittings and instruments.
4.2.3.2 Requirements, specifications for erection site

• Floor load (area load)
• Non-slip surface
• Railings to avoid fall of personnel
• Warning signal to alert personnel when present beneath the filter installation, if and
when the floors are subject to leaking (Danger of heat and/or caustic burns from
spilled corrosive and/or hot fluids or open discharge of filter-residue cake.
• Mounting of filter-vessel (brackets and/or claw-legs).
4.2.3.3 Engineering
4.2.3.3.1 General construction regarding integration of filter into the process
®
The FUNDABAC Filter is conceptually and in its design and execution a robust
and simple piece of equipment. Yet, seen from the flow of the process it is a complex
system. Contact should be made with the fabricator of the equipment during the lay-out
phase.Should the customer fail to contact us during this period, especially with regard to
general layout and construction, process integration, piping of buffer vessels, isometrics, etc.,
we cannot be involved in any warranties, if and when problems were to arise during start-up.
This isentirely the responsibility of the customer and partner for these discussions.
4.2.4 Assembly of Filter

4.2.4.1 Provisions and precautionary measures
4.2.4.1.1 Cranes & lifting rigging equipment
See point 4.2.1.4

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4.2.4.1.2 Room requirement

See point 4.2.3.1
4.2.4.1.3 Outdoor erection and assembly under strong wind & high platform (general)
WARNING: ACCIDENTS and risk of fall: these can lead to severe injury and
death.The place of work must be made secure by the customer, fully meeting relevant
regulatory requirements, to prevent accidents to personnel. The customer is liable for any
accidents to personnel. Pay attention to the following:
• Safe access to construction-site and to the filter

• Safe and good walks with secure railings around the filter (risk of fall)
• Non-slip floors, movable anchoring of personnel
• In case of out-door installation and poor climatic conditions, plan for roof above
assembly (meetingspace requirements)
4.2.4.2 Opening of the Filter

First, make certain that the filter is at ZERO pressure in a fully drained and rinsed state (see
7.2.1 on page 26). Vent valve must be open. Where the filter still shows a very high
temperature, allow it to cool down that same day, or overnight. WARNING! In the case of
injury to a person (with possibly subsequent condition affecting that person’s health, etc.) as
a result of inadequately washing of filter and filter cloths, the liability rests solely with
customer. Put the main-switch into its ZERO, resp. OFF position and secure it with a lock
against unauthorized turning to the ON position. Secure the key of this lock at a safe and
known location. Put the following panel next to the main switch for the length of the repair
work:
NICHT EINSCHALTEN REPARATURARBEITEN !

DO NOT SWITCH ON - MEN WORKING !
MACHINE EN REPARATION - NE PAS METTRE EN ROUTE !
NO CONECTAR - TRABAJOS DE REPARACION !
MACCHINA IN RIPARAZIONE -NON METTERE IN CIRCUITO !
To start repair, dismantle all pipe-line connections on the cover. This will permit the freed
cover to be lifted and moved side-ways. Disconnect all bolts and nuts on the main flange.
Clearly mark the cover flange and vessel flange at various points, so that on re-assembly the
cover is in exactly the same position as before (to match ALL piping connections as before).
The crane and lifting rigging devices are now fixed to the cover and lifting can start. All
sealing surfaces are carefully inspected, for possible damage and lack of cleanliness, as well
as for such gasketing that is fixed with adhesive. The cover is now lowered and carefully
brought to rest on previously positioned wooden beams on a very clean floor cover. If the

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gasket is still adhering to the vessel flange, it is inspected for tears or similar damages. All
seal surfaces, including gasketing, are carefully cleaned. If nothing untoward has been
observed, the gasketing can be reused, unless one-way gaskets were initially specified. If
damage has been observed a new gasket must be put into position. If the gasket sits loosely
on the flange surface, store it cleanly and carefully during the maintenance or similar
operation. If the gasket was fixed with an adhesive, cover it carefully with a thicker foil during
the opening operation.
4.2.4.3 The mounting of piping assemblies, fittings, instrumentation and pumps
4.2.4.3.1 Lay-out of filtrate outlets
a - Register-shut-off valves (manual)
b - Register-headers (flanged or welded)
c - Collector-manifold
d - Main filtrate-outlet valves (normally automated)
Additional sight glasses for Q.C. (optional)

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4.2.4.3.2 Register headers

Usually the three outer register outlets are brought to one header, and in pairs for
the other outlets. There are some exceptions; always follow directives
® on these matters,
issued by DrM, with the installation manual for your FUNDABAC plant, or on request. The
geometry of the down-stream outlets of the register headers should always be executed as
drawn on the drawing 6.4.3.1 on page 20, i.e. for two-armed “Y”, the effluent leg of the “Y” to
be centered, and for the three-armed “Y” layout effluent leg should be centered between the
two arms toward the center of the filter vessel. This lay-out very largely assures you of an
even distribution of the gas to the individual registers for blow-back and of the fluid used for
backwash for slurry discharge and cleaning of filter cloths.
4.2.4.3.3 Collector manifold tube (not applicable for CONTIBAC )

When the filter candles are subjected to blow-back, be it for cake discharge or for cleaning
the filter cloths, effectiveness demands a sudden peaking pressure surge. For this reason,
we recommend that the collector-manifold be built of a larger diameter than would normally
be required for the flows and velocities. Such a construction would turn the collector
additionally into an air buffer. You can also use a nearby separate large air buffer as an air
reservoir connected to the collector, instead of an enlarged collector pipe. Please contact
DrM to size and specify such a separate air buffer and the ancillary piping valves for such a
new alternative layout..
a collector-manifold pipe
b off-center reducer
c gas for blow-back
d filtrate, prefiltrate, gas for drying and draining by displacement
a collector-manifold pipe
b gas for blow-back
c filtrate, prefiltrate, gas for drying and draining by displacement.

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For the outlet of the collector downstream we show two alternative schematics. In case of
additional alternatives demanded by circumstances, you must observe the principles
demonstrated in the paragraph below. For the level of the register headers, the collector
manifold and the pipeline for the pre-filtrate/filtrate effluent flow, note the following:
Principally, the entire piping lay-out of the above system should be designed to prevent
® any
fluid in this system ever to drain by reverse flow into the core of the FUNDABAC candles.
Such a flow would partly and prematurely cause the filter cake to drop off. Dry cake
discharge would then become impossible. For this reason the piping lay-out upstream of the
collector-manifold must be in one plane, or it should point downward. In case you are forced
to lead the filtrate/prefiltrate lines upward, which we do NOT recommend, you must put a
check-valve into that line. Please contact DrM, Dr. Mueller AG, in case there are still open
questions concerning the piping lay-out of your filtration system. Please give us the following
dimensions:
4.2.4.3.4 Valves, Specifications
Valves in the filtrate outlet system (i.e. valves which serve 2 and 3 registers) must open/shut
very fast, i.e. <1 second. This is the only way of assuring a shock-surge for inflating the filter
hoses. The types of valve normally used for this are either butterfly or ball valve design.
Diaphragm valves are not well suited for this purpose.
4.2.4.3.5 Pump capacity

Normally the filtration pump also serves for filling the filter. Frequently you require a larger
capacity for filling the filter in 5 minutes, than is required of the pump for filtration. The curve
of your pump should take this aspect into consideration. Please remember that during the
filling of the filter vessel it is essentially free of pressure. Only when you fill the filter with cake
on the candles, i.e. for washing the cake, the filter must show counter-pressure. Filling time
longer than 5 minutes is acceptable if longer down-times can be accepted. When you fill the
filter for cake washing, that step should not exceed 5 minutes, since longer times may cause
cracks in the cake. Filling times below 4-5 minutes could put too high a load on the filter
internals.
4.2.4.3.6 Advice on piping layout

