WET SCREENING MACHINE M MOTOR Issued 15 Nov 16
Maintenance & Operation Manual
DISCLAIMER Derrick Corporation has taken care to ensure that all of its maintenance and operation manuals are accurate. However, we offer no guarantees or warranties in this regard. Our manuals are provided only as a guide to assist with the maintenance and operation. Derrick Corporation takes no responsibility for any losses, damage, or injuries that may occur as a result of using any of our manuals. It is ultimately the operator’s responsibility to ensure that the operation, repair, and maintenance of equipment complies with all applicable national and local regulations, including safety regulations. THIS MANUAL IS PROVIDED BY DERRICK CORPORATION ON AN “AS IS” BASIS AND DERRICK CORPORATION EXPRESSLY DISCLAIMS ANY AND ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL DERRICK CORPORATION BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, PUNITIVE, OR CONSEQUENTIAL DAMAGES OF ANY KIND WHATSOEVER WITH RESPECT TO THE MANUAL AND EQUIPMENT.
Derrick Corporation 590 Duke Road Buffalo, New York 14225 Phone: 716.683.9010 Fax: 716.683.4991 www.derrick.com
UNIT NUMBER IS KEY TO DERRICK SERVICE All inquiries to Derrick must include the equipment unit number. The stainless steel unit number tag attached to each piece of Derrick equipment is your key to efficient service and support.
Typical Derrick Unit Number This unique number gives vital information to Service personnel who use it to identify the correct parts when filling orders, provide accurate responses to service questions, track documentation, and trace the equipment’s history or configuration. In short, the unit number provides the critical information needed to ensure that Derrick customers receive the best possible service. The unit number consists of a two-character alphabetic prefix that identifies the equipment type and a series of numeric characters that signify the sequence of the machine’s manufacture. For example, unit number MA000001 would be the first screening machine manufactured by Derrick. Alphabetic prefixes currently in use are: MA - Screening Machine DI - Desilter DG - Degasser AG - Mud Agitator CF - Centrifuge DA - Desander To ensure that it will remain intact over many years of rigorous service, the heavy-gage tag is riveted to a structural member such as the shaker support structure. It is not to be confused with any other identifier on the machine such as a vibrator motor serial number. For convenient availability, the unit number is also recorded in the Operation and Maintenance manual shipped with the equipment. When contacting Derrick for any equipment question or need, always have the unit number in your possession. It’s the best way to get the most efficient service from our dedicated Service and Engineering personnel.
NAVIGATING THIS ELECTRONIC MANUAL In this electronic manual, all sections listed in the CONTENTS are hyperlinked to the corresponding text. Use the following instructions to quickly locate any information: 1. To view any section, display the CONTENTS page, move the cursor to the desired section title, and click on the title. 2. When finished viewing the section, press Alt + to return to the CONTENTS page. If desired to view the same section again, press Alt + or click on the title. 3. To jump to any page in the manual from another location, press Shift + Ctrl + N and enter the desired sequential page number (shown in the upper left corner of the screen). To return to the previous location, press Alt + .
To print all or any part of the manual: Blank pages are included to facilitate accurate two-sided printing of the entire manual on a standard office printer. To print any individual section or series of pages, simply enter the PDF page number range at the top of the screen (not the page number at the bottom of each page).
This document contains proprietary information of Derrick Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Derrick Corporation. Continuous improvement is a policy of Derrick Corporation. All instructions and procedures are subject to change without notice.
CONTENTS WET SCREENING MACHINES
Section
Page
1 - Introduction........................................................................................... 1-1
Date 15 Oct 15
Overview ............................................................................................... 1-1 Safety.................................................................................................... 1-2 Equipment Use ..................................................................................... 1-2 Description ............................................................................................ 1-2 Operation .............................................................................................. 1-2 Feeders................................................................................................. 1-3 Product Support .................................................................................... 1-4 2 - Safety..................................................................................................... 2-1
15 Jul 16
Introduction ........................................................................................... 2-1 Warnings ............................................................................................... 2-1 Safety Data Sheets (SDSs) ................................................................... 2-3 3 - Installation............................................................................................. 3-1
15 Sep 16
General ................................................................................................. 3-1 Safety.................................................................................................... 3-1 Installation Sequence ............................................................................ 3-2 Storage ................................................................................................. 3-2 Site Preparation and Clearance Requirements ..................................... 3-2 Equipment Handling .............................................................................. 3-4 Equipment Positioning and Leveling ..................................................... 3-4 Shipping Brackets ................................................................................. 3-5 Spray Bar Installation ............................................................................ 3-7 Feed and Discharge Connections ......................................................... 3-7 Electric Power Connections .................................................................. 3-7 Screen Panels....................................................................................... 3-8 Machine Startup .................................................................................... 3-8 4 - Operating Instructions ......................................................................... 4-1
15 Sep 16
General ................................................................................................. 4-1 Operating Safety ................................................................................... 4-1 Initial Startup ......................................................................................... 4-1 Normal Startup and Operation............................................................... 4-2 Changing Screen Frame Angle ............................................................. 4-2 15 Nov 16
TOC-1
CONTENTS Section
WET SCREENING MACHINES Page
Date
4 - Operating Instructions (Cont’d) Pool Configuration................................................................................. 4-4 Normal Shutdown.................................................................................. 4-4 Emergency Shutdown ........................................................................... 4-4 5 - Maintenance .......................................................................................... 5-1
15 Sep 16
General ................................................................................................. 5-1 Routine Maintenance ............................................................................ 5-1 Screen Frame ....................................................................................... 5-1 Vibratory Motor ..................................................................................... 5-3 6 - Screen System ...................................................................................... 6-1
12 Dec 08
General ................................................................................................. 6-1 Rapid-Change Draw Bolts ..................................................................... 6-1 Screen Panel Replacement................................................................... 6-1 Inspection, Repair, and Parts Replacement .......................................... 6-6 7 - Vibratory Motor Lubrication System ................................................... 7-1
17 Apr 1998
8 - Reference Drawings ............................................................................. 8-1
01 Jul 12
9 - Installation and Maintenance Log........................................................ 9-1
12 Dec 08
TOC-2
15 Nov 16
SECTION 1 - INTRODUCTION WET SCREENING MACHINES
OVERVIEW This manual provides instructions for installing, operating, and maintaining the Derrick wet screening machine (Figure 1-1). As shown, machines are configured in two styles: inclined and non-inclined. Note that the non-inclined machine has provisions for elevating the discharge end. The manual is divided into several sections to assist the user in readily accessing desired information. Personnel responsible for transporting, installing, commissioning, operating, adjusting, or maintaining this equipment should be required to read and understand the instructions in this manual. One copy of this manual should be available and accessible at the equipment location.
Figure 1-1. Typical Derrick Wet Screening Machines
15 Oct 15
1-1
INTRODUCTION
WET SCREENING MACHINES
OVERVIEW (CONT’D) For maximum safety and performance, no additions and/or changes may be made to the equipment without the explicit written permission of Derrick Corporation. Genuine Derrick repair/replacement parts are required.
SAFETY Section 2 of this manual contains relevant safety information relating to both operation and maintenance of this equipment. Be sure this information is read and understood by all operating and maintenance personnel.
SOUND EMISSION Hearing protection is recommended when working on or near the shaker. Based on measurements taken for technically comparable machinery, the machine emits the following airborne sound level: A-Weighted Machine Surface-Averaged Sound Pressure Level at 1m = 74 ±4 dBA
EQUIPMENT USE The wet screening machine is designed expressly for separating fine particles from the feed slurry. Derrick Corporation does not authorize any other use of this equipment. Intended usage of the equipment includes compliance with the operating, maintenance, and safety procedures included in this manual.
