From: Scott Gongaware

To: harris.jeff@ecrweb.com

Cc: Jim Elsesser; Harvey Senger; Eric Smith

Subject: MikroPul Baghouses - Ferro Alloy application

Date: Friday, August 05, 2011 10:54:06 AM

Attachments: 0262-11 EC R INC Reverse Air Primary.doc

0262 Scope Of Supply Pulse Jet secondary.doc

Jeff

I have attached Two (2) Scope of Supplies

1. Reverse Air Baghouse for Primary ventilation – 180,000 CFM

2. Pulse Jet Baghouse for Secondary Ventilation – 150,000 CFM

The Budget Price for Number 1 above is $6.1M

Budget Price for Number 2 above is 1.45M

Both are equipment only prices

I will be out till Aug 19th – Please contact anyone of the distribution list for questions

Kind Regards

Scott Gongaware

VP Large Systems

MikroPul 

724-934-3956
Scope of Supply

Typical Ferro Alloy Baghouse system

Eight (8) Module Negative Pressure Suction Type Fabric Filter System

MikroPul Pittsburgh Proposal No. 

November 4, 2008

1.0 Negative Pressure Reverse Air Cleaning Fabric Filter and Accessories

One (1) MikroPul Eight (8) Module Model 144-35-20 Negative Pressure Fabric Filter. 

Compartments are arranged in a double row configuration with a single plenum inlet and 

ducted outlet to a final stack discharge. The fabric filter will be designed and operate, to 

meet the following conditions:

Inlet Gas Flow 180,000 ACFM 

Application Submerged Arc Furnace Melt Shop 

Gas Temperature for Fiberglass Filter Bags 500° F maximum continuous

Gas Temperature for Design of Equipment 500° F maximum peak

Normal Operating Temperature 482° F 

Minimum Operating Temperature 70° F

Inlet Dust Loading 0.77 grains/ACF

Dust Bulk Density, Structural Design 70 lbs/ft3

Dust Bulk Density, Power Calculations 70 lbs/ft3

Dust Bulk Density, Volumetric Capacity 58 lbs/ft3

Number of Modules Eight (8) 

Bags per Compartment 144

Bag Arrangement 12 wide x 12 deep

Bag Reach from Cell Plate Walkways Three (3) maximum

Bag Length 420 inches (35’-0”)

Module Cloth Area 14,891 ft2 

Reverse Air Volume at 2.5:1 37,228 ACFM

Gross Air to Cloth Ratio @ 180,000 ACFM 1,50:1

Net Air to Cloth Ratio @ 217,228 ACFM 2.08:1

Net, Net Air to Cloth Ratio @ 217,228 ACFM 2.43:1

TYPICAL SCOPE DESCRIPTON BELOW

Modules:

The fabric filter will be constructed of modular design having no common walls between 

the housings. The design uses eight (8) modules that when installed on the support 

structure will have an air space between the modules with a minimum plate-to-plate 

spacing of 18 inches.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 2 of 27

Housing:

The module housing is to be stiffened 3/16” plate with design rating of ±20 inches of 

water for dust tight service. External stiffeners are mild steel. The modules will be 

painted with a high temperature aluminum paint. The internal walkways and platforms 

will be shop installed.

Module Upper Housing Access Doors:

Three (3) access doors are provided for each compartment: The doors will be 24 inches 

wide by 60 inches tall with one (1) door located at the upper access level and two (2) 

doors located at cell plate level. The doors have high temperature gaskets.

Hoppers:

Hoppers are pyramidal type with a valley angle of 60 degrees. The hoppers are 

fabricated from 3/16 inch thick A-36 steel plate. A 36” x 36” hinged, quick clamp access 

door is provided in each hopper. The door is a MikroPul design to provide proper sealing 

for a suction baghouse and allow for a basket stretcher to be handled through the opening. 

A confined space sign shall be mounted on each hopper access door. A special 

CascadairTM inlet gas diffusion baffle is provided in each hopper. The hopper bottom 

opening is 12 inches x 12 inches. The hopper bottom flange is designed to accept a 12 

inch discharge valve to mate with the pneumatic dust conveyor system. 

Hopper flange clearance to be 4’-0” from flange to bottom of supplied steel column base 

plate. 

Two (2), 12” x 12” pounding lugs will be provided on each hopper.

Cell Plates and Lower Internal Access:

Cell plates are fabricated from 3/16-inch thick A-36 plate and have 12.0” diameter holes 

on 14-inch centers in both directions. Two (2) walkways are provided at the cell plate 

level with nominal 24 inches of clear space between the filter bags. The maximum 

number of bags to be reached from any cell plate walkway is three (3) deep from the 

walkway. Access walks along the outside perimeter of the arrangement will be provided 

to access the module doors at cell the cell plate level. Walk ways are 30 inches wide.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 3 of 27

Bag Suspension and Upper Internal Access:

A full grating platform is provided at the bag suspension level inside the module. The 

grating is to be 1 1⁄4” x 3/16” type 19W4. The filter bags are suspended from bars welded 

to the grating via a chain and pin. A bag suspension spring is provided to maintain 

tension on each filter bag. Compartment upper access doors are served by a 30 wide 

perimeter access walkway.

Structural Steel:

The internal structural steel stiffening frame and baghouse sub-structure will be designed 

to meet local wind, snow and seismic loads. The support structure is based upon the 

hoppers of the fabric filter uniformly loaded with dust weighing 70 pounds per cubic foot 

with the accumulation taken as to the bottom of the hopper inlet ducts.

Stairway:

One (1) 30” wide stairway from grade to cell plate level and bag suspension level as

shown in General Arrangement drawings. 10” wide bar grating treads with checkered 

plate nosing, bar and rod hand rail are also provided.

Ladders:

One (1) OSHA compliant emergency egress ladder system to be provided from all levels 

to grade as required by code. 

Filter Bags and Suspension:

The filter bags are fiberglass with PTFE membrane (Mikrotex). The bag is rated at a 

maximum temperature of 550° F. Each bag weighs 10 oz./yd2 (nominal). The fabric 

mullen burst is 500 PSI (minimum) and the permeability is 7 ±3 CFM at 1⁄2 inch w.g.

Weave pattern – 3 x 1 twill.

Ring covers sewn with 2000 denier PTFE thread to meet warranty strength requirements.

Filter bags will be 12.0 inch diameter by 35’-0” long with 6.0 inch bottom cuff, 2.0 inch 

top cuff and eight (8) stainless steel anti-collapse rings with 1.75 inch covers. The bags 

have a shop installed 20-gauge galvanized cap with open eyebolt. The bottom snap 

band is stainless steel with a double beaded bottom for cell plate attachment. 1% spares 

is included.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 4 of 27

Bag suspension hardware is a double draw bar, spring assembly with chain and pin for 

fixing to bars on the upper level compartment grating floor. 18” spacing is provided 

between grating floor and bag top hook. 

Hoist:

A bridge crane with an electric hoist with sufficient capacity to lift all required 

maintenance materials to the service walkway is provided. The crane shall extend over 

one (1) end of the baghouse to provide clearance to lifting of materials.

Inlet Plenum:

The inlet plenum is located between the compartments at the cell plate level elevation and 

features a tapered top section and bottom exit design. The inlet damper valves are 

located in the duct stubs prior to the hopper inlet. The plenum is to be fabricated from 

3/16” thick sheet steel and stiffened for a negative pressure of 20 inches of water at 500° 

F. The plenum structural design is based upon the plenum being loaded with 70 pounds 

per cubic feet of dust at 25% volume. The plenum face cross section yielding an inlet 

velocity of 3,500 feet per minute

The plenum will have a minimum of two (2) 24” x 72” bolted opening access doors 

located in the plenum side walls.

