Bilfinger Water Technologies

______

JOHNSON INDUSTRIAL SCREENS

2
JOHNSON SCREENS:
AN OVERVIEW
INNOVATIVE DESIGN
______
Bilfingers brand of Johnson Screens specialises in
the design and manufacture of stainless steel filter
elements for liquid/solid and gas/solid separation.
Our screens are known for great strength, long
service life and a very high level of adaptability for
high-efficiency liquid/solid separation.
Johnsons screens are made by welding vee-shaped
wire on support rods, creating slots which enlarge
inwardly, meeting the most demanding standards
for ruggedness, durability, consistency and slot
openings. The vee-shaped opening allows only two
contact points with the particles, thus preventing
any risk of clogging.
CUSTOM DESIGNED AND ENGINEERED
Each project is designed to ensure complete
satisfaction. We provide guidance and support from
project conception to completion.
LONGER LASTING
Johnsons manufacturing standards are the most
stringent in the industry. Featuring the Vee-Wire
technology, the screens are extremely durable and
have high resistance to abrasion, corrosion and
impact damage.
LOWER MAINTENANCE
The rugged construction and high quality of the
materials produce a product that lasts longer and
requires less maintenance.
LESS COSTLY
Superior operating efficiency, reduced maintenance
needs and extended service life combine to decrease
the cost of Johnsons screens to plant operators.
MANY CONSTRUCTION OPTIONS
Johnsons screen surfaces can be used:
For direct screening
As filter media support (sand bed, activated
carbon, resins, catalysts)
Screens are available in slot opening from 25 m
up to 25 mm. Most common materials used are the
300 series stainless steel, but many exotic alloys are
available to suit specific applications.
Screens are available in a variety of shapes to suit
customer needs:
Cylinders
Flat or curved panels
Cones
Any form specific to a given application
The flexibility of the process allows the
manufacture of custom made screens for all types of
applications: new plant, expansions or upgrades.
3
 A HIGHLY TECHNICAL PRODUCT MANY AREAS OF SCREEN APPLICATION
______ ______

The design and manufacturing characteristics of Johnsons The strength, precision and design flexibility that characterise
screen surfaces provide the following advantages: our screens makes them the choice in a broad range of
industries and applications.
Non-clogging surface
Large open area MARKET/INDUSTRY
Low pressure drop Water and waste water
Hydraulic efficiency Pulp and paper
High flow rates Chemical
Mechanical strength Petrochemical
Abrasion-resistant Water supply
Easy cleaning Mineral and aggregate processing
Plastics extrusion
Machine coolant filtration
Architectural applications

4
If your process involves any aspect of fluid/solid separation, QUALITY
we have the products and experience to help you achieve ______
maximum efficiency and effectiveness.
The Johnson Screens brand has been delivering high quality
APPLICATIONS screens to various industries for more than a century; and
Separating though technology has changed, our commitment to quality
Filtering products and services has not.
Media retention
Sizing Bilfinger is an ISO-certified company; each product is subject to
Dewatering a procedure of self-inspection by each operator throughout the
Classifying manufacturing process. A final inspection guarantees delivery
Straining of a product that fully meets the users technical specification.
Drying Bilfinger can provide the following documents upon request:
Water intake
Fish diversions Quality plan
Collection Manufacturing plan and production schedule
Process qualification record (PQR)
Welding procedure specification (WPS)
Welder performance qualification (WQR)
In-house inspection reports / material certificates
Chemical and/or mechanical analysis certificates

5
 CYLINDRICAL SCREEN FOR OUTSIDE
INSIDE FILTRATION

STANDARD EXTERNAL AXIAL WIRE CHANNEL ROD

______ (re-rolled) CONSTRUCTION
______ ______
External circumferential wire and
axial internal support rods. External axial wire with internal Perforated U-section channels
circumferential support rods. replace the internal support
Benefits: rods. When the filter is used as a
Economical Benefits: collector, flow is outside-in. When
Suitable for most applications Facilitates cleaning with an it is used as a distributor, flow is
Precision openings external axial-movement inside-out.
scraper
Products: Benefits:
Filter cartridges Products: Optimised collection and
Candle filters Automatic filters distribution
01
Header laterals Replaces perforated inner tube
Rotating drum screens
Nozzles Applications:
Resin traps Potable water treatment
Ion exchange
Oil refining processes

6
CYLINDRICAL SCREEN FOR INSIDE
OUTSIDE FILTRATION

INVERTED INTERNAL AXIAL WIRE INTERNAL CIRCUMFERENTIAL

______ (wire-base) WIRE (re-rolled)

External circumferential inverted Internal axial wire with external Internal circumferential wire with
wire and axial internal support circumferential support rods. external axial support rods.
rods.
Benefits: Benefits:
Benefits: Smooth internal screen surface Smooth internal filter surface
Economical Facilitates cleaning with an Custom inner diameter
internal axial-movement
Applications: scraper Products:
Inside-out flow The flow moves across the wire Screw press
edges for effective dewatering