On emptying the liquid contents of the filter vessel by disc-displacement, the liquid leaves the
filter vessel both on the feed and the filtrate sides. These two flows must never be allowed to
be joined. Such confluence could engender a gas liquid mix in the filtrate line, which would
develop pressure in that line, causing the cake to drop off. The vent-line may be joined to the
prefiltrate line, except if the drain line is used for recirculation and return to feed tank during

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the filter-down-time.The vent could then be blocked by the re-cycling stream, especially
during the cleaning of filter-media, during which step air must be allowed to escape very
gently.
4.2.5 Assembly of filter elements
4.2.5.1 Preparation of materials

• Put down wooden beams for resting the filter vessel-cover, to prevent damage to the
sealing surfaces.
• Prepare support tressels (wood or metal) and a table-top for the assembly of the filter
media (the table-top must be free from sharp edges nor show any rough edges nor
splintered surface).
• Use a crane and lifting rigging equipment (as under 6.1.4 on page 15).
• Prepare assembly and mounting tools. Such tools are supplied together with the filter.
For assembly with cloth clamps: clamp pincer pliers. For assembly with wedge rings:
Wedge ring key and 2 cloth fixing tools
4.2.5.2 Mounting of filter media

There are two modes of mounting the media:
• Wedge-rings
These are used for mounting media on plastic filter elements; in some special cases, these
wedge rings are also used on stainless steel filter elements. Please refer to separate manual
for mounting of wedge rings.
• Cloth clamps
These are mainly used for mounting cloths on stainless steel filter elements. Please refer to
separate manual for mounting of cloth clamps.
4.2.5.3 Installation of the spray nozzle

If there is only one spray nozzle, you wrap the threaded portion with PTFE tape clockwise
(2.5 to 3.5 times) and screw it into an intermediate flange. This assembly is now mounted on
an existing connecting flange, centrally located on the vessel cover. The connecting pipe
work is now mounted on this intermediate flange. If there are several spray nozzles, you
must lift the vessel cover. A ring-pipe line for receiving the spray nozzle is located on the
inside space of the cover. The threaded portion of the spray nozzles is wrapped with PTFE
tape as above. These spray nozzles are screwed into the threaded openings on the ring pipe
line. Firmly tighten the inserted spray nozzles.
4.2.5.4 Closing the filter

Closely inspect the main sealing surfaces, cleaning them thoroughly, if so required. Make
certain that the gaskets are fully and correctly seated. Lift the cover and carefully re-seat it on
the filter vessel, make certain that the gasket remains correctly seated and the market
positions are fully matched again, so that the cover is fully returned to its original position.
Proceed with fixing and tightening the cover a torque-like wrench or all driven wrench in the
following order:
• First tighten the screws marked bolts marked with 1 (red circle)
• Then tighten the screws marked with 2 (blue circle)

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• After that, tighten all other screws
CAUTION: All gaskets, nuts and bolts must be closely inspected prior to assembly and after
every dismantling of the filter. They must be inspected for any damage, stiffness and tensile
strength. Overall tensile strength of nuts and bolts can be adversely affected by climatic
conditions. Always clean the threaded portion carefully and even treat them with protective
materials, e.g. graphite paste, grease, etc. Make sure to use the specified torque for
tightening the nuts.
4.2.6 Special hints for installing pilot plants

Install such plants according to the supplied flowsheet. Several types and sizes of pilot plants
exist in our program, which is divided into the following groups:
• Mono-Candle with filtrate outlet and filter candle in mounted cover flange (with
security pin)
Remove the bolts on the cover flange, mount the candle on that flange, after
which you mount the filter hose cloth as described above. Carefully insert this
assembly into the filter vessel, without damaging the filter cloths.
• Mono-Candle with lateral filtrate cover and screw-fitted filter candle

Mount the filter hose cloth on the filter candle, wrap PTFE tape around the threaded candle
nipple (2.5 to 3.5 turns, clock-wise). Now screw the candle through the bottom opening of the
vessel into the internal threaded socket of the filtrate line, near the top of the vessel. First
tighten the candle manually, following up with an open wrench or a socket wrench at the next
nut welded to the bottom of the candle.
• Multi candle filters

The filter elements for these models are mounted in the identical manner as the
regular industrial models, described further back.
After the mounting of the internals, re-assemble all line-connections. Again, make certain that
all sealing surfaces are carefully cleaned and that there are no damaged gaskets. The filters
are now ready for operation.

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WARNING: On filter models, equipped with pneumatically driven discharge val-

ves, the control compressed air MUST be turned off before mounting the filter candle. Never
reach into a filter where the valve operating air has not been turned off.
4.2.7 Disassembly of the filter

If for any reason, complete disassembly of the filter becomes necessary (e.g.
relining or re-coating) you must follow assembly steps in perfect reverse.
Important: keep in mind that ALL internals must be removed before the filter ves-
sel itself is removed.
CAUTION: Before the filter vessel is turned into the horizontal position, remove
all internals. Mounted filter elements will be seriously damaged if and when turned
into the horizontal.
4.2.7.1 Special hints for the disassembly of pilot plants

Before a pilot plant is returned, the following points must be carefully noted:
• The entire pilot plant must be VERY thoroughly cleaned. The installation must be
absolutely clear of all reagents and products with which it was in contact during test
work, before it can be shipped!
• All internals must be removed before the pilot plant is shipped for return.
• Used filter hose cloth must be disposed of in full compliance with the environmental
laws pertaining in the country where the test work is executed.
• The pilot plant must be fixed and crated prior to returning it, so that no damage is
incurred.
4.3 Maintenance
4.3.1 Inspection
4.3.1.1 Filtrate side, inspection and control
If at all possible, the filtrate system should be under constant supervision. Proposal:
1. filtrate instrument inspection
2. sight-glass
3. sampling valve
4.3.1.2 Linings and/or coatings

Any damage to linings and/or coatings can lead to rapid corrosion of the filter and therefore
to leakage. Avoid extreme fluctuation in temperature, knocks etc. The filter could be rendered
inoperative and lose operating permit. Inspect linings and coatings regularly.