DESCRIPTION The wet screening machine hopper is designed to meet customer process requirements, having the size and location of discharge flanges determined by customer specifications. Discharge flanges are generally provided for undersize and oversize solids. Screen panels are installed on the bed of the screen frame and secured by the adjustable screen tensioning system. A combination of vertical supports and cross supports provide firm support and a curved bed for the screen panels. The curvature facilitates proper screen tensioning, provides efficient solids separation and ensuring long life for the screen panels. To maximize and transfer G-forces directly to the screens, the vibrator motor is attached directly to the screen frame over the center of the screening bed. Float mounts isolate the vibratory motion of the screen frame from the support frame. Screening beds are slightly crowned to allow proper tensioning of the screens. The support frame is a welded steel channel structure containing mounting provisions for the screen frame, electrical junction box, and hopper. The machine’s inclination, designed in accordance with customer specifications, is established by the support frame. Channel sections are welded to the angled frame to provide horizontal mounting surfaces for the inclined machine. The feeder distributes the process material evenly across the screen panels. To meet the customer’s process requirements, Derrick offers different feeder configurations. Typical feeders are described and shown later in this section.
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WET SCREENING MACHINES
INTRODUCTION
OPERATION The feed slurry is introduced into the machine through the feeder inlet flange. The feeder distributes process material evenly across the entire width of the screen frame. Undersize particles are separated by the screen panels and fall into the discharge hopper(s), while coarse particles fall off the end of the screen frame into the oversize chute. Depending on customer requirements, the wet screening machine may be designed for either separating a single particle size or to separate small and mid-size particles from the slurry. Repulp machines have a replaceable rubber-lined re-pulp tray and spray bar after each screen section. The spray bars continually dispense water into the re-pulp trays to add free water to the screening operation (Figure 1-2). This free water facilitates separation of the undersize material, allowing it to pass through the screen surface unhindered, thereby increasing the screening efficiency. By utilizing the transitional area between the two screen panels for the re-pulp process, screening efficiency is increased without adding significant length to the machine.
Figure 1-2. Re-Pulp Tray Operation
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1-3
INTRODUCTION
WET SCREENING MACHINES
FEEDERS The feeder distributes the process slurry evenly across the screen panels. Feeders available for the equipment are designed in accordance with customer specifications. Therefore, different configurations are used in various process applications. Typical feeders are described and shown below.
MS Feeder Multiple screen (MS) feeders are best suited to coarse particle separation applications. Process material enters the feeder through a fan-shaped nozzle that flattens and spreads the stream across the width of the feeder housing. The splash plate reduces the material’s velocity as it descends toward the discharge opening. A rubber curtain at the feeder outlet are the final stage in smoothing and evenly distributing the material as it flows onto the screen bed. The interior surfaces of the feeder box and inlet are completely lined with rubber to reduce wear. A breaker box may also be utilized on the feeder to reduce the velocity of the inlet flow before entering the feeder.
Weir Feeder The weir feeder is divided into inlet and outlet tanks. This design allows the inlet slurry to rise in the inlet tank until sufficiently high to overflow into the outlet section. Slurry is evenly distributed across the screen frame, as slurry flows uniformly over the weir. Pipe targets are provided on both sides and the rear of the feeder for locating the customer feed connection. A clean-out plug is provided at the bottom of the inlet tank to facilitate removal of accumulated solids.
PRODUCT SUPPORT Derrick Corporation offers 24-hour-per-day, 7-day-per-week product support for parts and service. The following table lists parts and service contact information: Location
Telephone*
Fax
E-Mail
Service Manager
716.683.9010
716.683.4991
Director - Service Operations
[email protected] [email protected]
Technical Service
716.683.9010
716.683.4991
[email protected]
Parts Orders
716.683.9010
716.686.0677
[email protected]
* Toll-Free North America - 1.800.990.4362
1-4
15 Oct 15
SECTION 2 - SAFETY WET SCREENING MACHINES
INTRODUCTION This section contains a summary of WARNINGS used in this manual and a list of safety data sheets (SDSs) applicable to the equipment. The wet screening machine has been designed to perform the stated functions safely.
WARNINGS All persons responsible for operation and maintenance of this equipment must read and understand all safety information in this manual prior to operating and/or maintaining the equipment. The safety warnings listed below are included in applicable procedures throughout this manual.
Work Area WARNING! ALWAYS BE AWARE OF WORK AREA HAZARDS TO PROTECT AGAINST SLIPS, TRIPS, AND FALLS WHEN WORKING ON OR NEAR THIS EQUIPMENT. WARNING! LOUD NOISE! WEAR HEARING PROTECTION AT ALL TIMES WHEN WORKING ON OR NEAR THIS EQUIPMENT. WARNING! VISION HAZARD! SAFETY GLASSES MUST BE WORN AT ALL TIMES WHEN WORKING ON OR NEAR THIS EQIPMENT TO PREVENT SERIOUS EYE INJURY OR PERMANENT LOSS OF VISION.
Electrical Hazards WARNING! TO AVOID SERIOUS PERSONAL INJURY BE SURE EQUIPMENT IS LOCKED OUT, TAGGED OUT, AND DE-ENERGIZED PRIOR TO PERFORMING MAINTENANCE AND/OR ADJUSTMENTS. WARNING! MOTOR MUST BE OPERATED AT THE DESIGNATED SUPPLY VOLTAGE. WARNING! HIGH VOLTAGE MAY BE PRESENT. BE SURE FUSED DISCONNECT SUPPLYING ELECTRIC POWER TO THIS EQUIPMENT IS OPEN. LOCK OUT AND TAG OUT POWER SUPPLY TO PREVENT ACCIDENTAL APPLICATION OF POWER WHILE MAINTENANCE AND/OR ADJUSTMENTS ARE IN PROGRESS. WARNING! ELECTRICAL CONNECTIONS MUST BE MADE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE (NEC) AND ALL APPLICABLE LOCAL CODES. FAILURE TO COMPLY MAY RESULT IN AN UNSAFE CONDITION THAT COULD INJURE PERSONNEL OR DAMAGE EQUIPMENT. ENSURE THAT ALL ELECTRICAL AND CONDUIT CONNECTIONS ARE SECURE.
15 Jul 16
2-1
SAFETY
WET SCREENING MACHINES
Equipment Handling
WARNING! DO NOT REMOVE SHIPPING BRACKETS UNTIL EQUIPMENT HAS BEEN POSITIONED AT FINAL INSTALLATION SITE.
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WET SCREENING MACHINES
SAFETY
Operation WARNING! MOTOR HOUSING BECOMES HOT DURING OPERATION AND MAY CAUSE SEVERE BURNS. DO NOT TOUCH MOTOR HOUSING DURING OR IMMEDIATELY AFTER MOTOR HAS BEEN OPERATING. WARNING! ALL OPERATING AND MAINTENANCE PERSONNEL MUST READ AND UNDERSTAND ALL SAFETY INFORMATION IN THIS MANUAL BEFORE WORKING WITH THE EQUIPMENT.
Maintenance WARNING! HIGH VOLTAGE MAY BE PRESENT. ALWAYS OPEN FUSED DISCONNECT SUPPLYING ELECTRIC POWER TO THE EQUIPMENT, AND LOCK OUT AND TAG OUT POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE AND/OR ADJUSTMENTS OF EQUIPMENT.
Storage WARNING! MOTOR MAY BE DAMAGED BY STORING IN A HIGH HUMIDITY ENVIRONMENT (GREATER THAN 50% RH). OUT-OF-SERVICE MOTOR(S) MUST BE STORED IN A LOW-HUMIDITY ENVIRONMENT.