Products:
Trommel screens with internal
feed
Systems with an internal rotor
or screw
Dewatering systems
Baskets
Automatic filters

7
 PRODUCTS

FLAT SCREENS CANDLE FILTERS

______ ______

Bilfinger offers a variety of flat screens The filtration capacity can be modified easily
for the malting and brewing industries. by varying the number of candle filters to
These Johnson Screens Vee-Wire screens are obtain the required filter area. Johnson Screens
ideal for: Vee-Wire candle filters are used widely in the
brewing industry for filtration. Housed inside a
Lauder tubs cylindrical vessel, the filtration capacity can be
Germination modified easily by varying the number of candle
Kilning filters to obtain the required filter area. Features
Ultra filtration include:
Steeping
Malt extraction Small diameter usually less than 50 mm
Substantial length usually greater than 1,000
Used in the kilning, germination and drying mm
phases of the malting process, Johnson Screens Very fine openings: 25 to 150 m, according to
malting bed screens are the ideal choice for the application
malting floors and other screening needs in the IMAGE 02
malting process.

These screen panels can be designed to

minimise dead spots in the malting floor, over
supports or other structures, to further improve
the overall process. In between malting batches,
the screens are very easy to clean, reducing
contamination during the process.
IMAGE 01

01 02

8
 SUPPORT GRIDS
______
The support grid system is available in an
assortment of framing options and designs - as
a one-piece construction or in multiple sections
for on-site assembly and ease of retrofitting
through existing manways. Because of their
strength, durability and flow characteristics, our
support grids are widely used in hydrotreaters,
desulfurizers, molecular sieves, gas sweeteners,
ion exchangers and other absorption systems.
Benefits
Self-supporting structure
Exceptional resistance to collapsing or
buckling, even in operations where screens
must withstand extremely high loads
More effective open area than grids using
wire mesh or grating
Smooth surface of the screens reduces
abrasion of media
Features
Slot size can be designed for direct media
retention
Grids can be supplied with support beams,
rope packing, bolting and all necessary
accessories
IMAGE 03
03
OUTLET BASKETS
______
A large range of industries use cartridges.
Rugged, precise and easy to clean, these filter
elements are suitable for all industrial processes.
They can be used for:
Conventional filtration, outside-in
Reverse filtration, inside-out
The use of extremely fine wire maximises the
open area. This process is all the more true for
slots smaller than 100 microns.
The following types of fittings can be welded
to allow incorporation of cartridges into any
process:
Collars
Flanges
BSP or NPT threaded end fittings
Machined rings for fittings with O-rings or
flat baskets
Other fittings
IMAGE 04
04
9
10
JOHNSON SCREENS
CENTRIFUGE BASKETS
CONTINUOUS CENTRIFUGE BASKETS
- STARCH PROCESSING
______

Bilfingers Johnson Screens starch baskets are custom made to fit into any existing or new
centrifuge application. They improve starch refining by providing accurate and customised slot
sizes, specific to your needs. Features of this basket include:

Increased fibre dewatering compared to nickel screens

Extended wear life
Custom manufactured to each centrifuge design
Variable slot openings from 20 m and up
Fine Johnson Screens Vee-Wire construction prevents clogging
Capable of withstanding high backwash pressures

CONTINUOUS CENTRIFUGE BASKETS

- SUGAR PROCESSING
______

Johnson Screens patented fine Vee-Wire continuous centrifuge basket is guaranteed to provide a
high mechanical strength, a precise slot opening and a larger percentage of open area, increasing the
amount of sugar crystal recovery.

The self-supporting structure of the basket is designed and engineered to withstand the high
stresses and load conditions of the sugar industry. Features of this basket include:

Replaces electroformed and laser screens

Variable slot openings from 20 m and up
Long lasting, fewer change-outs
High resistance to abrasion
Fast and easy installation
Low maintenance, easy to clean