Outlet Plenum:

The outlet plenum is located between the compartments at the bag housing elevation and 

features a tapered bottom section and top inlet design. The outlet and reverse air damper 

valves are located in the top section of the plenum. The plenum is to be fabricated from 

3/16” thick plate steel and stiffened for a negative pressure of 20 inches of water at 500° 

F. The plenum structural design is based upon the plenum being loaded with dust at 70 

pounds per cubic feet of dust at a uniform depth of six (6) inches. The plenum face cross 

section an outlet velocity of 2,640 feet per minute with

Reverse Delivery Air Ductwork:

The reverse air duct is located above the modules and from the modules to the reverse air 

fan outlet at grade. It is designed to transport the reverse air from the grade mounted 

reverse air fan to the compartment reverse air inlets then to the recirculation damper. It is 

to be fabricated from 3/16” thick steel plate and stiffened for a negative pressure of 30 

inches of water at 500° F. The ductwork structural design is based upon the ductwork 

being loaded with 70 pounds per cubic feet of dust at a depth of six (6) inches. The 

ductwork is 48 inch diameter with proper transitions to the fan outlet. 
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 5 of 27

Reverse Air Inlet Ductwork:

The reverse air inlet ductwork is 50 inches in diameter and runs from the outlet ductwork 

of the baghouse to the reverse air fan inlet at grade elevation. Proper transitions to the fan 

inlet are included. The ductwork is 3/16 inch stiffened plate construction for -20 inches 

of water.

Inlet Dampers:

One (1) manual butterfly-type inlet damper shall be provided per compartment. 36 inches 

x 66 inches. These dampers are located in the inlet elbow to each compartment hopper. 

The damper actuators are mounted at the damper with chain fall to grade elevation. 

Lock-out provisions for Closed positions are provided. 

Outlet Dampers:

One (1) outlet damper, multiple leaf poppet type with rolled angle seat shall be provided 

per compartment. The dampers are mounted above the outlet plenum. Each damper is 

60 inch diameter. The shaft shall be stainless steel. Damper shaft seals are to be split 

gland type. 

Outlet Damper Air Cylinders:

Each outlet damper will be provided with an air cylinder operator. The cylinders are 

Parker Model 2A with 10 inch bore and 60 inch stroke, solenoids and speed controls and 

Allen Bradley limit switches. Rod aligning couplers are included. Rods are chrome 

plated.

Reverse Air Dampers:

One (1) reverse air, multiple leaf, spring disc design, poppet-type damper with rolled 

angle seat shall be provided per compartment. The damper is mounted on top of the 

module in the reverse air box. An access door in the damper housing shall be provided to 

access the seat and damper wafer. 

Each damper is 50-inch diameter. Damper shaft seals are stuffing box type. 

Reverse Air Damper Air Cylinders:

Each reverse air damper will be provided with an air cylinder operator. The cylinders are 

Parker Model 2A cylinders with 10 inch bore and 40 inch stroke, solenoids and speed 

controls and Allen Bradley limit switches. Rod aligning couplers are included. Rods are 

chrome plated.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

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Reverse Air Recirculation Damper:

One (1) reverse air, multiple leaf spring disc design, poppet-type recirculation damper 

with rolled angle seat shall be provided for the baghouse. This damper provides for 

recirculation of the reverse air preventing dead head operation of the reverse air fan. The 

damper is also used during the MikroPul soft re-inflate sequence. The damper is 

mounted on top of the baghouse at outlet plenum elevation to tie the reverse air duct 

system to the baghouse outlet plenum. An access door in the damper housing shall be 

provided to access the seat and damper wafer. The damper is 40-inch diameter. The 

damper shaft seal is stuffing box type seal. 

The poppet blade is removed through a bolted panel on the housing. 

Reverse Air Recirculation Damper Air Cylinder:

The reverse air recirculation damper will be provided with an air cylinder operator. The 

cylinders are Parker Model 2A with 8 inch bore and 32 inch stroke, solenoids and speed 

controls and Allen Bradley limit switches. Rod aligning couplers are included. Rods are 

chrome plated.

Reverse Air Fan By-Pass Dampers:

Two (2) reverse air fan by-pass dampers, butterfly type shall be provided for the 

baghouse to provide by-pass of the reverse flow in the event of a reverse air fan failure.

One (1) damper is designated as the reverse air shut-off damper while the other is 

designated as the reverse air by-pass damper.

These dampers are in addition to the outlet guillotine damper on the reverse air fan.

Reverse Air Fan By-Pass Damper Air Cylinders:

The reverse fan by-pass dampers will be provided with air cylinder operators. The 

cylinders are Parker Model 2A with stroke to suite arrangement, solenoids and speed 

controls and Allen Bradley limit switches. Rod aligning couplers are included. Rods are 

chrome plated.

Main System By-Pass Dampers: (design to include future 25% flow)

By-Pass dampers NOT included, however provisions will be made to the duct to allow 

installation of by-pass dampers at a later date

. 

Main System By-Pass Damper Air Cylinder:

Not included
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 7 of 27

2.0 Air Moving Equipment and Accessories

Base Main ID Fan:

Two provided – One (1) operating and One (1) stand by, Class IV, double width double 

inlet, Arrangement 3, heavy-duty exhaust fans with backward curve blades for 

continuous operation are provided. The fans are arranged for top vertical inlet and 

bottom angular up outlet.

The fans are designed for 180,000 ACFM each at 482°F and 15.5 inches of water, based 

on a gas density of 0.042 lbs./cu. ft Actual volume capacity in single fan operation will 

be confirmed following final system design and fan selection.

Backward Curved Type (single thickness Airfoil) Arr. #3, Class IV

1,180 RPM for Direct Drive

Beck electric variable position damper actuator

Bearing vibration and temperature included

Inlet and outlet flexible isolation joints

Inlet boxes with louver dampers

Flex type coupling for variable speed application

2 1⁄2” drains

Split housing for wheel removal

Outlet guillotine damper with electric operator

Anti-friction grease lubricated bearings

Final fan performance to be provided based upon certified

information and final duct S.P. confirmation.

450 Operating HP @ 16 ” WC, @ 180,000 ACFM and 482° F 

I.D. Fan Hoist and Trolley Monorail:

A monorail beam for each I.D. fan will be furnished for the purpose of installing and 

removing the fan wheel and shaft from the fan housing.

The hoist, trolley and spreader beam required for each monorail will be supplied and 

installed by others.

Space is provided in the 480V MCC/PLC control panel for an electric hoist starter.

Main Fan Bearing Vibration Sensors:
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 8 of 27

Each main fan bearing shall be equipped with a Vibration Pick-up/Transmitter (4-20mA). 

The output shall be for monitoring and alarm with shutdown on high set point.

Main Fan Bearing Temperature Sensors:

Each main fan bearing shall be equipped with one (1) 100-ohm platinum RTD sensor

with 4 to 20 milliamp output. The output shall be for high temperature alarm.

Main Fan Inlet Damper Actuators:

“Beck” electric inlet damper actuators shall be provided capable of variable position 

continuous modulating control. Linkage for mounting of the damper actuator at grade on 

a separate pedestal. The Beck actuators include position feedback transmitters.

Main Fan Guillotine Isolation Dampers:

Two (2) fan outlet guillotine valves with electric motor drive are provided, one (1) for 

outlet isolation of each fan. The valves shall provide less than 1% leakage in the Closed 

position with 13 inches of differential pressure across the valve. Drive with electric 

motor and Open/Close limit switches is included.

Base Main Fan Motors: 

Each main fan shall be equipped with a 600 HP; 1180- RPM inverter type, mill duty 

motor. The motor will be rated for 2,300V/3Ph/60Hz operation with a 1.15 service 

factor. The temperature rise at the 1.15 service factor will be a Class F rise based on 

resistance. Motors shall include stator RTDs, bearing vibration, temperature sensors and 

space heaters. The motor has a WPII type motor enclosure. 

All fan motors to have motor current protection to alter fan inlet damper position for 

motor current control.

Reverse Air Fan: 

One (1) reverse air fan SWSI for direct drive with Arrangement 3. Radial tip 

construction. 

