Tubular Self Cleaning Filter Manual
Table of Contents
Manual Overview
Tubular self-cleaning operation manual (including self-cleaning filter)
I. Scope of Application
This manual applies to industrial pipelines (such as cooling water pipes and process circulation pipes) and civil pipelines (such as tap water pipes and underfloor heating pipes) for media such as water, low-viscosity oil (viscosity meets conventional low-viscosity standards) or neutral solutions. It is compatible with stainless steel (304/316), PVC-U, PPR, and cast iron (without severe rust on the inner wall). It is also applicable to pipeline self-cleaning filters (including filter body, control valve, stainless steel filter screen and drive motor) that are used with the above-mentioned pipelines.
1.1 Scope of Application for Pipeline Self-Cleaning Filters
| Applicable categories | Specific scenarios and requirements |
| --------------------- | ----------------------------------- |
| Applicable media | 1. Industrial water: cooling circulating water, chilled water, boiler feedwater, and process water without strong corrosive components; 2. Domestic water: tap water, underfloor heating circulating water, and swimming pool water; 3. Low viscosity oil: lubricating oil and hydraulic oil (viscosity meets conventional low viscosity standards and does not contain excessive solid particulate impurities). |
| Applicable industries | Power (power plant cooling systems), chemical industry (process media pretreatment), HVAC (air conditioning water circulation systems), municipal (tap water supply), food industry (auxiliary water for non-direct contact with food), manufacturing industry (equipment lubrication systems). |
| Applicable equipment front end | Pre-protection is used for equipment such as heat exchangers, centrifugal pumps, solenoid valves, flow meters, and nozzles that are easily clogged by impurities. |
| Inapplicable scenarios | 1. Highly corrosive media: strong acids/bases with extreme pH values, media containing high concentrations of chloride ions; 2. Ultra-high temperature media; 3. Filtration scenarios requiring high-precision filters; 4. High-viscosity media. |
II. Preparatory Work
1. Preparation of tools and materials
- Tools required: a pressure gauge with appropriate range and accuracy, an adjustable wrench for pipe interface bolts, a self-cleaning circulation pump to meet circulation requirements, pipe wrenches for pipe diameter, pH test strips within the standard range, a turbidimeter with acceptable accuracy (optional, for acceptance testing), an endoscope (optional, for inspecting pipe wall scaling), a torque wrench for filter flange bolts, and a level for leveling (for filter installation).
- Cleaning agents : For regular scaling (calcium carbonate, magnesium carbonate), use citric acid or EDTA-2Na of the corresponding concentration; for oily scaling, use a neutral degreaser (pH within the neutral range); also, use clean water that meets municipal tap water standards (for rinsing), and a neutral filter screen cleaning agent recommended by the filter manufacturer (for cleaning filter screen blockage).
- Safety equipment includes chemical-resistant protective gloves (nitrile), goggles, non-slip work shoes, protective clothing for contact with degreasing agents, and insulating gloves for installation of the electrical components of filters.
- Auxiliary supplies : Prepare a wastewater collection bucket with sufficient capacity, PTFE tape, rags, a marker to indicate valve status, sealing gaskets (nitrile rubber/fluororubber) that match the filter flange, and electrical insulating tape.
2. Preliminary Inspection
- Pipeline condition check: Close the main pipeline valve and observe the pressure gauge to confirm that the pressure has dropped to a safe value (pressure relief complete). Check the pipeline joints, valves, and flanges for leaks. If there are leaks, the seals must be repaired first.
- Valve function check: Operate the inlet valve, outlet valve, bypass valve, and drain valve one by one to ensure that the opening and closing are flexible, without jamming or internal leakage (no significant pressure rise after closing).
- Cleaning equipment inspection: Check the power cord and plug of the self-cleaning circulation pump, and test run to confirm that it is operating normally without abnormal noise; check the shelf life of the cleaning agent to ensure that it has not separated or deteriorated.