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4.3.1.3 Exceeding operating pressure

The pressure limit set by terms of pressure code stamp must not be exceeded. If such an
occurrence is likely, a safety relief valve is a must.
4.3.1.4 Tightness
Leakages showing at the flanges need immediate attention and correction.
4.3.1.5 Corrosion
Environmental conditions, such as acidic or caustic vapors, sprays and liquids, leaking
flanges, etc. can cause external corrosion of the filter vessel. Such conditions can lead to the
loss of your operating permit. You must provide and maintain an environment that is as clean
as possible. You are advised to perform inspections at regular intervals.
4.3.1.6 Parameters
Changes must not be made in the parameters without the advice of and execution by
competent, qualified personnel.
4.3.1.7 Instrument air

Since the major portion of the valves are pneumatically driven and controlled, it is very
advisable to supervise the pressure of the instrument air. Failure or disturbances in the
instrument air net will lead to failure in the performance of the valve-drivers.
4.3.1.8 Pumps
Pumps must be inspected by the buyer whether they meet specifications and operating
manuals. Make certain that the oil level and pressure control for mechanical seals is in full
working order.
4.3.1.9 Compressed air / inert gas / steam

The pressure ranges, specified by DrM must be met to prevent any damage to filter media
and elements. (See para. 3.2.2 on page 4). If applied pressures do not meet these
specifications, DrM cannot accept responsibility to damaged filter media and elements.
Example:
Applied pressure which is too low or too high for cleaning filter media and discharge of filter
cake can lead to the veritable destruction of filter media and filter internals.
4.3.2 Maintenance
4.3.2.1 Motors
Follow manufacturer’s instructions.
4.3.2.2 Gears
4.3.2.3 Pumps
4.3.2.4 Valves and their drives


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4.3.2.5 Filter media

The life-expectancy of filter media vary within wide time limits. As a rule, the quality of the
filtrate indicates the state of the filter cloth. If above measure brought about equilibration of
normal quality of filtrate, you can exchange the offending filter media during your planned
maintenance shut-down.
4.3.3 Repair work
4.3.3.1 Replacement of filter media

Principally follow instructions given in the separate manual on assembly and
disassembly of filter internals.
Please note the following useful instructions when disassembling filter internals:
• Carefully clean all filter internals after each disassembly, especially all seal surfaces
on the candles and register-couplings.
• Large and heavy deposition of dirt on the candles, prior to disassembly necessitates
that you thoroughly back-wash the filter before you proceed with disassembly as
above. This cleaning action prevents dirt contaminating and blinding the internal
downstream surface of the filter media.
• Inspect all parts for damage; if there is none you can proceed with reusing the parts.
4.3.3.2 When to replace filter media

It is up to the operator’s judgement, whether to change media on the entire register-row of
candles, or even on the entire filter (after a long period of operation, it is advisable to change
media on the entire filter.). In case of doubt, especially if the media have been in use for a
long period, it is good practice to replace all filter cloths and all of the seal cuffs on the
register couplings.
4.3.3.3 Environmentally safe disposal of worn-out filter components

Disposal of worn-out components must comply with environmental regulations obtaining in
the country of operation. Keep in mind that toxic materials are likely to adhere to such worn-
out components. The materials of construction of such compounds (e.g. steel, plastics, etc)
are known to the owner and operators from the specifications.
4.4 Failures & Breakdowns
General failures during operation:
4.4.1 Failure of the pump

For a fully automated filtration process, the program should ideally be written in such a
manner that no interruption of the process occurs, i.e.the software should automatically
program the filtration cycle to move to the next step (draining, etc.), after the onset of pump-
failure. The filtrate cycle should be carried on to its normal conclusion.
4.4.2 Failure of discharge of the filter cake

Should there be failure to discharge cake, you must NOT re-start the filter! Open the two
blind flanges in the upper and lower cylindrical portion of the filter vessel (viewing port and/or
probe-flange). See whether the cake is still adhering to the candles. If this is the case, repeat

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blow-back step. If this measure were to fail, refill the filter with liquid (preferably with
suspension-slurry). Follow immediately with the cloth cleaning procedure (blow-back). The
pump must be running during this step. Operate the filter on re-cycle, in order to re-
homogenize the cake solids that failed to be discharged. Allow a minimum of 20 minutes for
this operation. Afterwards resume normal filter operation.
4.4.3 Failure to discharge slurry residue

In case of failure to discharge slurry-residue, check the concentration of solids of the slurry. If
the reading shows too low a content, there is the possibility that the filter has been overfilled.
Check such parameters as pressure, through-put capacity, etc. Were the rise in pressure too
quick or through-put capacity were to drop abruptly, you must stop the filter immediately.
Drain filter completely. Now open all possible inspection ports, i.e. blind-flanged viewing port
and large nozzles, in order to facilitate quick internal inspection of filter. If you find that large
amounts of solids have collected in the filter, wash and rinse the filter, and preferably with
actual product (e.g. open lines: feed, vent, slurry discharge). Rinse, wash-rinse operation
should last 10-20 minutes.
4.4.4 Overfilling of filter with filter-cake solids

A one-time event of overfilling can have the following causes:
• The time lapse of prefiltration and/or filtration have become dramatically longer than
programmed, due to manual override interference.
• Increase in the solids content in the stream, while the programmed times have not
remained unchanged. Accumulating overfilling can develop if the filter cake, resp. slurry,
were not completely discharged. Were you to filter longer during the programmed cycle, you
would also, normally develop more cake, resp. slurry.
• FUNDABAC System
The filter cake is somewhat thicker than planned, the distance between the cake-surfaces is
now too small, which cause the cake to get stuck in the filter, since the cake portions get
wedged between the candles. This phenomenon will cause the major portion of cake to
remain in the filter. If you re-start the filter in this condition, the next cycle will build up more
and more cake solids.
You will observe a faster rise in pressure and a similarly fast decline in the rate of
filtration, when above conditions begin to obtain in the filter.
• CONTIBAC System
If the slurry is not fully discharged, you will build up residue from the filter bottom up,
increasing with each cycle.
CAUTION! You must never exceed the maximum cake volume, for which the filter is
designed. Overfilling the filter with cake solids will damage and possibly destroy the internals
of the filter. If the filter has been overfilled with cake, resp. slurry solids, you must open the
filter, clean it, lift out the internals and inspect them for possible damage.

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4.4.5 Failure of control instrumentation

4.4.5.1 Cake thickness probe
• Function:
Measure and check maximum cake thickness
• Possible consequence:
Overfilling of the filter.
4.4.5.2 Level probes

4.4.5.2.1 Probe for filling filter
• Function:
Sense and control filling of filter vessel
• Possible consequence of failure:

Filter fails to be filled or filling step gets stuck.
4.4.5.2.2 Draining probe
• Function:
Control during draining of filter under pressure
• Possible consequence of failure: Premature loss of filter cake due to loss of pressure;
may cause overfilling of filter.

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4.4.5.2.3 Protection against dry-run of pump
• Function:
Sensing of dry running of pump, which stops pump immediately when all liquid feed
ceases.

Destruction of pump
4.4.5.2.4 Flow meter

• Function:
Measure and control of the volume-flow, resp. accumulating volume-flow
Overfilling of filter.
4.4.5.2.5 Pressure transmitter

• Function:
Control of pressure in the filter during filtration and venting.
• Consequence of failure:
Overfilling of filter, or opening of discharge bottom valve when filter is still under
pressure
4.4.5.2.6 Position status of valves

• Function:
Sensing and control of valve-position.
Faulty work-cycle, which in turn causes various technical process problems.
4.4.5.2.7 Quality control of filtrate

• Function:
Measuring and reporting clarity of filtrate.
Disruption of process downstream if turbidity of filtrate is not sensed.
4.4.5.3 Failure of energy supply

Measures to be taken depend on type of process and must be judged from case to case.
4.4.5.3.1 Power failure

4.4.5.3.2 Instrument air


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4.4.5.3.3 Draining pressure medium / drying pressure medium / blow-back medium

CAUTION! Possible damage ensuing from failures listed above can have serious
consequences. Causes of such failures demand immediate and precise investigations.
Example: failure of supply of blow-back medium can lead to overfilling of filter (see 4.4.4)
since the cake-solids were not discharged from the filter.
For Initial mounting and starting of the Equipment, DrM recommends to have a DrM
technician on site. The Precoat filter will then be adjusted for best performance.
Further to above listed points, correct preparation of Charcoal Filter and Cartridge filter
according the relevant Procedures below.
4.5 Particular Operating Procedures

See Chapter 6.3
4.6 Filling with fresh charcoal

See Chapter 6.3.2
4.7 Charcoal Backwash Procedure

See Chapter 6.3.1
4.8 Inserting fresh Cartridges

See Chapter 6.3.3
5 START-UP
5.1 Normal Start Procedure
During normal operation of the Amine Precoat Filter a number of operator actions are
required which are listed below:
1 Start
The operator has to press the START input of the filter he wants to start first. Now the
sequence will start and advance automatically until main step Ad Precoat.
2. Precoat loading
The sequence release a CALL OPERATOR ALARM and waits until

- the operator has filled the required amount of percoat into the Precoat tank
- the operator has placed an empty cake drum underneath the discharge valve
- the operator has confirmed the above actions by pressing the corresponding START.
The sequence will advance automatically until main step Filtration.
Continous filtration takes place.

