AIR FILTER/BY-PASS ASSEMBLY PACKAGE

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1 AIR FILTER/BY-PASS ASSEMBLY PACKAGE MAINTENANCE AND OPERATING INSTRUCTIONS SUMMARY 0 Emissione Luca Passoni Marco La Rocca Marco La Rocca 15/11/01 Rev. Descrizione: Redatto: Convalidato: Approvato: Data: Description: Issued: Validated: Approved: Date: Pag 1 of 11

2 1. General features...page 3 2. Description Page 3 3. First stage: prefilter section......page 5 4. Second stage: high efficiency filter section......page 6 5. Installation & Handling Page 7 6. Preparation for initial start-up and Operating instructions Page 8 7. Maintenance Page 8 Pag 2 of 11

3 1. GENERAL FEATURES This document is realized for describing the new prototype silenced filtering unit designed to hold up nearly all airborne particles or inlet gases, in order to avoid compressor damage and to guarantee a high rate of clean air or compressed gas downstream the compressor. 2. DESCRIPTION Following the primary flow rate flowing trough the filtering unit, we find: 1. Inlet Louvre 2. Filter stages: Nr. 2 Prefilters LMEFIFP550 Nr. 1 High efficiency filter NBLFIFG Silencer 4. Outlet Flange While, following the by-pass flow rate flowing trough the unit, we find: 1. Inlet Flanged, 2. Discharge pipe 3. Double inverse conical silencer 4. Discharge baffle 5. By-Pass Louvered Outlet Pag 3 of 11

4 BY-PASS INLET PRIMARY AIR OUTLET (A) (B) Fig1- layout of the inspection side (A) and the flanged side (B). PRIMARY AIR INLET BY-PASS OUTLET Fig2- layout of the maintenance side. 3. FIRST STAGE: PREFILTER SECTION LMEFIFP550 Pag 4 of 11

5 PREFILTERS Fig.3- particular of the prefilter stage. Type Stage Filtering surface m 2 PREFILTER 1 ST 0,9 Nominal flow rate m 3 /h 3000 Pressure drop at nominal air flow rate Initial Pa Suggested value G 4 Efficiency Pressure collapse Rate Standard Remarks Tmax = 80 C H.R. = 100% EN 779 disposable self-estinguishing galv. frame 4. SECOND STAGE: HIGH EFFICIENCY FILTER SECTION NBLFIFG550 Pag 5 of 11

6 HIGH EFFICIENCY FILTER Fig.4- particular of the high efficiency filtering stage. The second stage high efficiency filter section has the following characteristics: Type Stage Filtering surface m 2 Nominal flow rate m 3 Pressure drop at nominal air flow rate Initial Suggested value Efficiency Cracking Rate Standard Remarks HIGH EFFICIENCY 2 nd Pa 650 Pa 1000 F 9 EN 779 Tmax = 60 C H.R. = 100% disposable galvanised steel 5. INSTALLATION & HANDLING Pag 6 of 11

Be sure that the position where the filter is to be installed is accessible for easy inspection, maintenance, replacement of filtering element, etc.

7 Be sure that the position where the filter is to be installed is accessible for easy inspection, maintenance, replacement of filtering element, etc. Take care to install the unit in a place where there is the smallest quantity of dust and avoid to place the air inlet near chimneys or other polluting sources. The unit is designed to operate in outdoor installations, however in this case, it is advisable to provide hot water or steam heated coils if filter is to be installed in a zone where icing or humidity could occur: this will prevent condense or icing in filters. Be sure to have a free space in front of the primary air inlet, suitable for execute maintenance procedures by the operators. In the units where filters is supplied as loose component, connect the outlet flange and the inlet by-pass air flow of the unit to the connecting piece of the compressor and be sure of: the utmost cleanliness during mounting or installation operation a perfect air-tight connection easy access for eventual inspections keeping the flange protection sheet in its place until the connection is made. Filter performance depends entirely on the correct operation during the above mentioned phases. WARNING Handling and lifting are foreseen only by fork lift Do not turn, lay down or jolt the unit Check that the flange gauge connections are perfectly closed Do not open the inlet door during function 6. PREPARATION FOR INITIAL START-UP & OPERATING INSTRUCTION This unit is designed for continuous operation according to rated capacity. Damages may be caused by: Pag 7 of 11