- Self-cleaning filter inspection: Visually confirm that the filter body is free from deformation and cracks, the filter screen is free from damage and corrosion, and the control valves open and close flexibly; Electrically check that the insulation layer of the motor power cord/control line is free from damage, the wiring terminals are secure, and the parameters on the motor nameplate match the on-site power supply; Verify that the quantity and specifications of the filter installation accessories (flanges, gaskets, bolts) conform to the manufacturer's instructions.
III. Operating Procedures (Pipeline Self-Cleaning)
Step 1: System shutdown and depressurization
Close the main inlet and outlet valves of the pipeline to be cleaned, open the end drain valve to slowly release pressure (at a speed that meets safety requirements), and close the drain valve after the pressure gauge displays a safe value. Mark the valve status with a marker.
Step 2: Isolate the pipes to be cleaned
Close all bypass valves on the branch of the pipeline to be cleaned to ensure that the cleaning fluid circulates only in the section to be cleaned; remove the end fittings (such as flange covers and valves) at both ends of the pipeline and wipe off the dirt at the interface for later use; if a filter has been installed, the inlet and outlet valves of the filter must be closed first, and the flange connecting it to the pipeline must be removed and stored separately.
Step 3: Connect the cleaning equipment
Connect the inlet of the self-cleaning circulating pump to the inlet interface of the pipeline via a hose, tighten it with a pipe wrench/wrench and seal it with an appropriate amount of PTFE tape; connect the outlet hose to the outlet interface of the pipeline and seal it; install a pressure gauge on the pump inlet hose and reserve a sampling port on the outlet hose (to test the concentration of the cleaning solution and water quality).
Step 4: Prepare the cleaning agent
Prepare the solution according to the type of scaling: use the corresponding concentration of citric acid or EDTA-2Na for light scaling; use a higher concentration of citric acid or EDTA-2Na for heavy scaling; and use the corresponding concentration of neutral degreaser for oily scaling. Stir until dissolved, test the concentration with pH test paper (it should meet the standard range of the corresponding reagent), and pour it into the circulating pump cleaning solution tank after it passes the test.
Step 5: Circulating cleaning
Turn on the power to the circulating pump, slowly open the pump outlet valve, and adjust the flow rate to a reasonable ratio to the pipeline design flow rate (pressure controlled within a safe range); take samples for testing regularly, and replenish the cleaning agent if the concentration is not up to standard; stop cleaning when the scale is basically removed (or the turbidity difference of continuous sampling meets the requirements).
Step 6: Rinse with clean water
Turn off the circulation pump, drain the residual cleaning agent, and then inject clean water; restart the pump to flush, and take samples for testing regularly until the water quality reaches neutral and the turbidity is within acceptable limits; after the standards are met, turn off the pump and disassemble the cleaning equipment hose.
Step 7: System Recovery and Acceptance
If a filter needs to be installed, proceed with the installation as described in subsequent chapters. If the filter has already been disassembled, reconnect it to the pipe flange, replace the gasket, and tighten the bolts to the manufacturer's recommended torque using a torque wrench. Reinstall and seal the pipe fittings at the end of the pipe. Slowly open the main inlet valve (at a speed that meets safety requirements), purge air, and then open the main outlet valve to resume operation. Acceptance criteria: No leaks at the interfaces; stable pressure after operation with a significant reduction in pressure loss compared to before cleaning; water quality meets media standards; filter self-cleaning function functions normally without abnormal noise.
IV. Precautions
- Safe operation : It is strictly forbidden to disassemble pipes, connect equipment, or disassemble filters under pressure; keep away from drain outlets when depressurizing; disconnect the power supply and wear insulated gloves before installing the electrical parts of the filter; wear protective gloves and goggles during operation; rinse immediately if cleaning agent comes into contact with skin, and rinse eyes and seek medical attention if it gets into eyes; store cleaning agents and filter screen agents separately, away from food, fire sources and children.