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3. Filtration
Once the pressure drop over the filter becomes high a CALL OPERATOR ALARM is
released and indicates need for a filter change.
Based on the plant operation the operator has to select:
Dual Filter "Swing" operation -> Press START input of stand-by filter.
Single filter operation -> Press START input of the running filter.
The sequence will advance following the operators’ selection.
4. Discharge
Once the filter is drained and dried, the cake will automatically discharge into the prepared
cake receiving drum.
At that the end of the cycle, a CALL OPERATOR ALARM is released to indicate that the
discharged cake has to be removed.
The operator has to confirm this action by pressing the START input.
5.2 Restart Procedure
This procedure is required after an UNEXPECTED STOP of the Filter Package.

Due to loss of flow (loss of filtration pressure) a loss of precoat material to bottom of
filter is considered possible.
Filtration must not be continued in such a case.

A manual check of the Filter Package in field is required to know the present conditions (i.e.
Pressure, level, etc)
Procedure for Restart:

1. Give a STOP to the Package PLC.
Select 'SEMI AUTO' operation mode.
RESET the affected filtration package to step 1.
2. Set the SERVICE selector to 'ON' position, check the cake drum to bee in place.
3. Check the plant condition. Filter to be full, Precoat tank to be empty.
4. Press the START button.
5. A cycle will start without precoating and without swing function.
(NO ADDITIONAL PRECOAT MATERIAL IS NEEDED)
The cycle shall run automatic until discharge of the cake.
6. Reset the SERVICE selector to 'OFF' position (low), empty the cake drum.
After a successful run of the 'Restart Procedure' the filter is waiting in '1 STAND-BY' position
and is ready to run a normal precoat filtration cycle.
Please note, that no additional precoat material is added under such condition.

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6 NORMAL OPERATION
6.1 General guideline
Filter operation is a Semi-Automatic operation controlled by a separate PLC.

Filter package condition and operatior input are possible from the remote over all Plant DCS
System.
The overall Fundabac description is given in the DrM standard Manual.
- 13595-65-M-N-0002-00
OPERATING MANUAL (Fundabac Filter) Annex I at end of this document
definition of the normal filtration sequence can be found in

CONTROL LOGIC DIAGRAM - 13595-65-S-N-0002-00 ( see point 10.10 ) (Valve
configuration and advance condition list)

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6.2 Dual Filter “Swing” Operation
In order to ensure a continuous forward flow each filtration package contains two identical
filters A and B. Each of the filters alone is able to handle the full design flow rate.
Normally one filter is in filtration while the second one is in a stand-by position. As soon as
the filter in service reaches a high differential pressure, the second filter is precoated and
prepared to take over.
When both filter are ready then a Flag-Hand-shake will initiate the swing operation.
Please note that both filters have to be in the AUTOMATIC operation mode to perform the
described swing operation.
While preparation is a semi automatic operation (i.e. tipping of precoat material is manual
from bags) the actual swing action is performed automatically, for proper timing and correct
changing of valves. However, it is operator duty to make sure that preparation of the stand-
by unit proceeds timely when required and indicated by a corresponding CALL OPERATOR
Alarm.
On the other hand it is possible to operate only one of the two filters, i.e. in case of
maintenance.
A number of safeguarding functions are provided in order to assure adequate and safe
performance of the described swing operation (refer to CONTROL PHILOSOPHY).
WARNING
IN CASE OF UPSTREAM EQUIPMENT FAILURE THE H2S CONTENT CAN EXCEED THE
DESIGN VALUES IN THE AMINE.
OPERATION BEJOND THE DESIGN LIMITS MAY REDUCE EQUIPMENT LIVE TIME AND
OVER ALL OPERATION SAFETY.
TO AVOID H2S EXPOSURE TO THE ENVIROMENT IN SUCH A CASE NO FILTER
CHANGE OVER OR REGENERATION SHALL TAKE PLACE.
THE MAXIMUM OPERATION DURATION OUTSIDE DESIGN CONDITION IS NOT
PREDICTABLE BASED ON DESIGN PARAMETERS AND SHOULD THEREFORE KEPT
TO A ABSOLUTE MINIMUM.

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6.3 Sequence description
6.3.1Main Step 1 – Stand-by
At the beginning of each filtration cycle the filter vessel CL-002 A/B is filled with liquid that
was received from the previous cycle and the precoat tank VA-009 is empty. All actuated
valves are closed except the overflow/vent valve.
The motor control centers (MCC) for precoat pump, pecoat mixer as well as all actuated
valves forming a part of the package are on automatic operation mode.
Main Amine pump PA-008 running signal must be present for operation start and therefore is
included in the NON CONFORMITY check.
If the above conditions are satisfied the filtration package is ready for an AUTOMATIC
operation. If not a NON CONFORMITY ALARM (N.C.) will be given. Please note that the
AUTO/MANUAL selector switch must be on AUTO position to perform an AUTOMATIC
operation.
The PLC is in a waiting position and will not advance automatically.
To start the new cycle the operator has to press the START push button once to enter into
the next step and proceed with the precoat preparation procedure. This is possible:
1. from the Field Local Control Station (LCS)
2. on the TOUCH SCREEN of the Remote Control Panel (RCP)
3. on the DCS in the control room (DCS)
Before proceeding to the next Main Step the PLC will check the status of the second filter for
conformity. Only if the second filter does not show the preparation Flag (i.e. the second filter
is either in Stand-by or in Filtration) automatic advance is possible. Otherwise the PLC will
rest in this step until the conformity condition is satisfied.
NOTE OF CAUTION
A MANUAL OVERRIDE OF THE DESCRIBED CONFORMITY CHECK SHOULD BE
PERFORMED BY WELL INSTRUCED PERSONNEL ONLY. POSSIBLE MISFUNCTION
DUE TO INTERFERENCE BETWEEN EQUIPMENT.
6.3.2 Main Step 2 – Fill Precoat Tank
The liquid volume is drained from the Amine Filter into precoat tank and is used in the
following Main Step for precoat suspension make-up.
The level in VA-009 is checked to be low (LSL-553), this is to assure that in the precoat tank
is enough capacity available to receive the filter volume.
The PLC opens the low pressure nitrogen supply (1 barg) and proceeds with the draining
operation until the level switch LSL-552A/B detect gas passing through the line. If not the
program gives a NON CONFORMITY ALARM and rest in step until the tank is drained
manually.