11
 PRODUCTS

NOZZLES SCREW PRESSES & SCREW PRESS BASKETS

Benefits
______ ______ P revents expensive resin/media loss into
piping distribution system
Protects
Nozzles are used in liquid/solid or gas/Bilfingers unique downstream
modular pumping
design drainer screw press
solid separation. Their design and quantity equipment
offers a single drive solution for conveying, washing,
will vary depending on application and dewatering and Vpressing
isibility of minor resin/media
solids for losses
the removal of in
customer-flow requirements. Nozzles allow prevention of major equipment
free water. This screw press has separate washing and failure
a more effective use of the treatment media.
dewatering zones and reduces water content of the solids
Features
up to four times.
Common applications include: Continuous slot design, allowing traps
to capture
Collectors and distributors installed Bilfinger manufactures media
screw particles
press baskets ofthat
anyare
size,
uniformly across a plate or a header custom designed providing
to fit intosufficient
any make open
andarea to of
model letscrew
lateral arrangement press. process flow move smoothly
Demineralizers, water softeners and in Stainless steel construction (other alloys
pressure and gravity sand filters can be includes
The variety of baskets used depending on pressure
high strength, Johnsonand
temperature)
Screens Vee-Wire and drilled hole slotted designs,
Benefits which provide increased
Various options for sizes,
open area, shapes
enhanced and
fibre
Economical design connections,
retention and improved depending
effluent clarity. on process flow
Non-plugging design IMAGE 05 characteristics
High open area Designed for full system pressure
Increased strength & corrosion resistance IMAGE 07

120 SIEVE BEND SCREENS

Features ______ SCREEN LATERAL SYSTEMS
Standard diameter: 50 mm ______
Johnson
Typical slot opening ranging from 0.2 mm Screens 120 sieve bend screens are used in
to 0.5 mm These
static sieves for assemblies
either dewateringconsist of a series ofAs
or classification.
Threaded end fittings or L bolts screen
the slurry flows overlaterals connected
the inclined screentosurface,
either amade
central
of
Primarily made of stainless steel; wires which are header pipe or a hub.
perpendicular Theya are
to flow, designed
layer of slurryfor
is
sliced away. effective media retention in a wide range of
however, special spherical nozzles made
from ABS or Kynar are also available applications, including ion exchangers, clay
IMAGE 05 Made from our and sand filtration
patented Johnsonapplications and carbon
Screens Vee-Wire
towers.
screens, the 120 sieve bend screens can provide up to 50
RESIN TRAPS percent more open area because of our greater range of
______ narrower wireBenefits
profiles.

A resin trap is a safety device used on the The design allows

Considering manual-handling a uniformBilfinger
restrictions, collection
overflow lines of ion exchange units, high- or distribution
developed an innovative flow of
split-sieve a gas orThe
concept. liquid
design
and a simple, through
purity water systems, activated carbonoffers economical benefit by reducing thedead
treatment media without
media filters. zones
physical size and also the screen weight.
The system can accommodate a wide
In many systems, a valve failure can allow variety
Features of the 120 of vessel
sieve sizes and
bend screen shapes with
include:
media to escape from the treatment vessel. side, centre, top or bottom inlet piping
The assemblies
Not only is the loss of expensive media Reduced equipment can be designed
and installation costs to
significant, but damage can easily occur to accommodate
Low maintenance costs flow in any direction
downstream pumping equipment. Better flow rate and finer fibre removal
Wide range of applications
Johnsons resin traps, placed inline, provide
Longer lifetime
positive protection. The traps can be Slot sizes range from 25 m to 10 mm
designed to capture media particles of any
Typically made with 300 series stainless steel
size. IMAGE 07

12
Features
Lateral spacing, length, diameter and slot opening
sizes are based on individual system needs: slot
size 0.05 mm and up in 0.01 mm increments, and
diameter from 20 mm up
Assemblies are typically made with type 304SS,
316LSS or other exotic alloys
Connections of the laterals can be threaded fittings,
couplings or flanges
IMAGE 06
through the system. The slurry is gravity fed to the
head box and then flows to the screen. The solids
retained from the screen gather for disposal or reuse.
These easy-to-install gravity screens feature low
operating and maintenance costs. The Bilfinger
team of engineers can customise according to client
specifications.
IMAGE 08

FRACTAL COLLECTORS & DISTRIBUTORS

______

Johnson Screens gravity screens are typically

applied to make coarse separations ahead of
additional processing systems. The system uses a
Johnson Screens Vee-Wire dewatering screen
to retain the solids while allowing effluent to run

05 06

07 08

13
 PRODUCTS

120 SIEVE BEND SCREENS

______

Johnson Screens 120 sieve bend has a greater screening

capacity than a flat screen due to forces exerted as material flows
against the curved surface. This curved profile wire screen is
mounted in a frame with the screen openings perpendicular to 09
the flow.

In a typical feed situation, the leading edge of the wedge wire

removes the water and fine particles through the screen up to
the cut point size, as the oversized particles move across the top
of the screen.

Separation size is considerably smaller than screen openings,

usually about one-half the opening size.

Sieve bend screens are ideal for sizing and dewatering

applications in liquid/solid separation situations. It is
extensively used for fine fibre removal in the starch industry. It
also is used in other industries such as food processing, waste
water cleanup and corn wet milling.