- Pipeline and filter protection : Citric acid cleaning agents are prohibited for aluminum pipes; special agents must be used instead. Chloride-containing cleaning agents are prohibited for stainless steel filter screens. The cleaning pressure should not exceed the pipeline design pressure, and the filter operating pressure should not exceed the rated value. Overheated pipelines should be cooled to room temperature before cleaning. The ambient temperature of the filter should not be lower than the freezing point; if it is lower than the freezing point, it must be insulated.
- Environmental requirements : Cleaning wastewater and filter discharge wastewater must be neutralized to neutral before being discharged; waste cleaning agent packaging and old filter screens must be recycled separately.
V. Troubleshooting (Pipeline Cleaning)
- The circulating pump pressure is 0 and it does not draw water: the possible causes are that the cleaning fluid tank level is too low or the pump inlet hose is leaking air; the solution is to add cleaning fluid to the sufficient level, or check the hose connection and re-seal it with Teflon tape.
- If the pipeline pressure does not decrease after cleaning, the possible reasons are insufficient cleaning agent concentration or blockage in the pipeline. The solution is to add cleaning agent and extend the cleaning time, or disassemble the pipe fittings at the bends to remove the blockage.
- Pipeline leaks during cleaning: Possible causes include loose bolts or worn-out gaskets. Solutions include shutting off the pump, depressurizing, and then tightening the bolts, or replacing the gasket with one made of a material compatible with the pipe.
- If the pH is still low after rinsing with clean water, the possible reasons are insufficient rinsing time or residual cleaning agent in the pipe. The solution is to extend the rinsing time and increase the flow rate, or to open the drain valve at the end of the pipe for reverse rinsing.
VI. Installation and Use of Pipeline Self-Cleaning Filters
6.0 Core Features of the Equipment
Working Principle
The filter operates in a closed loop: filtration - differential pressure trigger - automatic cleaning - discharge. During normal filtration, the filter medium enters, impurities are intercepted by the stainless steel filter screen, and clean medium flows out from the outlet. Accumulated impurities increase the pressure difference across the filter screen, reaching the set value or preset time of the differential pressure controller, triggering cleaning. The drive motor starts, rotating the filter screen; centrifugal force throws away some impurities, while a negative pressure is generated inside the filter screen, drawing in clean medium to form a backwash water flow, flushing away small impurities in the pores. The discharge valve opens simultaneously, discharging impurities with the medium. After cleaning, the motor stops, the discharge valve closes, and normal filtration resumes. Manual cleaning operates on the same principle, only triggered by pressing the "Manual Cleaning" button.
Equipment Features
- High degree of automation: Automatically triggers cleaning, eliminating the need for manual filter removal and reducing maintenance costs.
- Uninterrupted operation: During cleaning, the medium in the main pipeline flows normally without affecting downstream equipment.
- Durable filter: Made of 304/316 stainless steel, wear-resistant and corrosion-resistant, with selectable pore size.
- Low maintenance costs: The filter screen only needs to be checked periodically and does not need to be replaced frequently. Only the seals and motor need to be checked periodically, and the drain valve has a low failure rate.
- Protect downstream equipment: Pre-installation can prevent heat exchanger scaling, pump wear, etc., and extend equipment life.
- Highly adaptable: Equipped with a bypass valve, allowing switching in case of failure; supports horizontal/vertical installation (depending on manufacturer requirements).
6.1 Basic Components of a Filter
- Filter body: It houses the filter screen and provides a medium passage. It is usually made of carbon steel or 304/316 stainless steel with an anti-corrosion coating.
- Stainless steel filter screen: intercepts impurities such as mud, sand, and rust; the pore size is selected according to the medium.
- Control valves: including inlet and outlet valves (controlling the flow of the medium), drain valves (cleaning and removing impurities), and bypass valves (standby passage in case of failure).
- Drive motor: drives the filter screen to rotate or generates backwash water flow, mostly single-phase/three-phase asynchronous motor.
- Differential pressure controller (optional): measures the pressure difference between the inlet and outlet of the filter and automatically triggers cleaning when the set value is reached.
6.2 Installation Preparation
- Installation location: Select the main water inlet of the pipeline or the front end of key equipment; reserve sufficient operating space on both sides and sufficient space above to remove the filter screen; it must be installed horizontally, and a level should be used to calibrate and prevent tilting.