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The main draining operation is followed by a heel drain step where the lower cone part is
drained through the bended dip-in-pipe.
6.3.3 Main Step 3 – Add Precoat
In order to have enough liquid for a complete filling of the Precoat Filter CL-002A/B the
program now opens the precoat tank filling line, incorporating valve UV-569, until the level in
precoat tank is high (LSH-553).
For this filling operation a maximum allowable time is pre-set according to the SEQUENCE
LOGIC DIAGRAM. If this time has elapsed and the filling operation is not yet terminated a
NON CONFORMITY ALARM is given.
Now the program comes to a hold point without automatic advance.

A CALL OPERATOR ALARM (C.O.) will be given to inform the operator that a manual action
is required.
WARNING
OPERATOR SHALL NOT HOLD HIS HEAD INSIDE THE PRECOAT LOADING DEVISE
DUE TO PRESENCE OF NITROGEN.
The operator has to tip in precoat material manually from bags into the top of the precoat
tank while the mixer is running. DrM's recommended precoat material is CELLULOSE. The
consumption is about 0.7-1 kg per m2 filter area, respectively approx. 100 kg per filtration
cycle.
IMPORTANT: The type of filter aid should not be changed without consultation of DrM's
experts.
When all precoat material is added the operator has to press the START push button once to
enter into the next step. This is possible:
1. from the Field Local Control Panel (LCS)
2. on the TOUCH SCREEN of the Remote Control Panel (RCP)
3. on the DCS in the control room (DCS)
After 5 minutes running of the mixer, all precoat material is properly suspended and the
program advances automatically the next step.
Please make sure that the manual precoat loading valve on VA-009 is closed.

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6.3.4 Main Step 4 – Filter Filling
The precoat filter CL-002A/B is now to be filled with precoat suspension from VA-009 using
one of the pumps PD-002 A/B. Any gas inside the filter and the candles is displaced by
means of open vent and recycle lines to VA-009.
Starting the pump is performed as follows:

1. Open all lines to precoat filter, switch on pump and wait 5 seconds..
2. Receive "Pump in operation" confirmation from motor MCC.
3. Proceed with the filling operation - open feed line to filter.
The filling operation is terminated by the level switch LSH-551 A/B. For this filling operation a
maximum allowable time is pre-set. If this timer has elapsed and the filling operation is not
yet terminated a NON CONFORMITY ALARM is given.
The filter must not be filled completely, so as not to reduce sufficiency of cloth cleaning in the
following steps. All lines except the overflow/vent are closed.
6.3.5 Main Step 5 – Cloth Cleaning
The cloth cleaning operation is performed to remove fine debris from the surface and pores
of the filter clothes. Pressurized Nitrogen is pressed through the filter cloths from the filtrate
side while the filter is full of liquid. This avoids clogging and extends the life expectancy of the
cloths.
IMPORTANT: The pressure during blow-back must not exceed (2 barg) to avoid damage to
the filter cloths. The pressure will be set by PV-554 during DrM's commissioning and must be
checked from time to time at the associated pressure gauge PI-568.
The cleaning procedure is similar to the procedure for dry cake discharge: Each of the seven
register groups is purged with nitrogen for a few seconds. Between each purging a re-
pressurization time of 5 seconds is programmed.
At the end of the cloth cleaning procedure, the nitrogen supply is closed again and the
downstream pipe is released from pressure.
The register valves are open for 20 seconds to allow liquid to enter the candles
6.3.6 Main Step 6 – Homogenization
Prior to the precoat procedure a homogenization is to be performed by pump flow and

recirculation through the open vent/overflow line. However, the register groups and precoat
recycle lines remain closed, so as not to start the building-up of a precoat layer on the candle
surfaces during homogenization.
After 10 minutes of homogenization the program automatically proceeds with the precoating
procedure.
6.3.7 Main Step 7 – Precoating

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For precoating the register groups and precoat recycle lines open, then the vent/overflow line
is closed.
The precoat procedure is performed to achieve the following:
a) to avoid clogging of the filter cloths by fine debris

b) to improve the filterability of the product with regard to particle size and flow rate
after precoating time of 15 minutes has elapsed the filter is ready to start filtration.
Now the conditions are checked if an automatic transition to the filtration step is possible.
The PLC read the status of the second (linked) filter. Automatic advance is possible
1.) If the second filter shows the swing flag (i.e. it is ready for swing over).
2.) If the second filter shows NOT the preparation flag (FG-PRE) AND NOT the filtration flag
(FG-FIL) (i.e. it is in Stand by).
Otherwise the PLC will rest in this step until the above condition is satisfied.
For this conformity check a maximum allowable time is pre-set. If this time has elapsed a
NON CONFORMITY ALARM is given.
NOTE OF CAUTION
A MANUAL OVERRIDE OF THE DESCRIBED CONFORMITY CHECK SHOULD BE
PERFORMED BY WELL INSTRUCED PERSONNEL ONLY. POSSIBLE MISFUNCTION
DUE TO INTERFERENCE BETWEEN EQUIPMENT.
6.3.8 Main Step 8 – Filtration
Filtration Concept
As long as the cake is not discharged, there must always be a positive differential pressure
across the filter cake. Continuous flow through the cake must be possible at any time,
otherwise the cake may fall down from the vertical candle surface (cake slippage) and sink
into the cone. This is achieved by programming short intermediate steps between valve
changing (smooth operation).
The driving force for the filtration is a positive differential pressure in the main AMINE cycle
over the filter plant that must be continuously present.
During filtration the filter cake is build up on the existing precoat layer. The total cake
thickness is expected to be 10 mm but must not exceed 20 mm in order not to overfill the
filter. This is controlled by a differential pressure transmitter (PDT-551A/B).
When a differential pressure across the filter elements of 2.5 bar is reached a CALL
OPERATER ALARM will be given and the filtration must be terminated manually. However,
this limit is an amine process requirement and not a limitation set by the filtration plant.
Filtration may proceed up to at least 3.5 bar differential pressure (at design flow rate) without
risk of overfilling.

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An additional SAFEGUARDING function is provided. As soon as an alarm differential

pressure is reached (PDAH-551A/B) a NON CONFORMITY Alarm will be given. In case of
further increase to trip differential pressure (PDAHH-551A/B) an EMERGENCY SHUTDOWN
is activated automatically (refer to Control Philosophy for details).
Smooth change over

First the Amine Feed line is opened, filter pressure and flow increases to the design process
value.
The sequence waits to allow a pressure increase in filter CL-002A/B that is generated by the
main MDEA cycle upstream of the unit. This is to maintain a positive differential pressure
across the filter cake at the moment when Filtrate Valve opens and back pressure may enter
from the downstream main MDEA cycle.
The filtrate outlet line to the downstream carbon filter is opened, the actual forward filtration
starts and the swing flag is set. At this moment it is important that possible downstream
control devices (i.e. throttling control valve) do not interrupt the flow.
The Precoat pump stopped and the recycle line to the precoat tank closes.
The sequence waits in the filtration step for a pressure increase (PDT-551 A/B) what is
indication that the filtration has to be terminated (∆p max. reached) the sequence advances
and a CALL OPERATOR ALARM is released and two options are possible:
A) Dual filter swing operation:

The START of the second filter is pressed, While the first filter continous operation, the
second filter is prepared. As soon as it is ready, the second filter takes over filtration and the
first filter advance to drain.
B) Single filter operation (i.e. scheduled shut down):

The START of the effected filter is pressed to advance to the drain step.
Otherwise the PLC will rest in this step until PDAH-551 A/B and finally PDAHH-551 A/B is
rechecked, and an interlock will stop the Amine flow.
6.3.9 Main Step 9 – Filter Draining
Draining is a "smooth operation" and divided into various phases:

The liquid volume is drained into precoat tank and is used in the following filtration cycle for
precoat suspension make-up.
A level check (level < LSL553) secures that all liquid from the filter can be filled in the
Precoat Preparation Tank without overfilling.
In a first draining phase the filter vessel is partly depressurized and liquid is drained via the
filtrate outlet line until level in the filter vessel is lower than LSH-551A/B.
In the second phase the remaining liquid is drained with 1 barg Nitrogen to the precoat tank
via the feed line and for the lowest part of the Vessel via the heel volume drain line.
Draining proceeds until the level switch LSL-552A/B detects gas passing through.
If the precoat tank overfills during the drain procedure, then the program releases interlock
on the related valves, continuing is not possible until the tank is drained manually.