Radial tip Blade Fan, Arr. #3, Class IV

Rated at 40,000 ACFM (2.5:1 Reverse air ratio)

1180 RPM, 15.0” static pressure at 482° F 

Single width, single inlet with inlet box air pre-spin damper

Beck electric variable position damper actuator
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 9 of 27

Anti-friction bearings

Bearing vibration and temperature drilled for instruments

Inlet and outlet flexible isolation joints

Falk gear coupling 1⁄2 mounted to fan shaft

2 1⁄2” drain

Split housing for wheel removal

Guillotine outlet damper with electric operator

128 Operating HP @ 16” WC, 40,000 ACFM and 482° F

Optional Spare Reverse Air Fan and Motor: 

Not Included

Reverse Air Fan Bearing Vibration Sensors:

Each reverse air fan bearing shall be equipped with a Vibration Pick-up/Transmitter (4-

20mA). The output shall be for monitoring and alarm with shutdown on high set point.

Reverse Air Fan Bearing Temperature Sensors:

Each reverse air fan bearing shall be equipped with one (1) 100 ohm platinum RTD. The 

output shall be for high temperature alarm.

Reverse Air Fan Inlet Damper Actuator:

A Beck electric inlet damper actuator is included for control of the damper position. The 

Beck actuator is variable position type with position feedback transmitter. 

Reverse Air Fan Motor:

One (1) 200 HP, TEFC, NEMA Design B, 1200 RPM motor 1.15 SF. Rated for 480 

volts, 3 phase, 60 Hz operation. Motor to be supplied with bearing vibration pickup/transmitters, bearing temperature RTDs and motor winding RTDs – one (1) per phase.

The final motor HP selection is dependent upon the final reverse air fan selection and fan 

HP ratings.

Air Receiver (for Baghouse):
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 10 of 27

300 gallon air receiver to be used for compressed air provided by others.

3.0 Dust Handling Equipment

Baghouse Hopper Dust Discharge Valves:

A gate type sized as required, nominal 6 inches is provided at the discharge of each 

hopper flange. The valve will include air cylinder actuator, solenoids and air speed 

control valves. Open/Close limit switches are also provided.

Spark Box Dust Discharge Valves:

A gate type sized as required, nominal 6 inches is provided at the discharge of the spark 

box. The valve will include air cylinder actuator, solenoids and air speed control valves. 

Open/Close limit switches are also provided.

Pneumatic Conveying System and Dust Handling System:

The pneumatic system will convey dust from the following pick up points:

Eight (8) baghouse module hoppers

One (1) spark box hopper

The system is designed to operate at the following capacities with the volume of 310,000 

ACFM:

The anticipated dust load to the system is approximately 0.77 grain per actual cubic foot 

on average. Using 316,900 ACFM as a design volume and using a bulk density of 58 lbs. 

per cubic foot, the dust load to the system would be 2,094 pounds per hour. The dust 

conveying system has been sized for 4,000 pounds per hour to provide extra capacity 

allowing recovery from maintenance down time.

Each baghouse hopper is capable of storing approximately 1,000 cubic feet of dust or 

approximately 58,000 lbs., storage level is taken as the bottom of the baghouse inlet. The 

level probes will be located below this elevation to provide adequate alarm notice.

The additional capacity of nearly 100% is to allow for “catch up” in the event of a 

mechanical failure of the conveying system. 

In normal operation, the conveyor system will follow the cleaning cycle. When not in the 

cleaning cycle, the conveyor system will follow a cycle pattern to continuously remove 
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 11 of 27

dust from the system hoppers. The system is controlled from conveyor line pressure and

will continue to remove dust from a hopper until the system pressure indicates that the 

hopper is empty or the timer “override” steps to the next compartment. 

An operator may manually select a specific module to convey from or allow the system 

to simply operate automatically in normal mode. 

Timer control settings and pressure settings are adjustable from the HMI.

Using a dust density of 58 lbs./cubic foot, the conveying rate from a hopper would be 

51.7 cubic feet per hour.

At the above system capacity the system would off-load all of the 24 hours of dust 

storage to the silo in 25.2 hours in event of a complete system failure while with the net 

take away capacity of (4,000 – maximum inlet load) = 1,952 lbs. per hour net.

The following is provided:

• One (1) lot of six-inch diameter conveying pipe with wear back, ceramic lined (or 

equal) elbows and discharge equipment.

• One (1) positive displacement blower with inlet filter, silencer, check valves, 75 HP, 

480V/3Ph/60Hz 1800 RPM TEFC motor. 

• The final blower motor HP selection is dependent upon final blower HP selection 

which may vary dependent on silo location and conveying distance. 

• One (1) silo mounted receiver.

• One (1) silo mounted filter separator with double discharge valve, air cylinder, 

solenoids and speed control valves with Nomex bags.

• One (1) sound enclosure for 85 dBA sound level.

• Nine (9) hopper pick up points.

• Discharge ductwork to transport blower discharge to baghouse inlet. 

• Broken bag detector.

• Filter separator.

Batching Silo:

A 12 foot diameter, 2500 cubic foot dust silo is provided for batch storage of the 

collected dust. The silo is welded steel construction from mild steel 3/16” thick. 

Perimeter roof access handrail is provided. The silo hopper is a 60° conical hopper with 

a 14 inch diameter discharge flange. 

Silo includes roof mounted pressure/suction relief hatch and roof mounted Siemens or 

equal radar type dust level indicator. 

Silo access is via stairway from grade to hopper level platform and a spiral stairway is 

provided from hopper level platform to silo roof. 
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 12 of 27

Support structure is arranged for approximately 23’-6” clearance under the silo hopper 

discharge flange, 70 lb/cf product weight, 20 PSF Deck Live Load.

Silo Coatings:

Interior Epoxy = 2.0 mils AVG DFT per SSPC PA-2

Exterior Primer Epoxy = 2.0 mils AVG DFT per SSPC PA-2

Exterior Top Coat = Performance Urethane 1.5 mils AVG DFT

Coatings are applied over an SSPC-SP 6 and thermally cured.

Standard Color to be tan (special colors available at additional costs of $500.00)

Live Bottom:

Pulsonics, AR Fluidizing System located about the perimeter of the hopper. 

Discharge Slide Gate:

14 inch diameter air operated slide gate for isolation/maintenance of air lock and 

discharge spout.

Final Discharge Rotary Valve:

One (1) 14 inch diameter rotary airlock valve to be mounted directly beneath the slide 

gate. The valve is a cast iron construction and includes a gear reducer motor drive. A 

zero speed switch is included. The feed rate of this valve may be determined later.

Retractable Discharge Spout:

A retractable vented discharge spout mounted beneath the rotary airlock is provided. 

Spout it capable of positioning between 5’-0” and 14’-0” as specified. The spout includes 

an electric motor drive and tilt probe for automatic retract. Limit switch interlock so door 

will not rise until the spout is lifted to be provided. A hand held pendant controller is 

also included.

Discharge Building:

A building with approximate dimensions of 18’ x 100’ x 18’ high will be provided with 

electric motor drive roll up doors on each end. A building ventilation system with blower 

and ductwork to provide one (1) air change every five (5) minutes based upon the empty 

building volume of 32,400 cubic feet yielding a ventilation rate of 6,480 cubic feet per 

minute. A blower rated at six (6) inches of water and 7,000 ACFM will be provided. A 

close capture hood will be provided at the spout discharge. The blower will be radial 

blade design with 15 HP drive at 1800 rpm. Fan will have a ducted inlet and motor will 
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 13 of 27

be sized for start up with duct damper closed at 0°F and for continuous duty at 0°F. 

Vibration joints will be provided for the blower inlet and outlet. A 20-inch diameter 

damper with air operated control and limit switches will be provided to isolate the fan 

from the main duct system during non-operating periods and will provide damper closed 

start up. Limit switches are provided for position indication. Manually operated makeup air louvers are also included.

The fan discharge will be ducted to the baghouse inlet plenum.

