Field Operator Certification

Gravel Bed Filters

Learner Guide
 Gravel Bed Filters Learner Guide

Introduction
This lesson on Gravel Bed Filters, as with your other lessons on Auxiliary Equipment, consists of
two main learning components a self-directed/in-class component and an on-the-job component.
You are expected to complete both components as part of your Certification Program.

Review the remaining information contained in the Introduction section of this document prior to
beginning the Content section. If you have any questions about this information, speak with your
Instructor.

Objectives
Your learning objectives are broken down into two categories learning objectives for the self-
directed/in-class portion of your learning; and, learning objectives for the on-the-job portion of your
learning. They are listed below for your information.

Self-Directed/In-Class Learning Objectives

1. State the purpose of Gravel Bed Filters
2. Name the main components of Gravel Bed Filters
3. Explain the principle of operation for Gravel Bed Filters
4. State the applications for Gravel Bed Filters in cement manufacturing
5. Describe the running and static inspections for Gravel Bed Filters
6. State common problems and troubleshooting for Gravel Bed Filters
7. State safety concerns related to Gravel Bed Filters

On-the-job Learning Objectives

1. Perform a running inspection on Gravel Bed Filters
2. Perform a static inspection on Gravel Bed Filters

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Lesson Outline
The first portion of the lesson, the self-directed/in-class portion, involves reviewing the following
information:

The purpose and basic principle of operation of Gravel Bed Filters

A listing and description of the various components of Gravel Bed Filters
Various applications of Gravel Bed Filters
Inspection points of Gravel Bed Filters and basic troubleshooting
Safety concerns related to Gravel Bed Filters
Pictures and graphics are included where appropriate to help you understand how Gravel Bed Filters
function. At the end of this section, there are a series of questions that you will be required to
answer and review with your Instructor.

The second portion of the lesson, the on-the-job portion, primarily involves the completion of
several inspections on Gravel Bed Filters, including both a running and static inspection. When you
are ready to perform these inspections, inform your Instructor.

If you are a new Field Operator, you will complete a series of steps in your OJT portion of this
lesson. These steps are listed below for your information.

Step One
Your Instructor will walk through an inspection procedure with you. At that time
you can ask questions and take down any notes required.
This walkthrough may be completed out in the field or during a meeting with your
Instructor.
Step Two
Your Instructor will demonstrate an inspection procedure in the field.
Step Three
You will conduct an inspection procedure in the field under the supervision of your
Instructor.
Your Instructor will provide you with feedback about your performance during the
inspection.
Step Four
You will complete a full inspection procedure without any assistance from your
Instructor.

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This inspection will be assessed against the inspection checklist contained in this
document. If you achieve 100% on the inspection, you will be certified on it. If you do
not achieve 100% your Instructor will provide you with further feedback and you will
have the opportunity to be re-assessed.
If you are an experienced Field Operator, you may already be quite familiar with inspection
procedures. Discuss this with your Instructor and you may only be required to actually complete
Step Four as discussed above.

Reference Material
NA

Pre-requisites
NA

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Gravel Bed Filters Learning Content

Purpose
The purpose of Gravel Bed Filters (GBF) is to remove all the dust particles from the hot gas
stream of the clinker cooler in order to meet environmental standards.
In cement manufacturing applications:

Gravel Bed Filters recuperate the clinker dust in the cooler exhaust gas and evacuate
it to the clinker evacuation system.
The hot cleaned gas is then evacuated to atmosphere or introduced into grinding
circuits for drying

Gravel Bed Filter Components

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Components

1. Raw Gas Plenum

Steel duct to convey extracted gas from the clinker cooler for distribution to each one of the
cans
This plenum is wide enough to act as a fall out chamber reducing the gas velocity resulting in
a primary separation of the coarser particles of clinker dust

2. Cyclone-type Separator

Section of the can allowing medium size particles to be separated due to the swirling action
created by the tangential connection to the plenum

3. Airlock

A rotary valve or a double flap gate is installed at the bottom of the lower cone to control the
evacuation of material and prevent in-leakage

4. Vortex Tube

Cylindrical tube connecting the separator to the gravel bed filter compartment

5. Gravel Bed Filter Compartment

Located at the top of the can containing the gravel bed, the stirring rakes and the screen

6. Gravel Bed

Layer of regular size pebbles to capture dust particles

7. Clean Gas Compartment

Located right under the gravel bed screen

8. 3-Way Valves

Plate valve controlled by a hydraulic pump blocking the clean air compartment and opening
to the reverse air system