SAFETY DATA SHEETS (SDSs) Safety Data Sheets (SDSs) advise personnel of the properties and any possible hazards associated with these materials. Emergency first aid procedures, special precautions, emergency telephone number, and other relevant data are contained in the SDSs. These documents are prepared by the product manufacturers, which have sole responsibility for accuracy of the information. The SDSs listed below apply to products used in the manufacture of the Derrick equipment. Only these products or equivalent substitutes may be used in this equipment. Dates shown are current as of the publication date of this manual. The latest SDSs may be obtained from the product manufacturer. DESCRIPTION - WHERE USED
SDS NO. / DATE
Paints and Coatings PPG Dimetcote 302H Green 302F0250 Resin - Top Coat
1302H-5A / 04-11-10
PPG Dimetcote 302H Clear 302G0910 Cure - Top Coat
1302H-B / 01-21-10
PPG AT68HS-5 Green Base Component / Undercoat
AT68HS-5 / 12-26-14
PPG AT68HS-B Hardener Component / Undercoat
AT68HS-B / 03-15-14
PPG AT68HS-P Zinc Powder Component / Undercoat
AT68HS-P / 06-17-14
Sundur Beige Polyester TGIC - Vibrator Motor
P-1609 / 10-30-02
Lubricants and Sealants Exxon Mobil Mobilith SHC-100 - Vibratory Motor Bearings
Mobilith SHC 100 / 03-25-09
Loctite 76764 Anti-Seize Lubricant - Fasteners
76764 / 05-27-09
Hylomar AF Sealant - Electrical Couplings
7631-86-9 / 08-23-00
15 Jul 16
2-3
SECTION 3 - INSTALLATION WET SCREENING MACHINE
GENERAL This section describes the recommended installation procedure for the Derrick wet screening machine. The screening machine is usually shipped fully assembled, requiring no additional assembly.
SAFETY Read and understand ALL safety information presented in this manual before installing and operating this equipment. Refer to Section 2 for a summary of Warnings addressing installation, operation, and maintenance of this equipment. Prior to assembling and installing the equipment, review the equipment handling information in this section. Note particularly the information concerning “lift points” and the use of spreader bars before lifting or moving the equipment. Failure to observe proper equipment handling procedures may result in serious personal injury or death and/or damage to the equipment.
INSTALLATION SEQUENCE Following is the sequence of steps for installing the screening equipment. The sequence presented may vary depending on selected options, the user’s facilities, and previous experience with this type of equipment. 1. Read and understand all safety information in Section 2 before installing and operating this equipment. 2. Position and level equipment at installation site. 3. Remove shipping brackets. 4. Connect facility feed line to feeder. 5. Connect facility discharge lines to undersize and oversize collection flanges. 6. Connect electric power supply to the equipment. 7. Install screen panels. 8. Refer to Section 4 - Operating Instructions for startup and operating instructions.
STORAGE Machine If the machine will not be installed immediately, protect unit as follows: • Cover unit with a UV-resistant tarp or UV-resistant shrink wrap. Install vents when using shrink wrap. • For extended storage, measure insulation resistance of motor windings every 3 months. Resistance must be 1k Ohms minimum per volt of rated voltage. Repeat insulation resistance test before placing equipment in service. Refer to Section 7 for additional motor storage information.
Polyweb Screen Panels Protect Polyweb screen panels as follows: • Store below 100°F (38°C) • Avoid ultraviolet (UV) exposure 15 Sep 16
3-1
INSTALLATION INSTRUCTIONS
WET SCREENING MACHINE
SITE PREPARATION AND CLEARANCE REQUIREMENTS Prior to placement of equipment, verify that electricity is available at the installation site and that feed and discharge lines are provided. Also ensure that clearances around machine are adequate. 1. Provide adequate clearances on all four sides of machine and/or multi-machine installations (Figures 3-1 and 3-2). 2. Confirm that mounting structure is properly positioned and adequate to support the weight of the screening equipment support frame. 3. Check that flange sizes and locations will match the undersize and oversize discharge flanges. 4. Confirm that feed line flange corresponds with the feeder inlet flanges. 5. Verify that electric power supply available at the site agrees with electric power requirements of the equipment.
Figure 3-1. Clearances - Single Screening Machine
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WET SCREENING MACHINE
INSTALLATION INSTRUCTIONS
Figure 3-2. Clearances - Multiple Screening Machines
EQUIPMENT HANDLING Four reinforced lifting lugs are built into the equipment frame to allow attachment of overhead-lifting devices. The lifting arrangement for inclined machines is shown in Figure 3-3, and the non-inclined machine arrangement is shown in Figure 3-4. Lifting points are labeled “LIFT HERE ONLY.” DO NOT attempt to lift the equipment by attaching slings or similar lifting aids to the vibratory motor or other nondesignated portions of the machine. Spreader bars are required for lifting.
15 Sep 16
3-3
INSTALLATION INSTRUCTIONS
WET SCREENING MACHINE
EQUIPMENT HANDLING (CONT’D)
Figure 3-3. Lifting Arrangement - Inclined Wet Screening Machine
3-4
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WET SCREENING MACHINE
INSTALLATION INSTRUCTIONS
Figure 3-4. Lifting Arrangement - Non-Inclined Wet Screening Machine
EQUIPMENT POSITIONING AND LEVELING WARNING! NO MODIFICATIONS TO SCREEN FRAME ARE PERMITTED, AND NO ADDITIONAL PARTS MAY BE BOLTED OR WELDED TO SCREEN FRAME. SCREEN FRAME MUST NOT CONTACT ANY NON-VIBRATING AREAS OF MACHINE. Before installing the screening equipment, ensure that the mounts at the installation site have sufficient capacity to support the weight of the machine. Also, be sure that the machine will not rest on the lines connected to the discharge flanges. To ensure adequate clearance for lines and flanges, check vertical measurements of upper and lower mounts against equipment dimensions on engineering drawing in Section 8. After positioning, the screening machine must be leveled in both directions (Figure 3-5) to provide even distribution of the process material across the screen panels. The placement of levels shown is typical but does not apply to all machines due to the wide variety of possible configurations. The precise location of the levels must be determined during the installation procedure. A 4-foot level is recommended. Non-compressible shims should be used as required to level the machine. 1. Using the four designated lifting lugs on the support frame labeled “LIFT HERE ONLY” carefully hoist and position machine onto the upper and lower mounts at the installation site. 15 Sep 16
3-5
INSTALLATION INSTRUCTIONS
WET SCREENING MACHINE
EQUIPMENT POSITIONING AND LEVELING (CONT’D) 2. During positioning, ensure that the support frame will be properly supported and that the discharge flanges align with the flanges of the facility pipes. 3. After confirming that all required installation conditions have been met, secure support frame to structural supports.
Inclined Screening Machine
Non-Inclined Screening Machine Figure 3-5. Typical Leveling Procedures
SHIPPING BRACKETS Note! Do not discard shipping brackets after removal. These components should be re-installed whenever the machine is moved to prevent movement of the screen frame during transit. After final positioning and leveling of the equipment is completed, remove the PVC plugs (Figure 3-5) that were installed to stabilize the screen frame during transit. The PVC plugs secure the movable 3-6
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WET SCREENING MACHINE
INSTALLATION INSTRUCTIONS
screen frame to the stationary support frame. In addition, for linear motion machines two shipping pins are installed to secure the motor mount in position during transit. The PVC plugs and shipping pins must be re-installed whenever the equipment is moved and must be removed prior to startup and operation of the machine.