NOTE: No scales or load cells are included in this proposal. 

4.0 Spark Box:

One (1) spark box to drop out larger particles and sparks prior to the baghouse.

Maximum pressure drop through spark box to be less than 1.5” wg. vertical velocity 

based upon 180,000 ACFM discharge side is 1,500 FPM.

The spark box is fabricated from 3/16 in. A36 mild steel and stiffened for ±20 inches of 

water pressure and includes internal baffling. 

Spark box hopper to have minimum 60 deg. valley angle and to be fabricated with 3/16 

A36 mild steel and to be designed to be fully loaded with dust at 58 lbs./cubic foot. 

Hopper to have 36” x 36” access door. Two (2) poke holes to be included. Hopper to be 

equipped high dust level detector.

Spark Box Supports:

Structural support steel for local wind, seismic, equipment live and dead loads as 

applicable shall be provided. The clearance under the hopper is to match that of the 

baghouse hoppers for pneumatic conveyor layout. 

Spark Box Inlet Isolation Joint:

A lined and insulated isolation joint is provided at the inlet to the spark box suitable for 

the 550oF. 

Water Spray System:
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 14 of 27

We have contacted TurboSonics who has supplied many H2O Two-fluid type emergency 

cooling systems for many applications. After various meetings / discussions, Eramet has 

decided to use a horizontal type system

Horizontal Duct as Cooler:

Spray nozzles and basic equipment as listed below mounted in the horizontal duct run.

Access and required associated equipment included.

SYSTEM DESCRIPTION 

The SoniCool® System proposed herein is a cooling system designed to provide gas 

cooling from an inlet temperature to a discharge temperature set point by the injection of 

fine water sprays using a Turbotak dual phase nozzle. Sprays will evaporate to dryness 

within the horizontal cooling chamber section, with dry particulate discharge and no free 

water carryover. 

The system is designed on the basis of data provided by the Purchaser as outlined in the 

proposal.

The main objective of #1 Furnace Gas Cleaning System Project is to provide a new 

baghouse system is to replace an existing wet scrubber emission control system in 

order to meet State and Federal EPA emission requirements in the off-gas from #1 

Furnace. 

The SoniCool® system will normally not operate, and is installed as an emergency 

spray system to handle unexpected temperature excursions in the process gas flow. 

The final location and number of sprays as well as final process data to be 

determined

EQUIPMENT SUPPLY DESCRIPTION

 Nozzles are located in the furnace outlet duct location near the spark box 

and are oriented around the duct perimeter

 One Inspection door at nozzle elevation 

 Ports for nozzle spray assemblies

PLATFORMS 

 Connecting walkways and platforms

 At Nozzles 
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ATOMIZING NOZZLES

 Nozzles and lances as required

 All nozzles and lances are interchangeable 

 All operating nozzles and lances supplied 

 316SS, including mounting flange

 Unibody Spray lance with Angled Lance tip as required

 Turbotak air atomizing nozzles

 Nozzle configuration: 

 Welded construction, multiple orifice design.

 4” OD nozzle body

CONTROLS

 Automated controls for temperature setpoint control and response time

 Controls may be supplied as separate assemblies or integrated on one 

assembly

 Compressed air flow control – (automatic setpoint)

 Automatic air flow control valve, pneumatically 

actuated based on 4-20 mA input signal for 

airflow setpoint control

 Air flow and pressure indication with 4-20 mA 

output

 Inline air line strainer

 Water flow control (automatic temperature setpoint):

 Automatic water flow control valve, 

pneumatically actuated based on 4-20 mA input 

signal for temperature setpoint control

 Magnetic flowmeter water flow indication with 4-

20 mA output signal

 Local pressure indication as required

 At Turbotak nozzles:

 Quick connects and rubber flex hose connections
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 16 of 27

 Diaphragm isolated pressure indication

 isolating shutoff/adjusting hand valves for each 

air and water connection

 Air flow control with local flowmeter

Heat tracing, insulation or installation NOT INCLUDED

ONE (1) COMMON WATER PUMP SKID

One common pump skid to supply all water requirements

Two pumps installed. One is operating, one is an online spare, to deliver 

the required water flow at required operating pressure to flow control 

valves. All components mounted on painted, mild steel frame, with all 

interconnected piping and electrical. 

 Centrifugal type pump, multistage

 TEFC motor 

 Pressure Relief/recirculating valve

 Pressure indication and pressure switch

 All isolating valves, flow return, check valves as required

 Inlet parallel, single basket strainers

 Pressure indication and pressure switch

All isolating valves, flow return, check valves as required

“Preliminary Operating conditions below to be confirmed”

Operating Conditions

Number of Pumping 

Stations

1

Capacity gpm 250

Head ft 280

Pump

Type Ansi Centrifugal

Manufacturer Goulds

Model 1 1/2 x 3 - 10

Performance

RPM 3600

Rated Eff. % 60

BHP / Installed Motor Rated HP (kW) 30 (25) / 40 (30)
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 17 of 27

WATER SUPPLY TANK 

Heater with thermostat, not included

Quantity 1

Capacity gallons 1200

Style Carbon steel

Ventilation Flat bottom, flat top, round

Level Control 2” U-vent

Water connections Modulating float control valve, level switch with 

alarms.

Operating weight lb 11,000

ONE (1) AIR RECEIVER 

♦ One common air receiver

♦ Volume 8,000 gal

♦ Approximate size: 72 x 247 inch (approximate)

♦ Complete with safety valve pressure gauge and automatic drain valve

5.0 Electrical Engineering and Equipment

PLC & SCADA Programming

Supply of control design and programming services including the following tasks:

• Functional Specification.

• Technical review meetings at Mikropul and at Site if required.

• PLC software programming with descriptors.

• SCADA (operator interface) software programming, fully tagged and annotated, with 

the following features as a minimum:

• Graphic overview of entire dust collection process, including system ductwork / 

dampers if applicable.

• Individual graphic displays of each module including details on all operating 

parameters.

• Damper positions.

• Motor status of all motors and amperage of main ID Fans

• Compartment status.

• Compartment Cleaning Status.

• Graphic displays for the dust conveying system including details on all operating 

parameters.

• Device pop-up windows for all control devices.

• Baghouse Temperatures.

• Baghouse system pressure drop.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 18 of 27

• Baghouse compartment pressure drop.

• Main ID Fan Damper position and motor amperage.

• Bag leak detection system.

• Hopper and Silo high level.

• Real time and historical trending of all analog points, including temperatures, 

differential pressures and all temperatures and vibration points for exhaust fans.

• Logging of above analog points to file.

• All alarms logged with time and date stamp.

• Hardware FAT (factory acceptance testing) at vendor system’s facility.

• Software FAT (factory acceptance testing) at vendor system’s facility.

Electrical Engineering for Contract (Equipment Supply Scope)

Supply of electrical engineering including the following tasks:

 P&I Diagrams.

 Electrical equipment list.

 Electrical equipment location diagrams.

 480 volt MCC - Single line diagrams and schematic wiring diagrams.

 480 volt MCC - Layout Diagrams

 480 volt Soft Starter – Single line diagrams and schematics wiring diagrams.

 480 volt Soft Starter – Layout Diagrams

 Ethernet and ControlNet RIO communications diagrams.

 RIO panels layout diagrams.

 PLC and RIO control panel terminal block layout diagrams.

 PLC and RIO control panel I/O Drawings.

 PLC and RIO control panel schematic drawings.

 PLC and RIO control panel backboard layouts.

 PLC and RIO control panel door layouts.

 PLC and RIO control panel bills of material.

 Control Room Layout and Design

 Control Room Lighting and Electrical Services

 Specifying of dust collector instrumentation and control equipment.

PLC Control Panel

 1 - NEMA 12 Enclosure, approximately 60” high x 36” wide x 12” deep, with 12” 

high mounting feet.

 1 - Modicon Quantum PLC c/w Rack, Power Supply, all required I/O and 

communications modules.