Features of the Johnson Screens 120 sieve bend screen include:

Reduced equipment and installation costs

12
Low maintenance costs
Better flow rate and finer fibre removal
Wide range of applications
Longer lifetime
Slot sizes range from 25 m to 10 mm
Typically made with 300 series stainless steel
IMAGE 07

CYLINDRICAL BASKETS
______

Cylindrical baskets can be designed for a flow from out to in

(standard construction) or from in to out (re-rolled construction).
They screens are adapted for self-cleaning filters or screw press
filters and can be cleaned with static scrapers.

Benefits
Self cleaning surface
High open area
Strong construction

14
 Features
Dimensions adaptable to any specific needs
Large range of constructions (wires, rods)
All slot sizes from 25m
Flanges and reinforcement rings available depending on the
application
10 IMAGE 12

PRESSURE SCREENS
______

Pressure screens are mainly used for the stock preparation in the
pulp and paper industry. They can be used for any application
regarding fibre or fine grain filtration.

Benefits
The continuous slot gives a greater performance thanks to a
higher open area

Features
Specific, contoured wire shape
Diameters from 200 mm to 1,500 mm
Increased screening efficiency
Special surface chroming process allows for less frequent cylinder
replacement

11
SCREW PRESS
______

For dewatering using a screw press, Bilfinger can provide a screen

designed to meet your exact specifications. Our high-strength design
can withstand the rugged operation while providing an accurate
slot width and maximising open area to maximise dewatering. For
use in numerous industrial designs. Abrasion resistant options are
available.

Benefits
High-strength design
High open area

Features
Accurate slot width
Custom designed to fit any application
IMAGE 13

15
 TECHNICAL DATA
STANDARD WELDING CONSTRUCTION
______
Corner Wire
Bilfingers standard welded construction uses resistance-welding Radius Width
in a continuous elliptical motion to join the wire and rods. The Slot
resistance welds the continuous length of wire to the rods as it
Relief
circulates. Wire
Angle Screen
Height
Weld Penetration Height
Screens can be made in various formations, including cylindrical,
flat, or curved. Any variation of wire and rod sizes as well as slot Support Rod
Height
opening can be chosen to develop the exact screen of your choice.
Screens are available in slot opening from 25 m up to 25 mm. Most
common materials used are 300 series stainless steel, but many exotic alloys are available.

WIRE AND RODS INFORMATION

______

A wide range of wire and rod shapes make it possible to achieve the optimum balance of strength, open area, abrasion resistance
and dewatering/separation efficiency.

JOHNSON SCREENS ROUND AND STRIP SUPPORT RODS

Round rods are available in diameters ranging from 3.2 mm to 12.7 mm. Strip rods are available in widths
from 1.8 mm to 4.8 mm and heights ranging from 9.5 mm to 50.8 mm.

16

16
COMMON JOHNSON SCREENS SHAPED
SUPPORT RODS
Our shaped support rods range in widths
from 0.7 mm to 3.8 mm and heights ranging
from 2.6 mm to 3.0 mm.

63 Q25 93 XJR 156 SR250 SR475

OPEN AREA CALCULATIONS

To calculate the open area of a certain screen, use the simple formula provided:

Open area (%) = Slot size * 100

Slot size + Wire width

JOHNSON SCREENS VEE-WIRE PROFILES

Bilfingers Johnson Screens
Vee-Wire profile wires range in
20 30
widths from 0.5 mm to 5.0 mm and
47
heights ranging from 1.0 mm to 63 93
9.0 mm. Other wire shapes are also
69
available.
118
130

191

17

17
 EXCEPTIONAL PRODUCTS,
EXCEPTIONAL SERVICE
FIELD SERVICE
______

Bilfinger offers a complete field service activity with a team of specialised and experienced
supervisors available for various interventions like:

Full installation
On-site repairs
Technical assistance or expertise
Work supervision
Inspection

Flexibility and expertise allow us to propose this extended scope of services under tailor-made
contract conditions in order to better serve our clients requirements.

Our experienced welder/fabricators team is available for onsite installation, repairs and screen
replacement for emergency situations or scheduled as needed.

Able to evaluate the condition of screens and make recommendations as to the best course of
action, our field service team will be there to allow the screens to operate at maximum capacity.
Whether cleaning, making minor or major repairs, or doing a complete replacement of screens, our
technicians are equipped with all the tools, equipment and experience needed to provide the best
field service available.

Our experienced technicians are also available for supervision of installations and on-site repairs.

18
19
Bilfinger Water Technologies

General Industrial Business Unit

Australia
Phone +61 7 3867 5555
Fax +61 7 3867 5566
asiapacific.water@bilfinger.com

www.water.bilfinger.com

Quality
ISO 9001

Copyright 2014 All rights reserved to Bilfinger Water Technologies Pty Ltd 01 _1013.00