Note: Motor mount shipping bracket shown at right is used only on single motor linearmotion machines
Figure 3-5. Shipping Bracket Locations For high visibility, an orange label is applied to the gray plastic PVC plugs. To prevent loss, the two shipping pins (if installed) are attached to the machine by lanyards. Each shipping component is labeled DISCONNECT BEFORE STARTUP. Shipping brackets are installed on both the left and right sides of the machine and may be removed in any desired sequence. Remove shipping brackets as follows: 1. Remove all orange-labeled PVC plugs securing screen frame to support frame. No special removal sequence is required. 2. For single-motor linear-motion machines, unscrew motor shipping pins from inboard motor mount bushings. Withdraw pins from orange motor mount brackets and insert into holders near attachment point of each lanyard assembly. Leave orange motor mount brackets in place between motor bushings for future use when moving machine. Note! For single-motor linear-motion machine, do not remove orange bracket between motor mount bushings. 3. Examine machine to locate all other orange shipping brackets, and remove brackets. 4. Retain all removed shipping brackets and associated attaching hardware for future use. 15 Sep 16
3-7
INSTALLATION INSTRUCTIONS
WET SCREENING MACHINE
SPRAY BAR INSTALLATION The spray bars (optional) are packed separately and must be installed after positioning the equipment. Refer to the general assembly drawing in Section 8 for spray bar installation.
FEED, DISCHARGE, AND WATER CONNECTIONS After the screening machine has been secured at the installation site, connect the feed, discharge, and water lines to the equipment as follows. 1. Connect screening machine feed and discharge flange(s) to the corresponding facility lines. 2. Connect 2” water lines to spray bars (if installed).
ELECTRIC POWER CONNECTIONS WARNING! VIBRATOR MOTOR MUST BE OPERATED AT THE DESIGNATED SUPPLY VOLTAGE. WARNING! HIGH VOLTAGE MAY BE PRESENT. BE SURE FUSED DISCONNECT SUPPLYING ELECTRICAL POWER TO THIS EQUIPMENT IS OPEN. LOCK OUT AND TAG OUT POWER SUPPLY TO PREVENT ACCIDENTAL APPLICATION OF POWER WHILE MAKING ELECTRICAL CONNECTIONS. WARNING! ELECTRICAL CONNECTIONS MUST BE MADE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE (NEC) AND ALL APPLICABLE LOCAL CODES. FAILURE TO COMPLY MAY RESULT IN AN UNSAFE CONDITION THAT COULD INJURE PERSONNEL OR DAMAGE EQUIPMENT. ENSURE THAT ALL ELECTRICAL AND CONDUIT CONNECTIONS ARE SECURE. The machine is factory wired to operate at a single voltage and frequency (either 50 or 60Hz) only. The vibratory motors must be operated at the designated supply voltage and frequency. Refer to the wiring schematic in Section 8 for the machine’s power requirements. The customer-supplied fused disconnect and wiring to the equipment shall be suitably sized and in accordance with national electrical standards and all applicable state and local codes. While electrical maintenance is being performed, the machinery must be locked out and tagged out and in a safe condition. Personnel carrying out maintenance activities must isolate the machinery from its source of energy before intervening to prevent dangerous occurrences such as unexpected startup of the machinery, whether due to machinery faults, action of other persons who may ignore the presence of maintenance personnel, or inadvertent actions of maintenance personnel themselves. Electrical connections should be performed only by trained, qualified personnel familiar with highvoltage applications and knowledgeable of national electrical standards and all other applicable state or local codes for installation of industrial equipment. A customer-supplied fused disconnect is required for the primary power supply. The ground lug on the machine must be connected to earth/electrical ground. Connect the facility electric power supply leads through a starter box to the terminal block inside the equipment junction box (Figure 3-6). Match the lead designations, L1, L2, and L3 to the corresponding designations on the junction box terminal block. Note that the arrangement shown ensures that motors on dual motor machines rotate in opposite directions.
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WET SCREENING MACHINE
INSTALLATION INSTRUCTIONS
Dual Motor
Single Motor Figure 3-6. Junction Box Electrical Connections
15 Sep 16
3-9
INSTALLATION INSTRUCTIONS
WET SCREENING MACHINE
ELECTRIC POWER CONNECTIONS (CONT’D) A fused disconnect primary power supply is required for this equipment. The fused disconnect and interconnecting wiring to the equipment must be suitably sized and in accordance with National Electrical Code (NEC) standards and all other applicable state and local codes. Additional wiring requirements are as follows: 1. The fused disconnect device shall have sufficient interrupting capacity to clear the maximum fault current capability of the power supply system. 2. The GROUND connection in the power supply junction box must be connected to a known ground.
SCREEN PANELS Prior to installing screen panels, remove all packing and shipping materials from the bed of the screen frame(s). Refer to Section 6 for screen installation and tensioning procedures.
MACHINE STARTUP Refer to Section 4 for initial startup and operating procedures for the wet screening machine. WARNING! DO NOT ATTEMPT TO OPERATE MACHINE WITH SHIPPING BRACKETS INSTALLED.
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SECTION 4 - OPERATING INSTRUCTIONS WET SCREENING MACHINES
GENERAL This section includes initial and normal startup and shutdown procedures for the wet screening machine, as well as emergency shutdown of the equipment.
OPERATING SAFETY WARNING! HOT SURFACE! DO NOT TOUCH MOTOR HOUSING DURING OR IMMEDIATELY AFTER OPERATION. WARNING! ALL OPERATING AND MAINTENANCE PERSONNEL MUST READ AND UNDERSTAND ALL SAFETY INFORMATION IN THIS MANUAL BEFORE WORKING WITH THE EQUIPMENT. WARNING! MOVING PARTS! BEFORE STARTING, BE SURE THAT ALL PERSONNEL ARE CLEAR OF EQUIPMENT. WARNING! ALWAYS BE AWARE OF WORK AREA HAZARDS TO PROTECT AGAINST SLIPS, TRIPS, AND FALLS WHEN WORKING ON OR NEAR THIS EQUIPMENT. WARNING! LOUD NOISE! WEAR HEARING PROTECTION AT ALL TIMES WHEN WORKING ON OR NEAR THIS EQUIPMENT. G0013642
Caution! Do Not Attempt To Operate Equipment With Shipping Brackets Installed.
INITIAL STARTUP Use the Initial Startup procedure in Table 4-1 when the wet screening machine is being started for the first time, following parts replacement, or when equipment has been removed from service for an extended period. Table 4-1. Initial Startup Procedure Step
Procedure
1
Confirm that all operators and maintenance personnel have read and understand all operating and safety information in Section 2.
2
Verify that equipment has been installed properly and that services and utilities are available at the installation site.
3
Confirm that no modifications have been made to screen frame, no additional parts have been bolted or welded to screen frame, and screen frame will not contact any non-vibrating areas of machine during operation.
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OPERATING INSTRUCTIONS
WET SCREENING MACHINES
Table 4-1. Initial Startup Procedure Step
Procedure
4
Verify that screen panels have been installed properly.
5
Ensure that all tools, documents, and shipping brackets have been removed, and there are no obstructions to operation.
6
Start machine in accordance with Normal Startup procedure in Table 4-2, below.
NORMAL STARTUP Table 4-2. Normal Startup Procedure Step
Procedure
1
Verify that all personnel are clear of machine before applying electric power to equipment.
2
Close fused disconnect, and apply electric power to the vibratory motor(s). Allow vibratory motor(s) to reach operating temperature (about 5 minutes).
3
Start water flow to spray heads (if installed), and verify operation on all screen panels.
4
Start pump or open valve to introduce flow of material to feeder.
CHANGING SCREEN FRAME ANGLE For machines equipped with the capability of altering the screen frame angle, the screen frame angle may be raised or lowered to adjust the forward progress of the slurry over the screen bed (Figure 4-1). The angle setting is determined by several factors: • Particle size • Concentration of solids in the slurry • Feed rate • Type of slurry • Type of screen • Screen cut point Since the MS feeder is rigidly mounted to the feeder leg, the feeder must be re-positioned if the screen frame angle is to be changed. Machines having weir feeders require only changing the float mount positions at the discharge end to set the desired angle.