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6.3.10 Main Step 10 – Cake Drying
After draining the pressure inside the filter is increased to 2-3 barg by PV-554.
To have a low Nitrogen consumption the cake is dried register group wise. A small Nitrogen
flow trough all candles is guaranteed by a small bypasse line over the register group valves.
This is to avoid a loss of cake.
The filter cake is dried register group wise one after the other one by passing Nitrogen
through at a maximum flow rate of 1000 Nm3/h. The drying time is preset to 3 minutes per
group but may be amended during commissioning, subject to drying operation performance.
During Drain and Drying a minimum pressure drop over the candles of 0.5 bar shall be
maintained to secure the cake from slipping down. The Differential pressure is monitored
and an optional low pressure warning can be defined.
A short opening of the heel volume drain line makes sure that any liquid collected during
drying in the filter cone will be displaced.
A complete draining of the filter vessel is necessary to allow a dry cake discharge.
6.3.11Main Step 11 – Vent Filter
The filter is depressurized via filtrate line until a pressure less than 0.3 barg is reached,
(Differential pressure < PDSL-551A/B).
For the depressurization a maximum allowable time is pre-set. If this time has elapsed
without reaching PDSL-551A/B a NON CONFORMITY ALARM is given.
In a second venting step the vessel is vented via overflow/vent line to the Precoat
preparation tank.
6.3.12 Main Step 12 – Cake Discharge
WARNING
OPERATOR TO STAY BACK FROM THE DISCHARGE AREA DURING OPENING OF THE
DISCHARGE VALVE AND CAKE DISCHARGE. POSSIBLE RISK OF
EXPOSEURE TO NITROGEN AND/OR AMINE VAPOR
REMARK:
Amount of discharged cake shall equal or higher then the amount of loaded precoat material.
Reduced discharge volume is a indication for a serious process failure and requires close
observation of the filter operation.
The discharge valve is opened. A number of interlocks assure that the discharge valve can
only be opened when the vessel is empty and depressurized, feed valves are closed and the
vent is open The discharge procedure is the same as for the cloth cleaning: Each of the
register groups is purged twice for 5 seconds. Between each purging a pressurization time of
5 seconds is programmed.

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At the end of the discharge, the blow-back line is depressurized and closed again.
The discharge valve should be kept open for at least 30 sec. to allow cake remaining on the
valve disc and vessel walls to slip down.
WARNING
NEVER PUT HEAD OR HANDS INTO THE OPENED DISCHARGE VALVE
IT MAY CLOSE AND CAN CAUSE SERIOUS INJURIES.
6.3.13 Main Step 13 – Drain Precoat tank to Filter
After all cake has been discharged from the filter the remaining amine volume in the precoat
tank will be pumped back to the filter in order not to be exposed to atmosphere for a long
time.
A CALL OPERATOR ALARM is released to indicate that the discharged cake has to be
removed.
The operator has to confirm this actions by pressing the START input.
Now the end of the filtration cycle is reached and the PLC jumps back to Step 1. and in the
Stand by position, waiting for a restart.
REMARK:
Amount of discharged cake shall equal or higher then the amount of loaded precoat material.
Reduced discharge volume is a indication for a serious process failure and requires close
observation of the filter operation.
6.4 DESCRIPTION OF OPERATOR ACTIONS
During normal operation of the Amine Precoat Filter a number of operator actions are
required which are listed below:
1 Start
The operator has to press the START input of the filter he wants to start first. Now the
sequence will start and advance automatically until main step Ad Precoat.
2. Precoat loading
The sequence release a CALL OPERATOR ALARM and waits until
- the operator has filled the required amount of percoat into the Precoat tank
- the operator has placed an empty cake drum underneath the discharge valve
- the operator has confirmed the above actions by pressing the corresponding START.
The sequence will advance automatically until main step Filtration.
Continous filtration takes place.
3. Filtration
Once the pressure drop over the filter becomes high a CALL OPERATOR ALARM is
released and indicates need for a filter change.
Based on the plant operation the operator has to select:
Dual Filter "Swing" operation -> Press START input of stand-by filter.

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Single filter operation -> Press START input of the running filter.
The sequence will advance following the operators’ selection.
4. Discharge
Once the filter is drained and dried, the cake will automatically discharge into the prepared
cake receiving drum.
At that the end of the cycle, a CALL OPERATOR ALARM is released to indicate that the
discharged cake has to be removed.
The operator has to confirm this action by pressing the START input.
Once the filter runs in Automatic mode, the system needs a low level of attention. In order to
keep a history of filter operation, the following parameter shall be reported in a Filter log for
each cycle:
- Duration of last cycle and reason of termination;
- Date, amout and type of Precoat material added;
.- Fundabac differential pressure (DP); - during prcoating,
- after 1 hour of filtration,
.- Fundabac-, Charcoal- and Cartridge filter DP - after half time of last filtration cycle
6.5 NORMAL FUNDABAC© FILTRATION CYCLE
6.5.1 Precoating
First part of each Filtration cycle consists of the following main steps:
1 STANDBY
2 DRAIN FILTER/FILL PRECOAT TANK
3 ADD PRECOAT
4 FILTER FILLING
5 CLOTH CLEANING
6 HOMOGENISATION
7 PRECOATING
6.5.2 Cake Removal
The second part of each filter cycle cycle consists of the following main steps:
9 FILTER DRAIN
10 CAKE DRYING
11 VENT FILTER
12 CAKE DISCHARGE
13 PRECOAT TANK EMPTYING
6.5.3 SWING-Operation
Combination of two filter allows uninterupted filtration with alternating use of filter A while B is
in regeneration and Stand by and visa versa.

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Before the old filter is taken out of service the new Standby filter has to be prepared for
filtration. The operator can choose the time when preparation begins. After PSH is reached
the START input of the corresponding filter is given any time but before the PAH is reached.
A typical operation pattern is :
START Filter A
Precoating filter A
Filtration Filter A until PSH
START Filter B
Precoating filter B
Filtration A and B, swing flag A
Cake removal Filter A -> Standby
Filtration Filter B until PSH
START Filter A
Precoating filter A
Filtration B and A, swing flag B
Cake removal Filter B -> Standby
Filtration Filter A until PSH

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6.6 PARTICULAR OPERATING PROCEDURE
6.6.1 CHARCOAL BACKWASH PROCEDURE
6.6.1.1 Definition
A Backwash is the process required to remove Carbon fines from a fresh load of Charcoal.
The equipment installed for precoating is used and therefore an almost automatic operation
for the backwash process is possible.
The fines are washed out of the Charcoal bed by use of the precoat pump. The
FUNDABAC© filter will remove the fines from the wash liquid.
6.6.1.2 Preparation
Due to involvement of a series of manual valves, the correct setting has to be double
checked against the check list below.
Previous the backwash the old charge of coal has to be removed and new coal is to be filled
in the Vessel. After a predefined soaking period with water, the Backwash can take place.
CHECK LIST:
Correct setting of the involved Charcoal filter:
- Isolation of the old charcoal filter towards the Amine stream.