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9. Clean Gas Ducts

Connections between the clean gas compartments and the clean gas evacuation plenum
Serve to direct the reverse air into the clean air compartment

10. Rakes

Series of fingers fixed on a rotating bar used to stir the pebbles in order to remove the
accumulated dust

11. Rake Drive

Drive to rotate the rakes during the cleaning cycle

12. Lower Cone

Bottom of the cyclone

Protected for wear with hard steel or ceramic lining

13. Wear protection

Hard steel plates or ceramics fixed to the wall of the cone to prevent high wear of the casing

14. Clean Gas Evacuation Plenum

Steel duct with connections to all units to induce clean gas from each clean gas compartment
to the exhaust fan and to atmosphere

15. Reverse Air Plenum

Steel duct with connections to all units to sequentially pressurize each clean gas compartment
with reverse air supplied by the reverse air fan
All the 3-way valves are located in this plenum

16. 3-way Valve Actuators

Hydraulic pistons used to individually control the opening and the closing of each one of the
3-way flow control valves

17. Reverse Air Fans (Also referred to as Scavenging Air Fans)

Fan/s used to supply the air for cleaning the gravel bed during the cleaning cycle

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18. Evacuation Screw/Hopper

Screw used to evacuate coarser dust particles separated in the raw gas plenum

19. Hydraulic Pumping Unit

Hydraulic pump and control valves used to individually actuate each one of the 3-way flow
control valves

20. Pressure Detectors

Pressure indication from the reverse air plenum/s is used to monitor and troubleshoot
the operation of the cleaning cycles

21. Lower Done Dust Evacuation

The evacuation of material from the cone is commonly accomplished by Screw or Drag
Conveyor

22. Gravel Bed Screens

The Gravel Bed Screens are comprised of a coarse and fine screen that lay one on top of the
other
These screens are used to support the filter media while at the same time allowing for the
unobstructed flow of gases passing through the compartment

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Principle of Operation

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Principle of Operation contd

Raw, hot gas is induced from the clinker cooler through the gravel bed filters by the cooler
exhaust fan
After exiting the cooler exhaust fan, the clean, hot gases are either evacuated to atmosphere
or re-introduced into the process
Raw gas from the cooler is drawn through a common plenum into all units except into the
one filter performing the cleaning cycle. At any given time, one unit is always in a gravel
bed cleaning cycle while the others are in the gas cleaning cycle
Coarse particles are initially separated from the gas stream in the GBFs raw plenum
This initial separation of coarse material takes place due to an increase in volume from the
inlet duct to the Raw plenum.
This increase in volume reduces the gas velocity in the Plenum and causes the heavier
material to fall out of suspension
The coarse material is then collected in the raw plenum hopper and evacuated via screw and
airlock to the normal clinker evacuation circuit
The gas then reaches the cyclone section of
the individual cans or filters where the
medium-size particles are separated by the
cyclone and collected in the lower cone
The collected material is then evacuated by
airlock to a common evacuation system
The pre-cleaned gas is induced into to the
vortex tube up to the gravel bed filter
compartment
The raw gas passes through the gravel bed
from top to bottom
The dust particles are deposited on the
surface of the gravel bed as well as being
collected in the voids
After passing through the bed of filter gravel
in the individual cans, the cleaned gas exits
the GBF through a common clean gas duct
that connects the GBF to the exhaust fan.
Cleaning the gravel of one unit is
intermittently initiated by a timer or by a control system.

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During the cleaning cycle, a particular filter is isolated from the regular operation by a 3-way
valve

The 3- way valve:

Isolates the individual filter from the
clean gas compartment (i.e. isolates the
induced draft from exhaust fan)
Allows pressurized air from the
scavenging air plenum to flow through the
filter in the reverse direction
The reverse air is then forced via the clean
gas duct thru the gravel bed from bottom to
top
One minute after the opening of the 3-way
valve the gear motor starts to rotate the rakes,
stirring the gravel to help removing the dust from it

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S TIRRING R AKES

R AKE M OTOR

The dust particles are then carried by the reverse air through the vortex tube into the cyclone
housing, where the decreased gas velocities, as well as an abrupt change in direction result in
the settling of dust particles into the lower cone
The reverse air still containing a certain amount of superfine dust particles mixes with the
raw gas in the raw gas plenum and is drawn into the other filters operating in the cleaning
mode