Figure 4-1. Screen Frame Pooling Area
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WET SCREENING MACHINES
OPERATING INSTRUCTIONS
Feeder Position If changing the screen frame angle of a machine having an MS feeder, the feeder must be repositioned before setting the discharge end. Mounting holes are provided in the feeder legs for the available feeder mounting options (Figure 4-2). To change the feeder position, proceed as follows:
Figure 4-2. MS Feeder Mounting Positions 1. Turn off feed, and shut down, lock out, and tag out machine. 2. Refer to GA drawing in Section 8 to determine weight of feed end of machine, and attach a hoist capable of supporting the feed end weight to the lifting lugs on both sides of the screen frame. 3. Hoist the feed end sufficiently to remove the weight of the feed end from the float mounts. 4. Remove bolts and washers securing the float mounts to both feeder legs. 5. Using hoist, lift or lower screen frame until the next set of mounting holes aligns with the float mounts. 6. Secure float mounts to feeder legs with bolts and washers removed in step 4, above. 7. Set discharge end to desired angle, as described in the following paragraph.
Discharge End 1. With machine shut down, locked out, and tagged out as described in the preceding paragraph, attach a hoist capable of supporting the weight of the discharge end to the lifting lugs on both sides of the screen frame (Figure 4-3). 2. Hoist the discharge end sufficiently to remove the weight of the discharge end from the float mounts. 3. Remove bolts and washers securing all float mounts to support structure on both sides of the screen frame. 4. Using hoist, position screen frame until desired mounting holes are aligned with the float mounts. 5. Secure float mounts to structure with bolts and washers. Tighten securely. 6. Slowly and carefully lower the hoist until screen frame weight is fully supported by float mounts, and then disconnect and remove hoist.
15 Sep 16
4-3
OPERATING INSTRUCTIONS
WET SCREENING MACHINES
Discharge End (Cont’d)
Figure 4-3. Discharge End Angle Adjustment
Machine With Optional Lifting Mechanism On machines having the optional lifting mechanism, a ratcheting operating handle is used to turn a mechanical jack that raises and lowers the discharge end of the screen frame. The operator may switch from raising to lowering by resetting the spring-loaded pawl so that the jack rotates in the opposite direction. A full 180 degrees of movement is possible in both directions. Moving the handle in one direction turns the jack, while in the opposite direction the jack remains stationary while the handle is moved. Proceed as follows to adjust the screen frame angle: WARNING! BE SURE THAT ALL PERSONNEL ARE CLEAR OF MACHINE BEFORE ADJUSTING ANGLE OF SCREEN BED. 1. Pivot operating handle (Figure 4-4) downward until horizontal, and set mechanical jack ratchet detent to either raise or lower discharge end of screen frame, as desired. 2. Using the operating handle, rotate jack left to raise or right to lower screen frame end to the desired angle. Use stamped markings on the upright shafts to assist in determining angular setting. 3. After reaching desired setting, check that the hitch pin holes in the stationary and movable upright shafts are aligned. Raise or lower screen frame as required to align holes, if necessary, and then insert hitch pins through stationary and movable shaft holes to secure screen frame in position. 4. After inserting hitch pins through stationary and movable shafts, insert hair pins through hitch pins.
4-4
15 Sep 16
WET SCREENING MACHINES
OPERATING INSTRUCTIONS
Figure 4-4. Lifting Mechanism Mechanical Jack Operation
POOL CONFIGURATION The most efficient pool configuration maximizes use of the available screen area. In general, the pool should cover all screen panels except for the discharge screen. Changing the screen frame angle allows the operator to respond to changing conditions and feed rates of the slurry. Suggested changes to an existing screen angle are shown in Figure 4-5. Note that the dark pattern at the left represents the area of the screen panels covered by the pool. The ideal coverage is for the pool to cover half the screen surface. If coverage retreats to halfway on the first screen panel, the screen frame angle may be reduced and/or flow increased. Finally, if the pool covers nearly all of the screen surface, the screen angle may be increased and/or flow decreased to reduce the pooling area. Pool Configuration
Angle Adjustment
Flow Change
Correct screen angle No adjustment required
Decrease screen angle
Increase flow
Increase screen angle
Decrease flow
Figure 4-5. Pool Configuration and Adjustments
15 Sep 16
4-5
OPERATING INSTRUCTIONS
WET SCREENING MACHINES
NORMAL SHUTDOWN The normal shutdown procedure in Table 4-3 shall be followed each time the equipment is shut down for maintenance and/or changing of screen panels. Table 4-3. Normal Shutdown Procedure Step
Procedure
1
Divert or discontinue flow of material to feeder.
2
Allow all oversize and undersize material and liquid to discharge from screen frame.
3
Wash remaining material from surfaces of screen panels and edges of screen panels where they contact sidewalls of screen frame.
4
Shut down electric power to stop vibratory motor(s), and open fused disconnect supplying electric power to the machine.
EMERGENCY SHUTDOWN To immediately stop the machine in case of emergency, open the fused disconnect supplying electric power to the machine.
4-6
15 Sep 16
SECTION 5 - MAINTENANCE WET SCREENING MACHINES
GENERAL Routine maintenance will ensure maximum life and trouble-free operation for your machine. While the maintenance schedule presented in this section is not rigid, modifications should be based on experience with operating the equipment at your facilities. A maintenance log should be kept to help establish a routine maintenance schedule, as well as to monitor and adjust the schedule as necessary throughout the equipment’s life. When establishing a maintenance schedule, consider duty cycle, ambient temperature, and operating environment.
ROUTINE MAINTENANCE Routine maintenance consists of overall inspection and cleaning. Table 5-1 lists the recommended routine maintenance procedures. Table 5-1. Routine Maintenance Action
Frequency
Inspect feed supply connections to feeders for leaks, and tighten connections as required.
Each shift
Inspect undersize and oversize discharge connections for leaks. Tighten connection(s), and/or add silicone sealant to prevent leakage.
Each shift
Remove accumulated process material from all non-vibrating areas of machine. Damage may occur if screen frame contacts this buildup.
Each shift
Check interior of feeder for accumulation of process material or other obstruction. Check for and clear feeder blockages, which may cause excessive splashing and uneven distribution of slurry onto the screen beds.
Weekly
Perform routine maintenance on vibratory motors as described in Section 7 Vibratory Motors.
See Section 7 for frequency
Lubricate mechanical jack assembly (if installed) using Dura-Lith EP, Mobilux EP, or equivalent grease.
Quarterly
15 Sep 16
5-1
MAINTENANCE
WET SCREENING MACHINES
SCREEN FRAME During normal operation, the screen frame and tensioning components accumulate residual process material that should be removed periodically. Refer to Table 5-2 for key inspection and maintenance locations. When replacing stringer protectors, use care to properly trim and install these components. Trim protectors carefully to provide a snug fit against the cross supports but without causing any buckling. After installation confirm that protectors lie flat and no gaps are present between ends of protectors and cross supports. In addition, the float mounts should be inspected and replaced when damage is evident. Since these components isolate the vibratory motion of the screen frame from the stationary parts of the machine, deterioration may occur over time. Table 5-2. Screen Frame Maintenance Action
Frequency
Periodically remove accumulated process material from interior walls and screen frame beds. Excess accumulation increases the load on the float mounts and reduces solids separation capabilities.
Each shift
Inspect float mounts for excessive sag (greater than 1” / 25.4mm) and/or signs of deterioration or damage. If excessive sag is found, clean excess buildup of process material from screen frames to reduce loading on float mounts. If excessive sag remains, or damage is evident, float mounts must be replaced as a pair (top and bottom).