- Filter vessel to be charged with Charcoal and filled with liquid
(water or amine)
- Water filling lines have to be closed
- Drain lines have to be closed
- Backwash valves to the Precoat pump have to be open
- Globe valve in the backwash line have to be set to reduce the flow.
Correct setting of other parts in the filter plant.
- Hand valve in the precoat pump outlet line between the outlet to
Charcoal filter and the return line has to be closed. The bachwash
liquid flow is forced trough the Charcoal filter.
- The SERVICE selector in the plant control has to be in ON (high)
position.
- The precoat tank was normal emptied to the standby filter during the
last cycle .
Pressure Drop of the precoat filter in operation has to allow a minimum of 1 day
operation before the PDSH set-point is reached.

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6.6.1.3 Backwash Procedure
The correct setting as above do allow automatic operation of the backwash cycle.
Initiating the backwash is done by pressing the START of the involved filter.
After initiating the filtration cycle starts, the Charcoal filter is full and effects the process as
much as a piece of pipe.
The sequence will run only the steps marked with the Service-flag, what is basically a
complete cycle except the steps adding and suspending of precoat.
Once the cycle is reaching the step 35 PRECOATING, the filtration is effective for the pre-
defined 900 sec. To enlarge the backwash time the sequence mode has to be set to SEMI-
AUTOMAT. The filter will remain in the actual situation until the mode is changed back to
Automat and the timer is expired.
All steps including filtration of the Main Amine stream are by-passed. Next the steps involving
drain, drying and discharge will run as marked with the Service Flag in the CONTROL
LOGIC DIAGRAM.
After discharge the hand valves have to be rest to normal position and the Service selector
switched off (0).
6.6.2 Charcoal change
6.6.2.1 Emptying of charcoal vessel
After the Charcoal filter reaches high differential pressure or the charcoal capacity is utilised,
the stand by filter is taken in operation. Then the old filter is taken out of service.
Proceed as follows:
Stand by unit shall be filled with Amine.

1) Open inlet block valve (top) of the stand by unit.
2) Open the slowly the outlet block valve (bottom) of the Stand By Unit. The Amine
begins to flow trough the standby filter.
3) Close slowly the inlet block valve to the old filter. Amine flow trough the old filter
stops.
4) Close the outlet block valve of the old filter. The Standby unit is now in filtration
and the old filter is isolated from the process and can be drained.
(Filter is still under operation pressure)
The Amine from the used old filter unit is drained. Depending on the further action with the
used charcoal load it should be washed before unloading.
The coal can now be unloaded by use of a flexible vacuum hose. It will be soaked out of the
Vessel into a tank truck.

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6.6.2.2 Filling with fresh charcoal
The Charcoal vessel is opened and the inside can be washed with water.
The vessel is filled 1/2 with Water
Charcoal is filled in from big bags or from a Truck.
The vessel is filled up to a level above the coal with water.
The vessel is closed and the coal is soaked with water for about 1 day.
Depending on process requirements the vessel is filled with water or the water is drained and
vessel filled with amine.
All valves are set to backwash conditions.
The backwash procedure is performed.
The backwash conditions are reset to operation conditions.
6.6.3 Procedure for Cartridge change
6.6.3.1 Removal of Cartridges
After the Cartridge filter reaches high differential pressure the stand by filter is taken in
operation. Then the old filter is drained:
Proceed as follows:
1) Open inlet block valve (top) of the stand by unit.
2) Open the slowly the outlet block valve (bottom) of the Stand By Unit. The Amine
begins to flow trough the standby filter.
3) Close slowly the inlet block valve to the old filter. Amine flow trough the old filter
stops.
4) Close the outlet block valve of the old filter. The Standby unit is now in filtration
and the old filter is isolated from the process and can be drained.
(Filter is still under operation pressure)
The old filter is drained, first the upper drain and second the lower drain is opened until the
liquid flow stops. The filter is blinded off.
The cartridges are washed with water and the filter is drained once again.
The drain line is dip in shape that allows drain below the installed skirt.
The Filter is opened and the upper part is lifted carefully by use of the installed lifting devise.
The cartridges are pulled out manually.
6.6.3.2 Inserting fresh Cartridges
The bottom part of the filter has to be washed above und under the cartridge support plate.
Any solids shall be washed out carefully to avoid contamination of the filter clean side.
The cartridges are inserted carefully, and proper tightening of the two mounted O-rings is
checked (requires min. 2 people).
The vessel upper part is lowered and set down on the gasket in position to allow the bolts to
fit in.
Vessel is closed and tightened.

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7 NORMAL SHUT DOWN PROCEDURE
7.1 General guideline
While Normal operation is alternating operation of filter A and B, for a shut down the current
filter cycle has to be terminated (including cake removal) without start of the stand-by filter.
7.2 Complete Cycle
The filtration is running until PSH is reached. By giving the START input of the filter in
operation. Filtration is terminated, the old filteris drained, the cake is dried and discharged
normal.
After discharge, the both filter are in stand by.
7.3 Premature Cycle termination
If filter operation until PSH is reached is not possible, the cycle has to be terminated manual.
This is possible by switching the package control to Semi-Automatic and press the
ADVANCE input once. The sequence will advance one step and wait. It is required to return
to Automat operation mode for a normal cake removal.
By giving the START input of the filter advances to drain, cake drying and discharge.
Removal of a cake from a premature terminated cycle can require additional manual
operations like manual reduction of nitrogen by-pass flow (FV-553A/B) in order to have drain
completed (only required if Drain time out appears).
After discharge, the both filter are in stand by.
7.4 Stop the Package
When both filter are in stand by, the stop command (one for each filter) will set all field
outputs to 0 or low state.
The Filter package is now de-energised and depressurised.
The precoat tank is 'empty' (LSLL still covered).
The both filter vessel are filled with amine.
For maintenance work, it is recommended to drain and rinse the vessel in question.

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8 EMERGENCY SHUT DOWN PROCEDURE
8.1 General
The quickest way to stop the plant is Emergency stop that will take all outputs to the field.
The package goes to the 'SAFETY CONFIGURATION'. All valves go to the fail position
(close)
8.1.1 Instrument air failure
In case of an Instrument air failure:

- Single acting, spring closing valves will fail close. The position
discrepancy alarm is released and the filter cycle goes on HOLD.
- Double acting valves will remain in there position. Due to installed Air
tanks, the valves will close if a package STOP is released.
8.1.2 Electric power failure
In case of an Electric power failure, all outputs to the field will be zero. The package goes to
the 'SAFETY CONFIGURATION'. All valves go to the fail position (close)
8.2 STOP Push Button (HS-552A/B)
The STOP push button is used to:

• inhibit all PLC outputs to the corresponding filtration package (SAFETY
CONFIGURATION)
• stop the automatic operation of the corresponding filter in case of emergency
Once the STOP push button was pressed the PLC enters into the STOP mode (SAFETY
CONFIGURATION) but keeps the actual step active. All actuated valves are closed and
motors are switched off. To re-enter into the RUN mode, the START push button has to be
pressed.
Note 1: The local STOP push button on the package LCS is not active if the local
LOCAL/REMOTE selector switch is on REMOTE position.
Note 2: The ADVANCE push button remains active when in STOP mode. This allows an
operator to advance the program to a certain step with all outputs inhibited (SAFETY
CONFIGURATION). This may be useful under special circumstances, i.e. to repeat steps
manually or for test duties.
IMPORTANT:
The STOP push button must be used with caution, considering the possible irreversible
effects on the filter cake (cake slippage).
8.3 EMERGENCY STOP Push Button (HS-558 only on LCS)