 1 - 1000VA Powerware or equal UPS

 1 - 120volt GFI receptacle for use by programmer.

 1 - 24vdc power supply, for Analog loop power.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 19 of 27

 1 - Allen Bradley 30mm, door mounted illuminated Control Power ‘On’ and 

Control Power ‘OFF’ buttons.

 Lot - Weidmuller terminals and fused terminals as required, all field items wire to 

terminals

 UL Listed.

(2) HMI / Computer / SCADA Stations

Each station will consist of the following equipment and software, both stations will be 

placed in the electrical control room:

 Dell OptiPlex 755 (or equal)

 Intel Core 2 Duo Processor, E6550, 2.33GHZ.

 Windows XP Professional SP2

 2GB DDR2 ram at 800MHz.

 Intel Graphics Media Accelerator GMA3000

 160GB IDE Hard Drive, 7200rpm.

 8x Slimline DVD-CDRW Drive.

 19” Dell Ultra Sharp LCD flat panel monitor or equal.

 Dell Enhanced Keyboard.

 Dell Optical USB mouse.

 PC Anywhere for offsite support, or equivalent

 Integrated Intel PRO 10/100 Ethernet

 WonderWare by Intouch, Runtime license.

 1000VA PowerWare or equal UPS.

480V Distribution System

One (1) Square D, Service Line QED Switchboard 277/480 volt, 3 ph, 4-wire solidly 

grounded neutral.

• 2-Section NEMA 1 approximately 90” high x 72” wide x 36” deep.

• 42KA RMS symmetrical bus bracing.

• 3000 amp main circuit breaker, top entry.

• 3000 amp tin plated copper horizontal power bus.

• 2 – 800 amp circuit breaker feeders for 600 hp Stand-a-long VFDs.

• 1 – 800 amp circuit breaker feeder for the 480V MCC.

• 1 200 amp circuit breaker feeder ~ (1) 45k VA baghouse lighting transformer, (1) 200 

amp baghouse lighting panel. Transformer and lighting panel supplied by others and 

mounted under baghouse. 

• 2 – 60 amp circuit breaker feeders – welding outlets.

• 1 – 30 amp circuit breaker feeder – silo discharge local control panel.

• 1 – 30 amp circuit breaker feeder – maintenance hoists.

• CSA Certified / UL Listed.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 20 of 27

480V MCC 

One (1) Allen Bradley, 480volt motor control center, 3ph, 3wire, solidly grounded 

neutral. Space saving NEMA Rated Starters, consisting of the following:

 5-section, NEMA 1, gasketed, class 1, type B, approximately 90”high x 100”wide 

x 15”deep.

 42KA RMS symmetrical bus bracing.

 800 amp incoming line lugs.

 800 amp tin plated copper horizontal power bus.

 300 amp tin plated copper vertical bus.

 1/4” x 1” horizontal ground bus.

 1 - 60amp Fused Feeder and (1) 25kVA Control Transformer, and (1) 42cct 

Lighting Panel for 120vac control power with 42 – 15amp, single pole breakers.

 1 - FVNR 15hp starter - Discharge Building Blower.

 2 - FVR 10hp starters - Main ID Fan guillotine dampers.

 1 - FVNR 200hp starter - Reverse Air Fan.

 1 - FVNR 75hp starter - Conveying System Blower

 2 – FVNR 30hp starters – Pumps for Nozzles.

 Lot – (minimum 1) empty section for future loads.

 All listed FVNR and FVR starters are complete with, Fused disconnects, control 

transformer c/w primary and secondary fusing. Motor fuses’ are Gould AJT.

 UL Listed.

Silo Discharge System Local Operators Panel:

• NEMA 4 enclosure approximately 30" high x 24" wide x 8" deep, wall mounted.

• 480/3/60vac door interlocked rotary style non-fused disconnect.

• 1 - Allen Bradley NEMA Rated, FVR starter for 1 1⁄2 hp silo rotary valve

• 1 – Allen Bradley NEMA rated FVR starter for 1 1⁄2 hp discharge spout

• 1 - Control transformer c/w primary and secondary fusing.

• Allen Bradley, 30mm door mounted operators.

• 1 - Rotary valve “start” push button.

• 1 - Rotary valve “stop” push button.

• 1 - Rotary valve “running” pilot light.

• 1 – Discharge spout “up” push button.

• 1 – Discharge spout “down” push button.

• 1 – Discharge spout “up” pilot light.

• 1 – Discharge spout “down” pilot light.

• UL Listed.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 21 of 27

Local Motor Operators:

• Each motor (6 in total) will have a local mounted operator station, consisting of the 

following:

o ‘Local - Remote’ Selector Switch

o ‘Start’ Button

o ‘Stop’ Button

o ‘Emergency Stop’ Button

(8) Compartment Remote I/O Panels:

• NEMA 4 painted steel panels, approximately 30” high x 24” wide x 8” deep, wall 

mounted.

• 200watt panel heater with integral thermostat and blower.

• 1 - Modicon Remote interface units.

• Lot - Modicon Remote I/O modules as required.

• 1 - Sola/Heavy duty surge protector.

• 1 - Selector switch for Compartment ‘Auto-Isolate’

• All I/O points will be wired terminals.

• UL Listed.

(2) ID Fan Remote I/O Panels:

• NEMA 4 painted steel panels, approximately 30” high x 24” wide x 8” deep, wall.

• 200watt panel heater with integral thermostat and blower.

• 1 - Modicon Remote interface units.

• Lot - Modicon Remote I/O modules as required.

• 1 - Sola/Heavy duty surge protector.

• All I/O points will be wired terminals.

• UL Listed.

(1) Reverse Air Fan Remote I/O Panel:

• NEMA 4 painted steel panels, approximately 30” high x 24” wide x 8” deep, wall.

• 200watt panel heater with integral thermostat and blower.

• 1 - Modicon Remote interface units.

• Lot - Modicon Remote I/O modules as required.

• 1 - Sola/Heavy duty surge protector.

• All I/O points will be wired terminals.

• UL Listed.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 22 of 27

(1) Dust Conveying System Remote I/O Panel:

• NEMA 4 painted steel panel, approximately 30” high x 24” wide x 8” deep.

• 200watt panel heater with integral thermostat and blower.

• 1 - Modicon Remote interface units.

• Lot - Modicon Remote I/O modules as required.

• 1 - Sola/Heavy duty surge protector.

• All I/O points will be wired terminals.

• UL Listed.

(1) Baghouse System Remote I/O Panel:

• NEMA 4 painted steel panel, approximately 30” high x 24” wide x 8” deep.

• 200watt panel heater with integral thermostat and blower.

• 1 - Modicon Remote interface units.

• Lot - Modicon Remote I/O modules as required.

• 1 - Sola/Heavy duty surge protector.

• All I/O points will be wired terminals.

• UL Listed.

OPTION – 480 V Soft Starters:

Two (2) 480 volt Soft Starter Panels, each consisting of the following:

• NEMA 12 rated ventilated enclosure, approximately 90” high x 42” wide x 20” 

deep, free standing.

• 1 – Main incoming fusible disconnect 480/3/60 Hz.

• 1 – Control transformer c/w primary and secondary fusing as required by code.

• 1 – 600 hp 780 amp Allen-Bradley SMC Flex controller for ID fan, 1.15 service 

factor.

• 1 – Fan ‘Local-Off-Auto’ selector switch.

• 1 – Fan ‘Start’ push button.

• 1 – Fan ‘Running’ pilot light.

• 1 – Fan ‘Speed’ pot switch.

• 1 – VFD ‘Fault’ pilot light.

• UL Listed.

OPTION - Shop Assembled Control Room

One (1) approximately 10’ x 24’ pre-assembled building, as manufactured by Provincial 

Partitions or equal, consisting of the following:

 Steel base (floor) with 1⁄4” steel checker plate, epoxy painted.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 23 of 27

 Pre-Finished walls:

 Exterior walls - 29 gauge pre-finished metal siding

 Interior walls - vinyl clad gypsum panels

 Insulation:

 Wall - R12 complete with poly vapor barrier

 Ceiling - R20 complete with poly vapor barrier

 Floor - R20 complete with poly vapor barrier - spray foam.