Monthly
Check tension and condition of screen panels. They should be in complete contact with the screen frame beds and should not have holes or other damage that would allow solids to pass through. Replace damaged screen panel(s).
Each shift
Inspect side supports, cross supports, and channel protectors (Figures 5-1 and 5-2) for deterioration or damage. Defective components may permit damage to the screen panels. Refer to appropriate drawing in Section 8 for replacement parts information.
Each screen panel change
Inspect screen tensioning components (refer to Section 6) for signs of deterioration or damage. The screen tensioning components apply tension to the screen panels to securely position them against the bed of the screen frames. Improper screen panel tensioning will reduce the life of the screen panels. Also refer to Section 6 for operation and repair parts.
Each screen panel change
Perform routine maintenance on vibratory motors as described in Section 7 Vibratory Motors.
See Section 7 for frequency
5-2
15 Sep 16
WET SCREENING MACHINES
MAINTENANCE
Dual Motor - Non-Inclined Screen Frame
Single Motor - Inclined Screen Frame Figure 5-1. Screen Frame Inspection and Maintenance - Dual Motor
Figure 5-2. Stringer Protector Wear Patterns - Cross-Sectional View
15 Sep 16
5-3
MAINTENANCE
WET SCREENING MACHINES
REPLACEMENT PARTS Refer to the engineering drawings in Section 8 to identify spare parts. Spares should consist of the components most susceptible to wear; however, all potential part replacements cannot be predicted. The complete spare parts inventory should be based on the user’s experience with similar equipment.
VIBRATORY MOTOR(S) Removal, installation, parts replacement, and troubleshooting procedures for the vibratory motor(s) are included in Section 7.
MECHANICAL JACK (OPTIONAL) The optional mechanical jack requires periodic lubrication and occasional adjustment of the spring plunger. Refer to Routine Maintenance at the beginning of this section for periodic lubrication instructions. If the ratchet action becomes noticeably imprecise or the pawl fails to latch during movement of the jack handle, the spring plunger should be adjusted as follows: 1. Turn adjusting screw (Figure 5-3) clockwise to increase spring tension on plunger. 2. Move operating handle in both directions to confirm proper ratcheting action and pawl engagement during jack rotation. 3. If pawl does not engage jack properly or ratchet action is insufficient, repeat steps 1 and 2.
Figure 5-3. Optional Mechanical Jack Plunger Adjustment
5-4
15 Sep 16
SECTION 6 - SCREEN SYSTEM WET SCREENING MACHINES - RAPID CHANGE DRAW BOLTS
GENERAL This section describes the rapid change draw bolts used to secure screen panels and contains screen panel replacement and maintenance procedures. Installation of the rapid change draw bolts is included to assist personnel in repair and replacement of these components that properly secure the screen panels. Refer to the applicable drawings in Section 8 to determine the component part numbers on your machine.
RAPID CHANGE DRAW BOLTS The rapid change draw bolt assembly allows screen panels to be changed quickly and easily. Several rapid change draw bolt assemblies are used in combination with a draw bar to apply tension to the screen panel (Figure 6-1). The lower edge of the draw bar engages a hook strip on the outside edge of the screen panel. The shaft of the draw bolt passes through the sidewall of the screen frame, and the T-shaped head of the draw bolt is passed through slots in the draw bar and then rotated to secure the drawbar in place on the hook strip. The nut on the outside of the screen frame is then tightened to apply tension to the draw bar and secure the screen panel tightly to the screen frame. Eight rapid change draw bolt assemblies— four per side—are required to secure each 48” x 30” or 36” x 30” screen panel.
Figure 6-1. Rapid Change Draw Bolt Assembly Components
SCREEN PANEL REPLACEMENT Proper screen functioning relies on tight retention and full contact with the screen bed and related components (side supports, cross supports, and channel protectors). This procedure describes the proper method for initial panel installation and replacement of damaged or worn screen panel(s). Screen panels and screen bed components should be inspected in accordance with Section 5 and should be replaced when wear is evident and the screen has become ineffective.
12 Dec 08
6-1
SCREEN SYSTEM - RAPID CHANGE
WET SCREENING MACHINES
Tools Required Two different styles of wrenches (Figure 6-2) may be used to tension, remove, and install the rapid change draw bolt assemblies. Both wrench styles are available from Derrick. The ratchet-type, doubleended box wrench allows the nuts to be loosened or tightened very quickly, while the T-handle wrench with socket is sufficient for these operations.
Ratchet Wrench (P/N PP1116)
T-Handle Wrench (P/N 5925-01)
Figure 6-2. Rapid Change Draw Bolt Assembly Wrenches
Removal 1. Shut down machine in accordance with Section 4, and lock out and tag out equipment. 2. Using appropriate tool or wrench, loosen nuts on all draw bolts on right side of screen frame in the sequence shown in Figure 6-3. Loosen each nut until fully disengaged from upper threads of draw bolt, with nut between the threaded areas of the bolt. Note! Right and left sides of the equipment are determined by standing at the feed end and looking toward the discharge end. 3. Loosen all draw bolts on the left side of the screen frame in the same manner as described in step 2. 4. From inside of screen frame, rotate heads of the draw bolts 90 degrees to the unlocked (vertical) position and remove both draw bars. If this is an initial installation, remove and discard shipping pads from draw bars (Figure 6-4). 3. Remove screen panel(s) from bed of screen frame. 4. Following removal of the screen panel, inspect condition of side supports, cross supports, and stringer protectors (refer to Section 5). Replace worn or damaged components, as required, to ensure that screen bed will provide full and even support for the screen. 5. Thoroughly clean any remaining residue or debris from side and cross supports and from stringer protectors before installing replacement screen panel(s).
Figure 6-3. Draw Bolt Loosening Sequence
6-2
12 Dec 08
WET SCREENING MACHINES
SCREEN SYSTEM - RAPID CHANGE
Figure 6-4. Removing Shipping Pads From Draw Bar
Installation Note that the draw bar for urethane panels has a “U” in the handle. Locating bars provided along the left interior wall of the screen bed ensure that screen panels are centered left to right on the screen bed. Draw bolts are then engaged and tightened in stages, going from left to right side and finishing with final tensioning on the right side. Note! Right and left sides of the equipment are determined by standing at the feed end and looking toward the discharge end. Correct installation of screen panels optimizes screen performance and extends life. To install screen panels, proceed as follows: 1. Before placing screen panel in the screen frame, verify that all components of the screen frame bed are in good condition (refer to Section 5). Replace any worn or damaged components. 2. Place screen panel on bed of screen frame, slide panel into contact with locating bars on left side of screen bed (Figure 6-5), and slide against shoulder of cross support at the feed end of the screen frame (Figure 6-6). Note! To ensure proper tensioning and prevent process material from passing beneath screen, the panel must contact the locating bars on the left side of the screen frame and be pulled rearward against the step on the cross support. 3. Verify that all draw bolts are present and in satisfactory condition. Wire brush threads, if necessary, to remove accumulated residue. Replace any distorted, severely corroded, or otherwise damaged draw bolts as described later in this section. 4. Check that draw bars are straight. Remove any accumulated process material from draw bar edge that engages screen panel hook strip.
12 Dec 08
6-3
SCREEN SYSTEM - RAPID CHANGE
WET SCREENING MACHINES
Installation (Cont’d)
Figure 6-5. Draw Bar Engagement With Hook Strip
Press screen panel against shoulder of cross support at feed end.
Rotate draw bolts to horizontal (locked) position.
Lift draw bar slightly to ensure that screen panel is above side support.