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The gravel bed cleaning process is indicated

on the scavenging air recorder according to
the following pattern
Pressure is negative = All valves
opened to clean gases and closed for
scavenging air
Pressure raises very quickly = One
valve closes for clean gases and open for
scavenging air
Pressure holds high for a minute =
Reverse air blowing thru the gravel
Pressure starts to slowly decrease = Rakes starts running and moves dust from gravel
while the reverse air is blowing thru the gravel
Pressure raises again but only a little for a minute= Rakes stop rotating
Pressure falls down and turns negative = That specific valve closes for scavenging air
and open for clean gases

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Applications

In the cement manufacturing, gravel bed filters are commonly used for dust collection of
very hot exhaust air from clinker coolers
They can also be used in all others dry processes of cement manufacturing

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Inspection Points

Gravel Bed Filters Running Inspection

Check For OK

Inspect the condition and support integrity of all walkways, railings, stairs and safety guards
Check the exhaust stack for cleanliness of gas evacuated to the environment
Inspect all lower cones, ducts and shells to detect air in-leakage, material leaks and high temperature
spots using hand pyrometer
Check that all access doors and inspection ports are closed and properly sealed
Listen for abnormal noise during the actuation of each one of the 3-way plate valves
Check the movement of each one of the 3-way valve actuators for full stroke in and out
Inspect the actuators for signs of hydraulic oil leaks
Inspect hydraulic oil lines and the pumping system for hydraulic oil leaks
Inspect hydraulic system for proper fluid level
Check each of the rake drive motors for cable strain and connection damages
Check each of the rake drive motors for material build up on the cooling finds or cooling fan cover
Remove build up
Palm test the motor casing temperature for each rake drive
If too hot to touch, record temperature with hand pyrometer or contact thermometer
Palm test the drive reducers casing temperatures
If too hot to touch, record temperature with hand pyrometer or contact thermometer
Inspect the GBF for missing or damaged insulation on main structure, material cones and hoppers
Inspect the rake drives for signs of leaks, lubrication levels
Listen for abnormal noise or vibration in all rake drive system components
Inspect drives mounting base for damage, cracks and loose bolts
Inspect field control station for damage or cable strain
Remove any obstructions for access
Check the pressure gauges used on scavenging air plenum for damage and support integrity

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Gravel Bed Filters Running Inspection (each Scavenging Fan)

Check For OK

Inspect the drive motor for build up on cooling fins and cooling fan inlet screen
Remove build-up
Inspect drive motor electrical connections for damage or strain
Inspect the drives mounting base for damage, cracks, loose bolts
Palm test the motor casing temperature
If too hot to touch, record temperature with hand pyrometer or contact thermometer
Inspect the condition and support integrity of all safety guards
Inspect field control station for damage or cable strain
Remove any obstructions for access
Inspect the equipment for general condition cleanliness, damage
Check that all access doors and inspection ports are closed and properly sealed
Inspect the condition of the final drive. V-belt condition, tensioning, sheaves, direct coupling
Verify the direction of rotation of the fan with fan housing design
Inspect damper linkage, bearings, bushings, connections for wear, damage
Verify free operation of damper, if applicable
Listen for abnormal noise or vibration in the fan or drive system

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Gravel Bed Filters Running Inspection (GBF Exhaust Fan)

Check For OK

Inspect the drive motor for build up on/in cooling fins/tubes and cooling fan inlet screen
Remove build-up
Inspect filters if applicable
Inspect drive motor electrical connections for damage or strain
Inspect the drives mounting base for damage, cracks, loose bolts
Palm test the motor casing temperature
If too hot to touch, record temperature with hand pyrometer or contact thermometer
Inspect the condition and support integrity of all safety guards
Inspect field control station for damage or cable strain
Remove any obstructions for access
Inspect the equipment for general condition cleanliness, damage
Check that all access doors and inspection ports are closed and properly sealed
Inspect the condition of the final drive. V-belt condition, tensioning, sheaves, direct coupling
Verify the direction of rotation of the fan with fan housing design
Inspect damper linkage, bearings, bushings, connections for wear, damage
Verify free operation of damper, if applicable
Listen for abnormal noise or vibration in the fan or drive system
Verify that the damper drive is selected to automatic
Verify control response by forcing small position change from control room
Test for excessive hunting or malfunction
Rotate damper drive hand wheel and verify control response

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Gravel Bed Filters Running Inspection (Screw Conveyor)