 Rooms:

 High Voltage Room - to contain 480V MCC and (2) 480V soft starters.

 Operators Room / Storage Area - room for desk (supplied by others) and for 

storage of Baghouse maintenance items.

 Wall and roof structure to consist of metal framing members

 Roof covering to consist of single ply EPDM membrane

 Ceiling to consist of vinyl clad panels.

 Doors and Frames:

 (2) Exterior doors, door frames complete with pre-finished metal slab door, 

hinges, seals, sweeps, lockset and closers, (1) 3’ x 7’ main door, (1) 6’ x 8’ double 

door.

 Electrical includes:

 Exterior HPS light c/w photo cell

 Exterior ground fault receptacles.

 Lot - interior lighting as required.

 Lot - interior receptacles as required.

 Lot - Installation of 480 V VFDs, 480V MCC and PLC control panel, complete 

will all internal wiring between VFDs, 480V MCC and PLC panel, completely 

tested prior to shipment.

 HVAC System as required

 

Instrument List:

- Four (4) Rosemont Temperature thermocouple with transmitters

- Ten (10) Rosemont pressure transmitters

- Eight (8) Hopper level detectors, capacitance type level probe with 20” insertion 

length

- Sixteen (16) Baghouse Inlet damper limit switches

- Sixteen (16) Baghouse Outlet damper limit switches

- Sixteen (16) Baghouse Reverse air damper limit switches

- Two (2) Baghouse Recirculation damper limit switches

- Eight (8) main system by-pass damper limit switches

- Four (4) main ID fan inlet damper Limit switches

- Four (4) main ID fan outlet guillotine valves limit switches

- Two (2) reverse air fan damper limit switches

- Four (4) Main air fan bearing vibration detectors

- Four (4) Main air fan bearing Temperature detectors
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 24 of 27

- Two (2) Reverse air fan bearing vibration detectors

- Two (2) Reverse air fan bearing Temperature detectors

- Two (2) limit switches for silo discharge retract spout

- Eight (8) bag leak detectors with transmitters

- Two (2) Main Fan inlet damper actuators

- Two (2) Main Fan outlet guillotine valve actuators

- One (1) Reverse air Fan inlet damper actuators

- Thirty-two (32) Baghouse system ductwork damper actuators

- One (1) Silo radar level detector 

Motor List: (Final Motor Sizes TBD)

- Two (2 ) 600 HP, 2400 V/3PH/60 Hz for main ID Fans 

- One (1 ) approx 200 HP, 480 V/3PH/60 Hz for reverse air fan motor

- Two (2) 10 HP, 480V/3PH/ 0 Hz, Main Fan Guillotine damper motors-Reversing

- One (1) 1.5 HP, 480V/3Ph/60 Hz, Silo discharge Rotary valve motor- Reversing

- One (1) 75 HP, 480V/3Ph/60Hz, Positive displacement blower motor.

Note: Electrical quantities of limit switches, transmitters etc will be adjusted to 

include requirement for spray tower and pelletizer

6.0 Ductwork

MikroPul will provide A36 mild steel ductwork as follows and as generally shown on the 

general arrangement drawings:

• Beginning at the existing off-gas duct flange at the building east wall to the inlet 

of the spark box. (if selecting horizontal spray cooler)

• Beginning at the existing off-gas duct flange at the building east wall to the inlet 

of the vertical chamber, out of the vertical chamber and into the sparkbox. (if 

selecting vertical spray cooler)

• From the outlet of the spark box to the inlet of the Baghouse inlet plenum.

• From the outlet of the Baghouse outlet plenum to the inlet of the Fan inlet 

manifold.

• From the outlet of the fan outlet manifold to the stack.

• From the dust discharge building to the baghouse inlet duct for building 

ventilation. 

Included in all ductwork will be required expansion joints, inspection doors, support 

steel, saddles and trusses as required.

Support steel of dirty side duct to be designed based on 33% full of dust. 
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 25 of 27

All Ductwork will be constructed of minimum 3/16” A36 mild steel. The ductwork will 

be shipped in full diameter sections and lengths as allow by trucking limits. This will 

speed up installation.

The inlet and outlet of each main fan and the reverse air fan will have isolation joints to 

reduce vibrations being transmitted from the fans to the ductwork. 

Main Stack:

A 10’-6”diameter by approx. 93 foot tall outlet stack will be provided for final system 

discharge. The stack will be constructed of minimum 3/16 inch A36 mild steel plate at 

the discharge with thickness at the base a minimum of 1⁄4” thick plate dependent upon

final stack design. A 360° access platform will be provided that test port elevation with 

caged ladder system to grade.

Two (2) 4” IPS test ports with caps will be furnished at 90° orientation for stack testing.

Access to the interior of the fan outlet manifold will be by means of two (2) 24” x 72” 

quick opening access doors located on either side of the manifold.

7.0 Painting:

All exterior surfaces of the baghouse and all related cladding, ductwork, silos, and other 

items supplied shall be painted a color of gray, to be matched by the Vendor to a color 

sample that will be provided by the Owner. No paint used shall contain lead. 

Inlet manifold, modules and dust hoppers shall be shop painted on the exterior with an 

approved heat resistant aluminum paint capable of withstanding 550°F and be 3.0 mils 

minimum dry film thickness. No internal surfaces are painted.

Exposed Structural Steel: All exposed structural steel shall be cleaned in accordance 

with Structural Steel Painting Council (SSPC) Specification SP-6. All surfaces will be 

sprayed with one (1) coat of red oxide primer, not to exceed 3 mils dry film thickness. 

After complete drying, all surfaces will then be painted with a finish coat of ICI Devoe 

Devran 224HS paint. Thickness of top coat not to exceed 1.5 mils DFT. Total dry paint 

film thickness to be 4.5 mils or less. Final or top coat to be readily available grey color 

mutually agreed upon by MikroPul and Eramet.

Internal Structural Steel: Structural steel that is not exposed to the elements or is 

protected by dust building siding will be cleaned in accordance with SSPC SP-3. All 

surfaces will receive one (1) coat of standard red oxide primer, thickness not to exceed 3 

mils DFT.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 26 of 27

Baghouse Housing, Plenums, Poppet Boxes and Hoppers: All external surfaces will be 

cleaned in accordance with SSPC SP-6. All cleaned surfaces will then receive one (1) 

coat of high temperature aluminum paint, 3 mils dry film thickness. This coating is 

designed to withstand continuous exposure to 550° F.

Ductwork and Stack: All external surfaces will be cleaned in accordance with SSPC SP6. All cleaned surfaces will then receive one (1) coat of High Temperature Aluminum 

paint, 3 mils dry film thickness. This coating is designed to withstand continuous 

exposure to 550° F.

Manufacturers’ Supplied Equipment: All motors, compressors, gear reducers, valves, air 

cylinders, rotary air locks, dampers, electric actuators, man doors, conveyors and any 

other items purchased by MikroPul as a separate component or part of a sub-assembly 

will be finished coated per manufacturer’s standards.

Handrails, Ladders, Ladder Cages, Toe Boards: All handrail, ladders, ladder cages and 

toe boards (except for toe boards at bag suspension and cell plate levels within the 

baghouse) will be cleaned per SSPC SP-6 and painted with one (1) coat of OSHA Safety 

Yellow, 1.5 mils DFT.

Other Surfaces: All items fabricated from aluminum, stainless steel or any steel that has 

been galvanized will not be painted.

8.0 Optional Installation Services

furnish all labor, miscellaneous materials, consumables, tools, mobile equipment and 

supervision required for the total turnkey installation of all equipment and materials 

supplied by MikroPul as stated in MikroPul’s “Scope of Supply” and as follows:

• All receiving, unloading and transporting of all equipment and materials to the 

site.

