WATER TREATMENT PLANT – PHASE 2

DOCUMENT NO: MUK-62-MGT-AIC-09011

FILTER PRESS ERECTION AND INSTALLATION PROCEDURE

OCCIDENTAL MUKHAIZNA LLC

MUKHAIZNA FACILITIES DEVELOPMENT

DOCUMENT REVISION HISTORY

Rev Date Remarks Originated by Checked by Approved by
A 1/7/2011 First Issue Vendor SJG DSR
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WATER TREATMENT PLANT PHASE 2
FILTER PRESS ERECTION AND INSTALLATION PROCEDURE

MUK-62-MGT-AIC-09011
MUKHAIZNA FACILITIES DEVELOPMENT

TABLE OF CONTENTS
1. Installation

1.1 SAFETY INSTRUCTIONS

1.2 RECEIVEING AND INSPECTION
1.3 FILTER PRESS HANDLING
1.4 STORAGE
1.5 ERECTION
1.5.1 LEVEL AND SQUARE INSTRUCTIONS
1.5.2 OPTIONAL SLIDE PLATES
1.5.3 INSTALLATION OF THE FILTER CLOTH
1.5.4 ELECTRICAL CONNECTIONS

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CHAPTER 3
INSTALLATION

3.1 SAFETY INSTRUCTIONS

Each filter press must be carefully inspected after equipment is received. Do the following:

Check to see if the filter press has been damaged during transport as soon as it arrives at the
job site.

Immediately check to see if the consignment is complete; later complaints cannot be considered.

For filter presses with electrical units, check that the electrical specifications on the name plate
correspond to the operating conditions.

The electrical connections must be carried out by qualified personnel. The direction of rotation of
the electric motors must conform to the direction of the arrows shown on the hydraulic unit.

WARNING: High-voltage and rotating electrical machinery can cause serious or

fatal injury. Installation, operation, and maintenance of rotating electrical machinery
must be performed only by qualified personnel.

Upon arrangement, the filter press must be horizontally aligned in longitudinal and cross
directions. Check that all process piping (slurry, filtrate, compressed air, water, and the like) has
been properly installed and tested.

The contact surfaces of the filter press must be examined from time to time, especially if
arranged in steel frames. A lowering of the contact surface results in distortion of the filter press.
Distortions may cause filter press malfunctions.

ANDRITZ recommends the service of a field service technician for the startup of the equipment.
Consult the factory for service availability.

3.2 RECEIVING AND INSPECTION

The filter press ships as one complete unit. It is delivered to the job site under full closing
pressure. If the filter press is being installed in its permanent position, it will go from the
transport to its foundation. Upon arrangement, the filter press must be horizontally aligned in
longitudinal and cross direction. If the filter press is to be stored, refer to the storage instructions
in § 3.4.

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3.3 FILTER PRESS HANDLING

As stated earlier, the filter press ships as one complete unit under full closing pre ssure. Check the
closing pressure. The filter press cannot be lifted if the hydraulic closing pressure is less than 100
bar (1,450 psi). If the pressure is less than 1,450 psi, call ANDRITZ immediately.

WARNING: Do not lift the filter press if hydraulic pressure is less than 100 bar
(1,450 psi).

CAUTION: Lifting equipment is dangerous. If you drop the equipment, you could
damage the equipment and injure yourself.

WARNING: Do not walk or stand below a suspended load. If the load falls, you
could be seriously injured or killed.

WARNING: Only a qualified rigger and proper lifting equipment may be used
when lifting and moving the press. Make sure the lifting equipment has the capacity to
lift the filter press. Otherwise, the equipment might fall and be damaged and/or
personnel may be injured or killed.

All limit switches and brackets that may interfere with the lifting slings or rigging must be
removed prior to lifting.

Two cranes or a spreader bar the length of the filter press can be used for lifting the filter press. A
straight pull is allowed on the ends of the filter press.

Carefully remove the filter press from the transport vehicle. A set of lifting eyes/lifting lugs is
located at each end of the filter press. Use the diagram below to locate the lift points and attach
the lifting rig.

The filter press is typically shipped with shipping beams under each end. Remove these beams
before setting the press.

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Place the filter press in position. The side rail supports (where required) must be installed lo ose
until the filter press has been leveled. The side rail supports (where required) must contact the
bottom edge of the side rail (DO NOT WELD). Refer to figure 3-1.