- Material verification: Confirm that the filter model matches the pipe diameter; prepare matching flanges, gaskets (nitrile rubber for oil, fluororubber for water), and stainless steel bolts and nuts.
6.3 Installation Steps
- Pipeline pretreatment: Close the main valve of the installation section, depressurize to a safe value, open the drain valve to drain the medium; clean the inner wall of the pipeline with an endoscope or high-pressure water gun.
- Fixing the filter body: When the weight is large, it needs to be hoisted and fixed with a bracket to prevent the pipe from bearing the weight; calibrate with a level to ensure that the inlet and outlet flanges are concentric with the pipe flanges (the deviation meets the requirements).
- Connecting pipes: Place a sealing gasket between the flanges and align the bolt holes; use a torque wrench to tighten the bolts in a diagonal sequence (torque should conform to the manufacturer's recommendation) to prevent over-tightening on one side from deforming the flange.
- Electrical installation: Disconnect the power supply and connect the motor power cord to the distribution box (distinguish between phase wire and neutral wire for three-phase motors); connect the pressure gauge interfaces at both ends of the differential pressure controller to the inlet and outlet of the filter, and set the trigger value.
- Valve inspection: Operate each valve one by one to confirm that the opening and closing are flexible; close the bypass valve, open the inlet and outlet valves, observe the flange interface, and if there is a leak, tighten the bolts or replace the gasket.
6.4 Usage Method
- Initial startup: Slowly open the inlet valve, and after the medium fills the filter, open the top vent valve to release air. After the continuous medium is discharged, close the vent valve; fully open the inlet valve, and then slowly open the outlet valve to ensure that the operating pressure is within the rated range.
- Self-cleaning operation: Automatic cleaning is triggered by differential pressure or time, the motor starts, the drain valve opens to discharge impurities, and then it stops automatically; for manual cleaning, press the "Manual Cleaning" button, and press "Stop" after completion.
- Routine maintenance: Check the inlet and outlet pressure daily. If the pressure difference is abnormal, manually clean the filter or stop the machine to check the filter screen. Regularly open the drain valve manually to remove deposited impurities. After stopping the machine and depressurizing, the top cover can be removed to check the filter screen. If the filter screen is damaged, it needs to be replaced with the same model.
6.5 Filter-Specific Troubleshooting
- The self-cleaning function does not start: Possible causes include the differential pressure controller not being set or being damaged, poor contact of the motor power cord, or the drain valve being stuck. The solution is to reset the differential pressure or replace the controller, tighten the wiring terminals, and remove the drain valve to clean impurities.
- If the pressure differential remains high after cleaning, the possible causes are a damaged filter screen, impurities clogging the filter screen, or the drain valve not being fully open. The solutions are to remove the filter screen for inspection and replacement, clean it with a special agent, and inspect the drain valve to ensure it is properly opened and closed.
- Abnormal noise during motor operation: Possible causes include phase loss in a three-phase motor, worn motor bearings, or a stuck filter (foreign objects entangled). Solutions include checking the power cord to ensure normal power supply, replacing the bearings, stopping the machine, and removing the filter to clean out foreign objects.
- Flange interface leakage: Possible causes include aging or damage to the gasket, insufficient bolt torque, or flange deformation. The solution is to replace the gasket, tighten it according to the standard with a torque wrench, or repair or replace the flange.
This section provides comprehensive documentation for all products in the Tubular Self Cleaning Filter category. Please select a specific product below to view its detailed manual.
Available Products
SS304-2”- Tubular Self Cleaning Filter
Carbon steel-Tubular Self Cleaning Filter
SS316-4”- Tubular Self Cleaning Filter
SS304-8”- Tubular Self Cleaning Filter
SS316-8”- Tubular Self Cleaning Filter
10"-SS304 Tubular Self Cleaning Filter
SS304-200-Tubular Automatic Self-cleaning filter
SS304-4"-Tubular Self Cleaning Filter
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