Check For OK

Inspect the drive motor for build up on cooling fins and cooling fan inlet screen
Remove build-up
Palm test the motor casing temperature
If too hot to touch, record temperature with hand pyrometer or contact thermometer
Inspect drive motor electrical connections for damage or strain
Palm test the drive reducer casing temperature
If too hot to touch, record temperature with hand pyrometer or contact thermometer
Inspect the condition of the final drive. V-belt conditioning, tensioning, sheaves, direct coupling, chain
and sprockets
Listen for abnormal noise or vibration in the screw conveyor drive system
Inspect the condition and support integrity of all safety guards
Note general condition of screw conveyor, cleanliness, material leaks, lubrication leaks
Inspect the discharge chute for proper material flow, build-up or obstruction
Inspect field control station for damage or cable strain
Remove any obstructions for access
Check that all access doors and inspection ports are closed and properly sealed
Inspect the condition of screw conveyor protection devices, mounting, electrical connections, cable strain
Inspect the condition of screw conveyor shaft seals
Inspect the screw conveyor trough for damage, wear, missing flange bolts

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Gravel Bed Filters Static Inspection - External

Check For OK

Inspect the condition and support integrity of all walkways, railings, stairs and safety guards
Check that all access/material doors, inspection ports and covers are closed and properly sealed
Test the operation of each of the 3-way control valves
Listen for abnormal noise during the actuation of each one
Check the movement of each one of the 3-way valve actuators for full stroke in and out
Inspect actuators for signs of hydraulic oil leaks
Inspect hydraulic oil lines and the pumping system for hydraulic oil leaks
Inspect the hydraulic system for proper fluid level
Inspect all lower cones, ducts and GBF can structure for damage, corrosion, war and material leaks
Inspect the equipment for general condition cleanliness, damage
Check each of the rake drive motors for cable strain and connection damage
Check each of the rake drive motors for material build up on the cooling fins or cooling fan cover
Remove build up
Inspect rake drive reducers for signs of leaks, lubrication leaks
Inspect drives mounting base for damage, cracks and loose bolts
Test run each rake drive and listen for abnormal noise or vibration in the system components
Inspect the GBF for missing or damaged insulation on main structure, material cones and hoppers
Inspect field control station for damage or cable strain
Remove any obstructions for access
Check the pressure gauges used on scavenging air plenum for damage and support integrity

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Gravel Bed Filters Static Inspection Internal

Check For OK

Inspect the GBF inlet duct for signs of refractory damage, material build up, holes and wear
Inspect the raw gas plenum, including material hoppers for build up, wear, signs of thermal damage
Inspect the lower cones for wear and abrasion
Note the condition of wear plating
Check all vortex tubes for wear, damage and holes
Inside the clean gas plenum, check all 3-way plate valves for deformation and wear
From below, inspect the primary and secondary gravel bed screens for holes, tears and proper edge seals
From the gravel bed compartment, inspect all the rakes for deformation, missing fingers, broken, bent or
damaged shafts and proper clearance between rakes and screen (clearance should be minimum and
9/16 maximum between the tips of the rake and the screen)
Check each unit for the gravel bed height and quality of filtering media
The gravel bed should be 4 above the screen
Check all tipping valves for free movement and build up
Inspect the clean gas plenum for any build up

Gravel Bed Filters Static Inspection (each Scavenging Fan)

Check For OK

Inspect the drive motor for material build up on cooling fins and cooling fan inlet screen
Remove build up
Inspect drive motor electrical connections for damage or strain
Inspect the drives mounting base for damage, cracks, loose bolts
Inspect the condition and support integrity of all safety guards
Inspect field control station for damage or cable strain
Remove any obstructions for access
Inspect the equipment for general condition cleanliness, damage
Check that all access doors and inspection ports are closed and properly sealed
Inspect the condition of the final drive. V-belt condition, tensioning, sheaves, direct coupling
Inspect damper linkages, bearings, bushings, connections for wear, damage
Verify free operation of damper, if applicable

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Gravel Bed Filters Static Inspection (GBF Exhaust Fan)

Check For OK

Inspect the drive motor for material build up on cooling fins/tubes and cooling fan inlet screen
Remove build up
Inspect drive motor electrical connections for damage or strain
Inspect the drives mounting base for damage, cracks, loose bolts
Inspect the condition and support integrity of all safety guards
Inspect field control station for damage or cable strain
Remove any obstructions for access
Inspect the equipment for general condition cleanliness, damage
Check that all access doors and inspection ports are closed and properly sealed
Inspect the condition of the final drive. V-belt condition, tensioning, sheaves, direct coupling
Inspect damper linkages, bearings, bushings, connections for wear, damage
Verify free operation of damper
Verify that the damper drive is selected to automatic
Verify control response by stroking damper from 0 to 100% from control room
Test for excessive hunting or malfunction in automatic
Rotate damper drive hand wheel and verifying control response