• All mechanical and structural erection.

• Assembly and installation of all equipment.

• Assembly and installation of all duct supports and ductwork.

• Leveling, shimming and furnishing all shims.

• All support towers, bents and access platforms.

• Grout under all structural support steel and equipment bases.

• Installation of all air piping from the boundary limits to all damper actuators and 

magnehelic gauges.

• Set and perform final fan motor alignment.

• Touch up painting.

• All electrical installation and wiring from new baghouse battery limits.

• Lighting as required with distribution panel.
Ferro Alloy Baghouse System – Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262 Page 27 of 27

• Electrical control building.

• Bag leak testing.

• Bag precoating at start-up.

• Baghouse commissioning.

• Demolition of existing scrubber system.

• Site clean-up.

9.0 Purchaser to Furnish

• All foundations, design, excavation, backfill and installation.

• Clean dry compressed air @ 100PSI to baghouse receiver.

• Disposal of excavated material for equipment foundations (dewatering if required). 

• Identification of all site preparation and below ground utilities.

• All fire protection equipment, if required (fire extinguishers). 

• All emission testing.

• Control signals for MikroPul system interface.

• Data highway, if required.

• All approvals, licenses and permits as required for construction including, building. 

permits and environmental regulatory agency permits and approval.

• Supply of any required facility drawings, complete and accurate.

• All local and federal taxes as applicable or tax exemption number if such exists for 

pollution control equipment.

• Water and water piping for spray tower system

• Heat tracing if required

• Adequate lay down area within mutually agreeable distance from baghouse.

• Blasting if required.

• Adequate room for construction trailer within mutually agreeable distance of 

baghouse erection.

• Temporary power for construction and for trailer.

• Compressed air or nitrogen to boundary limits. 

• Main fan wheel trolleys, hoists and spreader beams.

• Agreement of final tie-in plan.

• Supply and installation of communication cables, such as, telephone, modem and 

LAN.

• All Owner costs associated with visits to the contractor’s facilities or the facilities of 

its suppliers.

• All existing structure suitability studies for new loads, etc.

• All building steel changes including roof sheeting, flashing, etc
Ferro Alloy Secondary Ventilation

MikroPul Pittsburgh Proposal 0262-11

August 5, 2011

MikroPul Pittsburgh proposes to supply a new Mikro-Pulsaire Pulse Jet system to treat 

the emissions from Ferro Alloy tap hole, runner, ladle and casting bins ventilation process 

to be located in XXXXXX. The equipment and services proposed will be designed to 

meet the following parameters.

Gas Volume, Design: 150,000 ACFM

Maximum Operating Gas Temperature: 275° F

Normal Operating Gas Temperature: 200° F

Dust Loading (average) Less than 1.0 grains / actual cubic feet 

Outlet Loading requirement: Less than 0.0022 gr/dscf

Number of Modules: Six (6)

Module Cloth Area: 8,456 square feet

Total Cloth Area: 50,736 square feet

Net Cloth Area: 42,280 square feet with Five (5) modules 

filtering

Gross Air : Cloth Ratio: 2.96 : 1

Net Air : Cloth Ratio: 3.55: 1

Dust Filtered: Metal fume

Application: Submerged arc furnace tap hole, runner, ladle 

and casting bins

Pulse cleaning mode: off or on-line

Baghouse Equipment

Six (6) Model 323(6)-16-20 TRH Mikro-Pulsaire top removal walk-in plenum dust 

collector module in a 2 x 3 arrangement. Each module is furnished with the following:

Inlet Design: Patented CascadairTM design distribution inlet device 

is proven to: 

 Provide extended bag life

 Lower pressure drop

 Reduce compressed air consumption

 Dispense air evenly

 Dramatically reduce maintenance and energy 
Ferro Alloy Secondary - Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262-11 Page 2 of 9

 costs

 Reduce dust retention on filters

Filter Bags: (1,938) 6.25 in. dia. x 16 ft. long 

16 oz./(sq. yd.), Density Polyester with PTFE finish on one 

side, triple sewn felt bags. 

STYLE : POLYESTER FELT WITH 

MEMBRANE 

FIBER : POLYESTER 

WEIGHT : NOMINAL 16.0 OPSY 

SCRIM : FIBER SUPPORTED 

PERMEABILITY : 7 - 12 CFM 

MECH TREATMENT : PTFE MEMBRANE APPLIED 

THICKNESS : 0.0550"- 0.0850" 

TENSILE : MINIMUM WARP 75 LBS -

FILL 150 LBS. 

MULLEN : MINIMUM 375 PSI 

SHRINKAGE : MAXIMUM 3 % FOR 2 HRS 

AT 300 DEGREES F.

Retainers: Total 1,938 galvanized carbon steel, one piece construction 

retainers complete with integral venturi consisting of 12 

vertical 1/8 in. dia. wires with horizontal rings spaced on 8 

in. centers. All wires and horizontal rings are welded to the 

inside of the retainer, eliminating bag wear and premature 

filter failure. All retainers have been fully inspected to 

ensure there are no burrs, which can rub against the bags to 

cause leakage.

Assembly to be Snap Band type.

Housing: 3/16 inch carbon steel, welded construction furnished 

complete with design rating of ±20 inches of water for dust 

tight service. The collector housing is fully welded 

eliminating possible dust leakage.
Ferro Alloy Secondary - Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262-11 Page 3 of 9

Hopper: 3/16 inch carbon steel, pyramid type with 60 degree side 

slope furnished complete with one (1) 24-inch squared 

hinged and clamped access door. Hopper supplied with 

flanged discharge for 12-inch valve. Each hopper to have 3-

inch dia. pipe nipple with threaded cap to rod out the hopper 

section above the discharge.

Clean Air Plenum: 3/16 inch steel, welded construction, walk-in plenum type, 

complete with one (1) hinged and clamped access door and

one (1) exhaust connection.

Inlet Manifold: 3/16 inch carbon steel manifold to evenly distribute the dustladen gas to each of the Six (6) modules. The manifold 

features bottom discharge (self-cleaning) design. The 

manifold will be stiffened for ±20 inches of water.

Outlet Manifold: 3/16 inch carbon steel manifold to evenly collect the cleaned 

gas from each of the Six (6) modules. The manifold will be 

stiffened for ±20 inches of water.

Tube Sheet Assembly: 3/16 inch carbon steel, bolted between plenum and housing 

flange, with openings for snap band bag and retainer 

assembly. Holes are on 8-inch center spacing in both 

directions.

Cleaning Assembly: The Mikro-Pulsaire has a rugged air distribution system 

that features thorough cleaning with no internal moving 

parts and an automated self-cleaning system that utilizes 

momentary jets of high-pressure air through a specially 

designed venturi to provide efficient, thorough cleaning. 

Consisting of a carbon steel air supply header, brass 

solenoid valves in NEMA 4 enclosure, MikroPul right angle 

valves, aluminum construction, factory installed to the 

collector plenum section. Specially designed, stiffened 

blowpipes included. 

Pulse Control: By local pulse timer, controlled by PLC, see below. Three 

modes of pulse operation would be available, 1) overall high 

dP; 2) timed sequence and; 3) manual override. Individual 

module pressure drop will be monitored as well as overall 

baghouse pressure drop.
Ferro Alloy Secondary - Scope of Supply August 5, 2011

MikroPul Pittsburgh Proposal 0262-11 Page 4 of 9

Electrical, Process Typical description Main PLC Control Panel consisting of 

the following:

Controls:

• 110vac power supplied to panel by customer

• NEMA 12 enclosure painted RAL 7035

• Siemens S7-315 PLC with 20% spare I/O

• Siemens TP177B, 5.7” color touch screen

• Siemens 1 pole circuit breaker for incoming 110vac 

power

• Receptacle provided for laptop connection

• Terminals, wire duct, wire, etc., as required

Inlet Dampers: Each module is equipped with a fabricated 50-inch dia., 

manually operated butterfly type damper. Open and Close 

limit switch included for each damper. This damper to be 

used during maintenance.