Figure 6-6. Screen Positioning
6-4
12 Dec 08
WET SCREENING MACHINES
SCREEN SYSTEM - RAPID CHANGE
5. Confirm that heads of left side draw bolts are oriented in the vertical (unlocked) position. 6. Position draw bar on left side of screen frame to engage hook strip along top outer edge of screen panel, and pass heads of draw bolts through slots in draw bar. Rotate heads of draw bolts 90 degrees to horizontal (locked) position. 7. Lift draw bar slightly to ensure that screen panel is above side support, and hand-tighten left side draw bolt nuts. 8. Repeat steps 5 through 7 on right side of screen frame. Note! In the following steps the tightening sequence must be followed. Incorrect tightening sequence will cause screen to flutter, resulting in premature wear. 9. Using ratchet or T-handle wrench, tighten the left side draw bolts from outside screen frame in the sequence shown in Figure 6-7. 10. Repeat tightening sequence on right side of screen frame.
Figure 6-7. Draw Bolt Tightening Sequence 11. After tightening all draw bolts, manually verify that screen panel is correctly positioned, properly tensioned, firmly in contact with screen frame bed, and that ribs are straight and aligned with stringer protectors of adjacent screen frame (Figure 6-8). When properly tensioned, exposed threads on all draw bolts should be about equal (usually about three threads), as shown. Re-adjust panel positioning and re-tension as required. WARNING! INCORRECT TIGHTENING WILL CAUSE IMPROPER SCREEN PANEL TENSIONING, RESULTING IN PREMATURE WEAR. BE SURE THAT CORRECT TIGHTENING SEQUENCE IS FOLLOWED.
Check panel tension by lifting at edge.
Check for straight alignment of panel ribs with stringer protectors.
Check for consistent number of exposed threads on all draw bolts.
Figure 6-8. Confirming Proper Screen Panel Installation 12 Dec 08
6-5
SCREEN SYSTEM - RAPID CHANGE
WET SCREENING MACHINES
INSPECTION, REPAIR, AND PARTS REPLACEMENT Rapid change draw bolt assembly components (Figure 6-9) should be replaced if inspection reveals distortion, damaged threads, severe corrosion, or galling. If any mounting holes are elongated, contact the Technical Services department for assistance in making the repair(s). Only rapid change draw bolt assemblies in serviceable condition may be installed as shown in Figure 6-10. Replace any draw bolt assembly that cannot be restored to fully serviceable condition. Draw bars should be inspected for distortion, corrosion, or material buildup. Thoroughly clean draw bars, removing any built-up material on the edge that engages the hook strip on the screen panel. Replace any draw bar that cannot be restored to fully serviceable condition. Rapid change draw bolt assemblies are available in several different material configurations to accommodate a wide variety of fluid applications. Refer to applicable drawings in Section 8 to determine the components of the draw bolt assemblies installed on your machine.
Figure 6-9. Rapid Change Draw Bolt Assembly Components
6-6
12 Dec 08
WET SCREENING MACHINES
SCREEN SYSTEM - RAPID CHANGE
1 - Insert draw bolt through frame from inside.
2 - Install O-ring on bolt.
3 - Push O-ring into counterbore in screen frame.
4 - Apply anti-seize compound to draw bolt threads.
5 - Orient extended washer with counterbored hole toward screen frame, and install on draw bolt.
6 - Push in extended washer fully to seat O-ring.
7 - Install lockwasher on draw bolt.
8 - Install nut on draw bolt.
9 - Install O-ring on unthreaded area of draw bolt.
10 - Using wrench, tighten nut until snug*. * Torque will vary depending on condition of channel protectors and cross and side supports. Figure 6-10. Rapid Change Draw Bolt Assembly Installation
12 Dec 08
6-7
MAINTENANCE AND OPERATING MANUAL DERRICK® AUTOMATIC and REMOTE AUTOMATIC LUBRICATION SYSTEM
Derrick Corporation 590 Duke Road Buffalo, New York 14225 U.S.A. (716) 683-9010 (voice) (716) 683-4991 (facsimile) rev. 4/17/98 (:\Shared\Manuals\Lub-rev2.doc)
Derrick®, Flo-Line®, FLC 2000™, Flo-Line Scalper™, Pyramid®, Sandwich Screens®, DE-1000™, Hi-G™, Vacu-Flo™, GBG™, PMD™, PWP™, SWG™, DC™, DF™, DX™, and GS™, are trademarks of Derrick Corporation. 10/97
Derrick Corporation • 590 Duke Road • Buffalo, New York 14225 • (716) 683-9010
DERRICK® AUTOMATIC & REMOTE AUTOMATIC LUBRICATION SYSTEM
4/98
Table of Contents Section
Page No.
INTRODUCTION: Principle of Operation ........................................................................................................................1 INSTALLATION: Lubrication System Cabinet ............................................................................................................. 2 Hydraulic Tubing ...............................................................................................................................3 Electrical Connections ............................................................................................................ 3, 4 Removing Air from the System ........................................................................................................4-8 OPERATION: Initial Start Up ....................................................................................................................................9-11 Monitoring the System.......................................................................................................................12 Approved Oils for Use in Derrick Vibrating Motors (Doc# PE-S-002) ........................................13 Recommended Oils for Extreme Temperature Duty (Doc# PE-S-002). .......................................14 Oil Testing Data (Doc# RD-S-001) .................................................................................................15 MAINTENANCE: Trouble Shooting................................................................................................................................16-17 Injector Specifications........................................................................................................................18 Adjustments................................................................................................................................................18 APPENDIX: Timer Repair Procedure (if applicable).................................................................................. DRAWINGS
Lubricator Parts List ..................................................................................................... Injector Accessory Kit ...................................................................................................... Injector Illustration & Main Feed Line Hook Up ............................................................ Overall Dimensions - Model 15,55, Remote Standard Non-XP, Remote XP ................ Loop and Main Feed System ............................................................................................ Lubricator Internal Part Description ................................................................................. Derrick Model 15 Lubricator Float Switch Detail ........................................................... Explosion Proof Lubricator Wiring 20A.......................................................................... Derrick Lubricator Timer Float Switch Connections ...................................................... Derrick Lubricator Starter Connections ........................................................................... Recommended Lubricator Interlock................................................................................. Liquid Level Sensor for Derrick Model 55 Lubricator.................................................... Pressure Switch Interface for Derrick Model 15/55 Lubricator ...................................... Injector Priming Instructions ............................................................................................ Dual Motor Injector Accessory Kit .................................................................................. Dual Motor Injector Accessory Kit .................................................................................. Single Injector Assembly w/ Bleeder ............................................................................... Dual Injector Assembly w/ Bleeder.................................................................................. Injector Units and Replacement Parts...............................................................................
11912-00 2640-00 4387-00 4388-00 4389-00 4390-00 5367-00 5486-00-007 5488-00 5489-00-004 5626-00 7043-00 7704-00 8382-00 9451-00 9451-00-003 10908-00 10945-00 13566-00-001
Oilfield Only Explosion Proof Lubricator Timer/Transformer Parts List.................................................. 11555-00
(10) (4) (2) (1) (2) (3) (4) (2) (1) (1) (4) (4) (-) (6) (5) (0)
(3)
rev. 4/17/98 (:\Shared\Manuals\Lub-rev2.doc)
Derrick®, Flo-Line®, FLC 2000™, Flo-Line Scalper™, Pyramid®, Sandwich Screens®, DE-1000™, Hi-G™, Vacu-Flo™, GBG™, PMD™, PWP™, SWG™, DC™, DF™, DX™, and GS™, are trademarks of Derrick Corporation.