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Gravel Bed Filters Static Inspection (Screw Conveyor)

Check For OK

Inspect the drive motor for material build up on cooling fins and cooling fan inlet screen
Remove build up
Inspect drive motor electrical connections for damage or strain
Inspect the condition of the final drive. V-belt condition, tensioning, sheaves, direct coupling
Inspect the condition and support integrity of all safety guards
Note general condition of screw conveyor, cleanliness, material leaks, lubrication leaks
Inspect the discharge chute for material build up or obstruction
Inspect field control station for damage or cable strain
Remove any obstructions for access to control station
Check that all access doors and inspection ports are closed and properly sealed
Inspect the condition of screw conveyor protection devices, mounting, electrical connections, cable strain
Inspect the condition of screw conveyor shaft seals
Inspect the screw conveyor trough for damage, wear, missing flange bolts
Inspect the condition of hanger bearing brackets and bearing condition
Inspect the screw flights for damaged, bent flights or worn flight sections
Check coupling bolts and bolt holes for excessive play
Inspect the drive reducer for oil leaks and oil level
Inspect reducer mounting and torque arm condition, if applicable
Inspect screw conveyor roller bearing condition and mounting

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Troubleshooting
The following troubleshooting information has been prepared to help you resolve common problems
associated with Gravel Bed Filters.

T ROUBLESHOOTING L OSS OF M ATERIAL F LOW

Problem Possible Reasons Actions Taken
Pressure not No raking Check the motor and the control panel
changing and
higher than usual Cleaning sequence stop

Very unstable Gravel airborne Check the sequence in the field and the control panel
pressure
Rakes started too late
Pressure unstable Gravel bed partially plugged Check the operation of the valve and the rake operation
and decreasing
Hole in the bed
Pressure not Gravel bed too low Make up gravel bed
changing and low
Pressure not Rakes start too early Check the sequence in the field
holding at the
beginning and lower
Pressure holding Too long a time between Check and modify the sequence
high more than one each cleaning
minute
Pressure holding 3-way valve stayed closed Check the hydraulic system and the actuator of the unit
very high during the for reverse air
cycle of one unit
Pressure None of the 3-way valves Check control panel and the hydraulic system
continuously stays operates
very high

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Safety Work Page

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Safety
Always lock out motors and hydraulic system prior to performing any service
Follow confined space entry procedures for internal inspections
Be aware of a fans potential to wind mill due to internally or externally induced airflows.
Be sure to secure the impeller shaft prior to servicing or inspecting the fan if there is any
danger of impeller rotation.
Wear a properly fitting respirator or dust mask when working inside the cans
Be aware that surface temperatures and internal gas may be very hot
Be aware that rakes motors, plate valve actuators and fan motors are controlled automatically
and can start and stop at any time
Keep the work area clear of grease, oil, water, and other objects that could cause a slip or a
fall
Never attempt to remove build-up off fan inlet or components while operating
Keep clothing, fingers, hair, and other parts of the body away from all drive components
Inspect all guards for damage and support integrity regularly
Know the location and function of all control stations
Keep all control stations free from obstructions to ensure access at all times
Keep area around the Gravel Bed Filters clear of obstructions and debris
Report all unsafe conditions or practices immediately

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Review Exercise
Complete each of these questions and review your answers with your Instructor.

1. What is the purpose of a Gravel Bed Filter?

2. What makes the Gravel Bed Filter unique from other types of emission control equipment?

3. List 5 components of the Gravel Bed Filter

4. What happens to the gas velocity as it enters the GBFs raw gas plenum?

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5. Where is the pressure being measured in a GBF to monitor cleaning performance and general
mechanical condition?

6. What is the meaning of the strong negative peaks shown on the trend recorder of a Gravel Bed
Filter?

7. What four mechanisms contribute to material separation in a Gravel Bed Filter?

8. What condition could explain a low pressure indication throughout a cleaning cycle?

9. State 3 conditions that would explain why a 3-way valve would not operate properly

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10. What unique feature does a Gravel Bed Filter possess which is unlike other types of emission
control equipment?

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11. Describe the applications for Gravel Bed Filters in cement manufacturing

12. Describe 5 running inspection points for a Gravel Bed Filter

13. Describe 5 static internal inspection points for a Gravel Bed Filter

14. Describe 5 running inspection points for points for the scavenging fan

15. Describe 3 safety hazards associated with the Gravel Bed Filter

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