Outlet Dampers: Each module is equipped with a fabricated 50-inch dia., air 

cylinder operated butterfly type damper. This damper is to 

be used for isolation during offline cleaning mode. Open 

and Close limit switch included for each outlet damper.

Module Supports: Structural support steel for local wind, seismic, equipment 

live and dead loads as applicable shall be provided. The 

clearance under the fabric filter hopper flange shall be Six 

(6) feet. Hopper loads for structural design are based upon 

the hoppers being 2/3 full by volume and with a bulk density 

of 70 lbs./cubic foot.

Module Access Platform: A common service platform between rows of modules is 

located at the tubesheet level. The platform is constructed 

from steel bar grating with bar and angle type handrail and 

kick plate is included at each end of the walkway.

Stairs: One (1) 48” wide stairway from grade to the tube sheet 

level. 10” wide bar grating treads with checkered plate 

nosing, bar and rod handrail are also provided.

Ladder: One (1) caged ladder system will be provided from tube 

sheet level to grade. 
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Rotary Valves: Six (6) 10” rotary valves, cast iron construction with vane 

wipers for connection to each pyramid hopper outlet flange. 

Each rotary valve is driven by a 1 HP gear motor.

Painting: All structural steel work and exterior surface of modules 

shall be primed and enamel finish painted (direct to metal) 

in the shop following an SSPC-SP2 and/or SP3 surface 

preparation. 

Instrumentation:

Module Timers Each module includes a clean on demand timer in a NEMA 

4X enclosure. 

Module DP Transmitter: Six (6) differential pressure transmitters are provided for 

remote indication of the module pressure loss as measured 

across the tube sheet The transmitter is a 0-20” W.C. range 

with a 4-20 mA output signal. 

System DP Transmitter: One (1) differential pressure transmitters are provided for 

remote indication of the baghouse pressure loss as measured 

from the inlet plenum to the outlet plenum. The transmitter 

is a 0-20” W.C. range with a 4-20 mA output signal. 

Leak Detection System: The baghouse shall be equipped with Six (6) leak detection 

probes to provide continuous monitoring of each module.

The output from the leak detection system shall be sent to 

the PLC.

Each probe will send a 4-20 mA signal.

Proximity Switches: Proximity switches (zero speed type) to be provided at each 

rotary air valve, Six (6) total.

Limit Switches: Open and Close limit switches are included for each module 

inlet and outlet damper, Twelve (12) total.

Hopper Level Probes: Capacitance type level probes to be provided for each 

hopper, Six (6) total. Model CLSI (or equal) detects the 
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presence or absence of material in contact with the probe by

sensing a change in capacitance.

Thermocouples: One (1) thermocouple with transmitter is provided. 

Manifold Pressure Regulators:Six (6) pressure sensors, one for each module

Compressed Air Pressure Transmitter: One (1) provided

Air Moving Equipment:

Air Moving Equipment and Accessories:

MikroPul will solicited fan quotations from various fan vendors and expects to negotiate 

with all of the bidders before award of a purchase order.

Main ID Fan: One (1) induced draft centrifugal, DWDI (double width, 

double inlet), Arrangement 3, heavy-duty exhaust fan with 

backward curve blades. 

The fan is selected to operate at 150,000 ACFM 

at 200°F and 18 inches of water.

Rated at 150,000 ACFM @ 18” and 200° F

1,200 RPM 

Electric variable position damper actuator (Beck)

Anti friction bearings

Bearing vibration and temperature ready

Inlet and outlet flexible isolation joints

Inlet boxes with louver dampers

Gear coupling half mounted to fan shaft

Drains with caps

Split housing for wheel removal

Clips for insulation to be provided by installation contractor

Main Fan Bearing Each main fan bearing shall be equipped with a vibration

Vibration Sensors: sensor pick-up. The output shall be for monitoring and 

alarm with shutdown on high set point.
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Main Fan Bearing Each main fan bearing shall be equipped with one (1) RTD

Temperature Sensors: sensor with 4 to 20 milliamp output. The output shall be for 

high temperature alarm.

Main Fan Inlet Electric inlet damper actuators shall be provided capable of

Damper Actuators: variable position continuous modulating control with 4 to 

20 ma positioner. Linkage for mounting of the damper 

actuator at grade on a separate pedestal.

(Main Fan Motor): 900 HP 1200 RPM induction motor. The motor will be 

rated for 4160V/3ph/ 60Hz TEAAC operation with a 1.15 

service factor. Motors shall include stator RTDs, bearing 

vibration and temperature sensors, and space heaters.

Ductwork / Hoods / Stack & Installation 

1. Unload, assemble and erect on concrete pads/piers furnished by others, Six (6)

MikroPul Model 323(6)-16-20 TRH Mikro-Pulsaire dust collectors including:

• One (1) lot of structural support steel

• Hoppers

• Clean Air inlet manifold

• Dirty Air Outlet Mainfold

• Tube sheet assemblies

• Walk-in plenums

• Cleaning assemblies

• One (1) Rotary air lock valve for each hopper

• One (1) hopper slide gates for each hopper

• One (1) common access platform

• One (1) caged access ladder

• One (1) access stairway

• Siding girts

• Total of 1,292 filter bags and cages

2. Furnish and install all required piping and shutoff valves to connect Eramet supplied 

compressed air to the Four (4) cleaning systems.

3. Unload, assemble and anchor in place on concrete pads, one (1) 150,000 CFM fan.

4. Design, fabricate and install two (2) Hoods (one approx. 8 ft. x 10 ft. over tap hole and 

one approx. 10 ft. x 20 ft. over ladle) and transition ductwork to form a 36 inch 

diameter trunk. 

• Hoods to be fabricated out of 3/16” A-588 Corten or A-36 mild steel
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• Transition piece Suitably stiffened for required static pressure using mild steel 

angle

• Flanged connections using mild steel angles

• Mild steel structural support towers 

• expansion joint as required

• include positioning dampers in duct prior to each hood (30% to tap hole and

70% to ladle

5. Design, fabricate and install 76 inch diameter ductwork from the transition piece to the 

baghouse, to the fan and from the fan to the stack.

• Duct will be fabricated out of 3/16” A-588 Corten or A-36 mild steel

• Suitably stiffened for required static pressure

• 76 in diameter or sized at approx. 3,800 FPM

• Based on 200 ft straight run to Pulse Jet

• Flanged connections

• Mild steel structural support towers with saddles

• One (1) expansion joint fan inlet box

6. Design, fabricate and install one (1) 7’-0” diameter by approx 65’-0” tall stack 

including:

• Stack shell will be fabricated out 3/8” and 1⁄4” mild steel plate

• Stack base will be fabricated out of 1” mild steel plate with 1” upper support 

ring

• One (1) inlet breechings with stiffeners

• Two (2) 6” diameter test ports

• One (1) 180 degree access platform

• Caged access ladders with intermediate rest platforms up to 180 degree test 

port access platform

• Expansion joints from fan outlet to the stack inlet breeching

9. Leak test filter bags.

10. Precoat filter bags.

11. Start up assistance.

12. Structural steel support towers, saddles and stack will receive one shop coat of 

industrial enamel.

13. 4 inch mineral wool with aluminum cladding Insulation for main ID fan to reduce 

noise levels
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Purchaser to Furnish

• Any required taxes.

• Means of cooling the gas to a maximum of 275°F prior to the MikroPul interface.

• All duct work not mentioned above

• Fire protection or explosion suppression equipment if required

• Thermal or sound insulation if required.

• Electrical service for all MikroPul supplied equipment.

• Means of collecting dust from Rotary airlock outlet.

• Foundations.

• MCC.

• Lighting.

• All motor starters.

• All building permits and licenses.

• FAA approval for stack and stack aviation lights if required.

• Tax Exempt Certificate at time of order placement.

• Disposal of all removed materials from the plant property if required.

• Stack sampling and testing if required.