Figure 3-1. Lifting Rig Diagram

3.4 STORAGE

If the filter press is to be stored for any length of time before installation, sunlight will deteriorate
the plastic components on the filter press (filter plates, cloths). Keep filter cloths in their original
packaging to protect them from humidity and sunlight. Cover the filter press with an opaque cloth,
such as a tarp. If any spare filter plates are shipped, store them vertically under the same
conditions as those for the filter press

The cylinder must be cycled at least once a month during extended storage periods to prevent the
seals from losing their flexibility. Other systems (plate shifter, bomb bay doors) must also be cycled
once a month to coat the components with hydraulic oil.

If the filter press is to be stored for extended periods, or if it is not possible to cycle the hydraulic
unit, then the following steps must be taken to prevent damage to the filter press and its
subsystems.

CAUTION: The filter press hydraulic system may have residual pressure. It is
necessary to bleed the pressure prior to removing any component.

Before removing any hydraulic system pressure, verify that the press is in its final storage
location.
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CAUTION: Moving the press without closing force from the main hydraulic
cylinder can cause equipment damage and may possibly void the warranty.

These are the step-by-step instructions for long-term storage of the filter press and its components.

1. If the hydraulic system was supplied with needle valves between the piston side of the cylinder
and the hydraulic unit, fully open the valves.

2. If the filter press has bomb bay doors, it is necessary to fully support the weight of the bomb
bay doors with cribbing along the length of the doors. Once the weight of the bomb bay doors
has been supported, the cylinder pin can be removed from the door drive arm.

3. Add 5 percent rust-preventive concentrate to the hydraulic unit tank. Cycle all hydraulic
systems of the filter press to circulate the rust-preventative concentrate through the system.

4. After cycling all hydraulic systems, fully open the filter press with the cylinder in the fully
retracted position. It may be necessary to relocate the position of the Press Open proximity
switch to allow the cylinder to fully retract.

5. Once it is certain that all residual pressure has been relieved from the cylinder, you can slowly
remove the main cylinder gauge and put a plastic cap over the threads of the gauge.

6. Remove the hose on the piston side of the cylinder. Start with the hydraulic unit side of the
hose to allow any additional hydraulic fluid to drain into an appropriate bucket.

7. Once all hydraulic fluid has been drained from the piston side of the cylinder, remove the end
of the hose next to the cylinder. Cap both ends of the hose with plastic caps and store it at a
temperature between 40 and 90 ºF, out of direct sunlight.

8. Remove the hose on the rod side of the cylinder. Start with the hydraulic unit side of the hose
to allow any additional hydraulic fluid to drain into an appropriate bucket.

9. Once all the hydraulic fluid has been drained from the rod side of the cylinder, remove the end
of the hose next to the cylinder. Cap both ends of the hose with plastic caps and store it at a
temperature between 40 and 90 ºF, out of direct sunlight.

It is now possible to remove the cylinder from the filter press for long-term storage. It may be
necessary to remove filter plates or any extension piece on the end of the cylinder rod to allow
enough room to remove the cylinder. Once the cylinder has been removed from the press, you can
continue with the long-term storage step-by-step instructions:

1. Plug all ports of the cylinder except the rod end port. Use plugs rated equal to or greater than
5,000 psi.

2. Fill the rod end port of the cylinder with hydraulic oil and plug with a metal plug.

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3. Add protective grease around any exposed area of the cylinder rod and clevis that is not
protected with paint.

4. Store the cylinder vertically to avoid permanent deformation of the seals. Store the cylinder at
a temperature between 40 and 90 ºF, out of direct sunlight.

The next part the long-term storage procedure is to remove the cylinder from the bomb bay doors
(if supplied).

1. Next, remove either hose from the bomb bay door cylinder. Start with the hose connection
closest to the hydraulic power unit. Slowly remove this connection to allow any residual
pressure to bleed off. Drain any hydraulic fluid into an appropriate bucket. Repeat this
procedure for the opposite hose on the bomb bay door cylinder.

2. Cap both ends of the hoses with plastic caps and store it at a temperature between 40 and
90 ºF, out of direct sunlight.

3. Fill the hydraulic cylinder for the bomb bay door with oil and cap all ports with metal plugs
rated equal to or greater than 5000 psi.

4. Store the cylinder vertically to avoid permanent deformation of the seals. Store the cylinder at
a temperature between 40 and 90 ºF, indoors & out of direct sunlight.

Once the bomb bay doors have been addressed, proceed to storage preparation for the plate shifter.

1. Remove the hoses for the plate shifter motor (if supplied) in the same manner as you did for the
bomb bay door hose removal.

2. Cap both ends of the hoses with plastic caps and store them at a temperature between 40 and
90 ºF, out of direct sunlight.

3. Fog the ports of the hydraulic motor with rust-preventive aerosol and cap with plastic plugs.

4. Grease and turn the roller bearings for the fully automatic plate shifter once a month to
displace any moisture that might have accumulated during storage.