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The local STOP push button on the package LCS is not active if the local LOCAL/REMOTE
selector is on REMOTE position. In case of an emergency the local EMERGENCY STOP
must be used instead.
The EMERGENCY STOP push button is red, of mushroom type and stay-put. It is to be reset
by twisting the mushroom head.
8.4 SHUTDOWN
8.4.1 Regular Shutdown
A regular shutdown means a scheduled shutdown (i.e. for maintenance purpose etc.) or any
other shutdown under NON EMERGENCY condition.
The sequence of filter in operation is ADVANCED (by ADVANCE and START) and will run in
AUTOMATIC mode through the complete cycle until the Control Logic enters Main Step 1
(Stand-by position). Now the plant is shutdown by pressing the STOP push button (provided
on DCS-VDU and LCS).
All actuated valves are closed. Flow through the filtration package as well as through the
Precoat Filter, the Charcoal Filter and the Cartridge Filter is stopped. No differential pressure
across any of the filters is present.
Both Precoat Filter have been discharged, vented and are filled with Amine from the Precoat
Tank. The Charcoal Filter and the Cartridge Filter are filled with liquid and some residual
pressure may be present inside the vessels at this time.
A regular restart of Filtration Package is possible without further manual action or

intervention.
8.4.2 Emergency Shutdown
An EMERGENCY SHUTDOWN means a non-scheduled intervention under EMERGENCY

condition (i.e. faulty operation, failure of equipment or a hazardous situation).
In such cases the Filtration Package can be stopped immediately by pressing the STOP
push button on the local EMERGENCY STOP on LCS.
All actuated valves are close immediately and precoat pump and mixer are switched off.
Flow through the filtration package is stopped. Due to lack of flow, no differential pressure
across any of the filters is present.
The Precoat Filter is filled with liquid and all cake or precoat material remains inside the filter.
Also, the Charcoal Filter and the Cartridge Filter are filled with liquid.
Residual pressure may be present inside the vessels according to the operating pressure
present at the moment of shutdown.
To restart the affected equipment the Restart Procedure shall be followed.
8.4.3 External Shutdown
An external shutdown means a non-scheduled intervention under EMERGENCY condition

(i.e. fire case) initiated from a source outside the filtration package.

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The external Shutdown will act as the above described EMERGENCY shutdown.
9 TROUBLE SHOOTING
The Troubleshooting of the filtration plant is described in in detail in the DrM standard
Manual. Please refer to
- 13595-65-M-N-0002-00
OPERATING MANUAL See part 4 where you may find the complete document.
Special care must be given to :
SAFETY Chapter 4
Upkeep and Maintenance Chapter 9
FAILURES & BREAKEDOWNS Chapter 10
Troubleshooting of Charcoal- and Cartridge-Filter:

Differential Pressure High: Filter internaly blocked Replace filling
Hand Valve position wrong Check position
Filter Flow rate to high Check and adjust flow rate.
Differential Pressure zero: Filter internaly brocken Replace Cartridges

Replace burst disc
Hand Valve position wrong Check position
Filter Flow rate to low Check and adjust flow rate.

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10 REFERENCE DOCUMENTS
10.1 PFD
13595-65-D-N-0002-00 Process flow diagram material balance
10.2 P&ID's
13595-65-D-N-0010-00 P&ID Page 1 & 2
10.3 Electrical Load Summary
13595-65-L-N 0008-00 List of electrical users & consumption of utilities aviable
10.4 Equipment summary
13595-65-X-N-0006-00 Data Sheet for Process
10.5 Equipment data sheets
13595-65-X-N-0002-00 Data Sheet for Vessel
10.6 Instrument data sheets for control valves, safety valves
13595-65-X-N-0016-00 Data Sheet for Instrument (Safety Relief Valves)

13595-65-X-N-0017-00 Data Sheet for Instrument (Pressure Regulators)
13595-65-X-N-0018-00 Data Sheet for Instrument (Flow Control Valves)
10.7 Cause & Effect Diagrams, Specification of Logic Sequences
13595-65-D-N-0005-00 Cause & Effect Matrix

13595-65-S-N-0002-00 Control Logic Diagram
13595-65-P-N-0002-00 Operator Panel Page Description
10.8 Package assembly
13595-65-D-N-0009-00 Piping Interconnecting drawings at battery limits
10.9 Process Documents
13595-65-G-N-0001-00 Process Description and Design Basis

13595-65-G-N-0003-00 Process Control Philosophy
11 ANNEX
11.1 FUNDABAC OPERATION MANUAL 13595-65-M-N-0002-00


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AgipGas BV WESTERN LIBYA GAS PROJECT

AGBV Job No. AGBV Doc. No.

ABB Lummus Malta

A4 05.01.05 FINAL MKG

File name: 13595G65MN000400_A3

ABB Lummus Malta

2 BASIS OF DESIGN .........................................................................................................................................8

3 PACKAGE FUNCTIONAL DESCRIPTION...............................................................................................9

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ABB Lummus Malta

4.6 FILLING WITH FRESH CHARCOAL

7 NORMAL SHUT DOWN PROCEDURE ...................................................................................................54

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ABB Lummus Malta

8.1.1 INSTRUMENT AIR FAILURE

9 TROUBLE SHOOTING ...............................................................................................................................57

However, in circulating solvent systems, ingress of contaminants or degradation of the

File name: 13595G65MN000400_A3

ABB Lummus Malta

• Finely divided small solid particles.

Common counter measures and their limits:

The FUNDABAC® way

File name: 13595G65MN000400_A3

ABB Lummus Malta

Purified Gas Acid Gas

Hot Rich Solvent

Raw Sour Gas

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ABB Lummus Malta

Precoat Filter (Tag No. 51/52/53-330-CL-002A/B)

File name: 13595G65MN000400_A3

ABB Lummus Malta

2.1 Precoat Filter

Typical precoat filter data:

2.2 Charcoal Filters

The filtration unit is equipped with two carbon columns.

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ABB Lummus Malta

UNIT cross carbon

2.3 Cartridge Filters

The Amine Cartridge Filters were sized to accommodate 24 cartridge elements.

Typical cartridge element data:

The expected run life of the cartridge element is approx 6 months.

3 PACKAGE FUNCTIONAL DESCRIPTION

File name: 13595G65MN000400_A3

ABB Lummus Malta

3.2 Charcoal Filters

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ABB Lummus Malta

3.3 Cartridge Filters

The Amine Cartridge Filters were sized to accommodate 24 cartridge elements.

Typical cartridge element data:

The expected run life of the cartridge element is approx 6 months.

3.4 BASIC CONTROL CONCEPT

3.4.1 Cycle Operation

3.4.2 AUTOMATIC/SEMI-AUTOMATIC OPERATION & STEP ADVANCE

A fully automatic as well as a Semi-Automatic execution of the above described filtration

In Automatic operation mode automatic Step Advance is foreseen. If the Advance

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ABB Lummus Malta

3.4.3 PLC Output Configuration

3.5 CALL OPERATOR ALARM (C.O.)

3.5.2 General CALL OPERATOR Alarm (UA-555A/B)