8 an air flow increase over 10% than the rated one excessive back pressure pulsation in case of uneven running of the compressor filter operating with pressure drop values higher than those indicated (see Maintenance instructions ) 7. MAINTENANCE The whole filtering stage is not of cleanable type so the maintenance is required. Therefore as soon as the pressure drop reaches its recommended value, the replacement of filtering element is recommended. When pressure drop reaches 900 Pa, the whole filtering stage must be changed. The prefilters can be replaced when the compression is running, while the high efficiency filter must be replaced only when the machine is out of service. New prefilters and a high efficiency filter have to be properly fitted as any breakage or leakage might jeopardize the filter efficiency of the whole unit. The special featuring of the filters, permits to easily substitute either the prefilters or the high efficiency filters. In order to check the correct operating conditions of the filters, some actions are recommended: the operator is recommended to register the pressure drop values on a diagram it is advisable to install a water U type pressure differential manometer inspection should be carried out every week The unit is already arranged for ¼ threaded connections downstream the filtration stage. Total initial pressure drop of filtration system is about 260 Pa (2.6 mbar) When the pressure drop of the filter elements rises up to 900 Pa (9 mbar), filters are to be changed. NOTE Should a sudden decrease of pressure be recorded or observed, the filter must be immediately replaced. Longer life of the filter is achievable by periodic inspection of the primary air inlet INSTRUCTIONS FOR REPLACEMENT Pag 8 of 11

Prefilters replacement Remove the weather louvre by turning the top knob

Pull out the filter elements using the handle (see following picture)

(proceed in reverse order) Absolute Filter replacement Stop the air flow

9 Prefilters replacement Remove the weather louvre by turning the top knob and lifting the louvre upwards (see following pictures). Pull out the filter elements using the handle (see following picture) Push in the new elements (proceed in reverse order) Reinstall the louvre (proceed in reverse order) Absolute Filter replacement Stop the air flow in the unit Remove the louvre (as per above Pre-filter replacement description) Pag 9 of 11

Unscrew the Filter to seal fixing knobs and remove the fixing rod by

filter by pulling it by the two handles as per following picture Place

Reinstall and lock the fixing rod screwing the fixing knobs (proceed in

to have a correct performance of the filter, you have to check that:

10 Unscrew the Filter to seal fixing knobs and remove the fixing rod by lifting and pulling it backwards (see following pictures Remove the filter by pulling it by the two handles as per following picture Place new element assuring the right position as per the picture below Reinstall and lock the fixing rod screwing the fixing knobs (proceed in reverse order) Reinstall the louvre (proceed in reverse order) In order to have a correct performance of the filter, you have to check that: the air inlet louvre is cleaned there is no internal rusting Residual risk Pag 10 of 11

11 The greatest care has been taken when designing and manufacturing the filtering group in order to reduce residual risk to zero. Nevertheless normal caution working on metal works is to be taken. 8. SPARE PARTS Spare parts shall be directly required to your local Ingersoll-Rand office: specifying the number of your purchase order and the part number of your unit which the spares refer to. Suggested quantity Equipment description Part number 2 Prefilters 14SP597 1 High efficiency filter 14SP598 Pag 11 of 11

2.- HANDLING OF VALVES BEFORE ASSEMBLY 3.- FITTING THE VALVE TO THE REST OF THE ASSEMBLY 5.- PERIODICAL INSPECTION OF THE VALVE AND MAINTENANCE

Page 1 of 16 CONTENTS 1.- INTRODUCTION 2.- HANDLING OF VALVES BEFORE ASSEMBLY 3.- FITTING THE VALVE TO THE REST OF THE ASSEMBLY 4.- OPERATION OF A BALL VALVE 5.- PERIODICAL INSPECTION OF THE VALVE AND