Cover the hydraulic unit’s electric motors with a plastic bag to protect them from moisture.
Additionally, remove the fan cover and rotate the motors by turning the fan once every 6 months.
Replace the fan cover after each rotation.

Leave the control panels in their shipping crates and/or covered with plastic to keep them clean
and dry. As an added measure, add a desiccant bag to help maintain dryness.

It is essential to keep a good inventory record of all equipment in storage. This equipment has
been accepted as complete during the signing of the shipping bill of lading. Therefore, any missing
parts shown on the packing list are the customer’s responsibility.

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3.5 ERECTION

Because the filter press is shipped completely assembled, the main equipment erection tasks are to
level and square the filter press and to install ancillary equipment. Sturdy, plain, and exactly
horizontal foundations which are made according to the filter press dimension sheet are the basic
requirements for a safe installation and a faultless function of the filter press.

CAUTION: If the filter press is supplied with slide plates, remove the shipping
bolts after setting the press in place. Failure to remove these bolts may cause
equipment damage and/or personnel injury.

3.5.1 Level and Square Instructions

The filter press must be squared (within ¼ inch) and leveled within 1/16 inch for proper operation.
See figure 3-2.

If the filter press has slide plates, these must be installed under the cylinder stand before leveling
the filter press. If the filter press has side bar supports, these supports must be installed under the
side bars before leveling the filter press.

The preferred method for leveling is to use a transit. If a transit is not available, a 48-inch-long
high-quality machinist’s level is acceptable.

If a transit is used, check the following locations — as close to the cylinder as possible — on the
filter press for levelness:

Top of side rail as close to the cylinder as possible (points C and D in figure 3-2).

Top of side rail at each side rail support (where required).

Top of side rail as close to the head plate end as possible (points A and B in figure 3-2).

If the press is not level, it should be shimmed from the bottom of the foot pads until it is level. If
slide plates are provided with the cylinder stand, the shims should be placed under the slide
plates. Do not place shims between the cylinder stand foot pad and the slide plate. If side bar
supports are provided, place the shims under the foot pad of the side bar support.

After the filter press has been leveled, it should be checked for squareness. Squareness should be
checked while the press is under pressure.

NOTE: Check level and square again after the first cake has been
processed.

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Figure 3-2. Checking the Filter Press for Level and Square

3.5.2 Optional Slide plates

The slide plates are anchored with either bolts or a Hilti Corp. space anchor system as shown in
figure 3-3. These systems are not supplied by Andritz. It is the customer’s responsibility to choose
the correct system for the application. It is also the customer’s responsibility to choose the correct
torque value based on the anchoring system.

The cylinder stand should rest freely on the slide plates. It is not necessary to lubricate the slide
plates. The slide plates are bolted to the bottom of the cylinder stand foot pads for shipping and
lifting purposes. All four bolts must be removed before operating the filter press.

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Figure 3-3. Mounting the Cylinder Stand

3.5.3 Installation of the Filter Cloths

For protection during transport from Andritz facility to final destination, the filter cloths are
removed and packed for shipment together with the machine goods for this order.

Filter cloths are to installed prior to 1st start-up under direct Andritz supervision as a part of
operator/maintenance training

Refer to figure 3-4. Use the following procedure for installing the filter cloth:

1. Lay the filter cloth on a flat surface. Fold one section of cloth diagonally to create a diaper
shape.

2. Fold edges so they overlap.

3. Roll this folded portion as tightly as possible into a cylinder.

4. Push this cylinder of cloth through center hole of filter plate.

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5. Spread the rolled cloth out on back side of the plate.

6. Turn cloths until grommets are properly positioned with the plate.

7. Secure grommets for intermediate plates with electrical ties.

8. Secure grommets on the sides of the end plates by screwing a self-tapping screw through the
grommet into the side of the filter plate.

9. Secure grommets on the top of the end plates by one of two methods:

- Using self-tapping screws as described in step 8

- Slipping the grommets over the pins in the top of the plate. Loosely secure grommets in place
by wrapping an electrical tie around the top of the plate pin. Push the electrical tie down on
the cloth grommet. Tighten the electrical tie so the tie does not come off the plate pin.

10. Cut all excess lengths from electrical ties to prevent the excess length from getting stuck
between the filter plates during opening and closing of the press.

Figure 3-4. Folding the Filter Cloth

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3.5.4 Electrical Connections

All field electrical connections must be made by qualified personnel. The direction of rotation of the
HPU electric motor must conform to the direction of the arrows shown on the hydraulic unit.

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