Derrick Corporation • 590 Duke Road • Buffalo, New York 14225 • (716) 683-9010
Derrick Automatic & Remote Automatic Lubrication System
1
April 1998
INTRODUCTION
Principle of Operation Derrick automatic lubrication systems are specifically designed to lubricate the bearings of Derrick high frequency vibrating motors. Components include an oil reservoir (either 15 or 55 U.S. gallons), a gear pump driven by a fractional horse power motor, a 5 micron oil filter, a pressure gauge, an electronic timer, and an injector for each motor bearing. Electrical components are contained within either NEMA 4 (weather tight), or NEMA 7 & 9 (explosion proof) enclosures. Lubricating oil is distributed to the bearings through stainless steel tubing and high pressure flexible hose. Injectors operate on a positive displacement principle. When the lubricator timer energizes the motor/pump assembly, the system is pressurized to 850-1200 psi. This state must be held long enough (typically 18 seconds) for a control piston inside the injector to shift, thereby allowing oil to fill a charge cavity. When the pump stops, pressure is relieved allowing the control piston to reset, and permit oil to flow from the charge cavity to a discharge cavity still contained within the injector. As the first step of this process is repeated (pressurization), oil contained in the discharge cavity of the injector is displaced and exits through flexible hose to the vibrator bearing. Gear pump discharge pressure can be viewed on the pressure gauge. This gauge should read 850 to 1200 psi when the pump is running. The pump has an internal pressure relief system that limits discharge pressure to 1200 psi. Derrick offers an optional adjustable pressure sensor for the customer's remote monitoring of the pump discharge pressure. For more information on this system please consult with your Derrick representative. Some lubricator models are equipped with a low level switch in the oil reservoir. This sensor can provide a contact closure for a control room alarm, warning light, or buzzer. The customer is required to supply intrinsically safe components for explosion proof lubricators being used in hazardous areas. For applications where single phase power sources are not available, Derrick offers a transformer unit to convert your three-phase power to a compatible single phase source to power the lubricator. Also, Derrick is willing to offer design options and alternatives, for unique operating conditions which are encountered.
The following pages refer to drawings which are located at the end of this manual.
Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
2
INSTALLATION Lubrication System Cabinet A. Automatic Lubrication System The Derrick Automatic Lubricator is an integral component of the machine. It is completely installed and tested at the factory. B. Remote Automatic Lubrication System The Derrick Remote Lubricator is housed within a steel cabinet, see drawing no. 4388-00 for overall dimensions. The cabinet may be installed as a permanent fixture or a free standing unit. Some models have four 1 1/2” NPT couplings welded to the bottom which enable threaded pipe to be attached for legs if necessary (legs not included). It is recommended that placement of the cabinet meet the following requirements: 1.
The unit should either be located in a non-vibrating environment or mounted in a manner which isolates the unit from vibration, this prevents damage to sensitive internal electrical components.
2.
Locate centrally with respect to the location(s) of the vibrating screens and within the normal traffic pattern of operating personnel, not "out of sight" (personnel must be able to observe any abnormal condition).
3.
Lubrication points should not be located more than 100 feet horizontally or 50 feet vertically from the cabinet. Lubricator should be located below the unit being lubricated.
4.
Mobile equipment will not accidentally damage the cabinet or the hydraulic tubing which distributes the lubricant.
5.
The oil level sight gauge is clearly visible and easily accessible.
6.
Water or dirt will not fall directly on the cabinet.
Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
3
Hydraulic Tubing April 1998
A. Automatic Lubrication System This system utilizes 1/4” S.S. tubing from the filter outlet to each injector inlet. Flexible hose is used between points of relative movement and injector discharge to vibrator bearing inlets. All tubing and hoses are installed at the factory. B. Remote Automatic Lubrication System Machines constructed for one of the remote type lubrication systems have a ‘tee’ permanently mounted at the front of the support structure. Two outlets of the ‘tee’ have 1/4” S.S. tubing connected, which runs to each injector inlet. The third ‘tee’ opening must be connected during installation of the lubricator feed line, typically 3/8” S.S. tubing. Refer to drawing no. 4387-00. If more than one machine is to be lubricated, it is recommended that one of the following methods be used: 1. Locate a central position for a main feed line. Then run a series of minimal length branches to each vibrating screen. 2. Install a loop type feed system, which allows the lubricator to rapidly pressurize all points and facilitates bleeding. Refer to drawing no. 4389-00. At the lubricator cabinet, connect the main feed line (3/8” S.S. tubing) to the 1/4” NPT female outlet, using the fitting provided. The outlet opening has a 2” diameter plastic plug inserted which must be removed. It is recommended that this be cut to accomodate the feed line and reinstalled to prevent contaminants from entering the cabinet. Ensure all tubing is properly secured and away from vibration and traffic areas. Avoid sharp bends and alternating uphill/downhill patterns which make bleeding the system more difficult.
Electrical Connections CAUTION:
ALL ELECTRICAL WIRING, ENCLOSURES AND CONNECTIONS SHOULD COMPLY WITH NATIONAL ELECTRICAL CODE STANDARDS AND ALL APPLICABLE LOCAL CODES. FAILURE TO DO SO CAN RESULT IN AN UNSAFE CONDITION WHICH MAY DAMAGE EQUIPMENT OR INJURE PERSONNEL. ENSURE ALL ELECTRICAL AND CONDUIT CONNECTIONS ARE SECURE.
Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
4
Electrical Connections (cont.) April 1998
A. Automatic Lubrication System The lubricator motor is electrically connected to the vibrator starters at the factory. When the vibrators are energized, the lubrication system is also energized, ensuring oil flow to the bearings whenever the unit is running. B. Remote Automatic Lubrication System Power must be supplied to the lubricator from an external source. The label on the cabinet near the power inlet opening defines the voltage, frequency and number of phases required. Several supply power variations exist in both explosion proof and non-explosionproof configurations. Contact a Derrick representative for standard remote automatic lubricators available, and if unique supply power situations are encountered. NOTE: Single phase lubricators use timers that are NOT dual voltage devices, and cannot be field converted. A possible interlock arrangement as shown in drawing no. 5626-00 starts the remote lubrication system when the vibrating motors are engergized. This ensures that the motor bearings are lubricated whenever the screens are operated. Alternative interlock systems may be used with plant electrical and maintenance personnel approval. The oil reservoir may be equipped with an internal low level float switch. This sensor can provide a contact closure for a control room alarm, warning light, or buzzer. The type of low level switch depends upon the oil reservoir volume (15 or 55 gallons). Refer to attached drawing for sensor details. With explosion proof lubricators, the customer is required to supply intrinsically safe components in order to ensure explosionproof integrity. The float switch is not rated for hazardous areas. In certain situations, it may be beneficial to control the operation of the lubrication system (operating frequency and duration) with existing plant control systems, bypassing the lubrication system timers. Please contact Derrick for further information.
Removing Air from the System A. Automatic Lubricator System After machine assembly at Derrick Corp. these lubrication systems are completely purged of air, run and checked for normal operation. Additional purging should not be required.
Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
5
B. Remote Standard & Selectable Voltage Automatic Lubrication Systems The Derrick Standard & Selectable Voltage Remote Automatic Lubricator Systems require bleeding after all tubing and fittings have been installed. CAUTION:
The following steps must be followed correctly - FAILURE TO DO SO MAY CAUSE BODILY HARM AND/OR EQUIPMENT FAILURE.
1.
Locate the injector closest to the lubricator and loosen the small bleeder valve to a point where it can further be loosened by hand.
2.
Open the timer enclosure cover and place the LINE PRIME/NORMAL RUN switch to the LINE PRIME position, then close and secure the timer enclosure cover.
3.
Turn the main starter control switch to the ON position. The lubricator motor will now run continuously until it is turned off.
4.
Follow the INJECTOR PRIMING INSTRUCTIONS (Drawing No. 8382-00). NOTE: A good deal of oil must be allowed to drain prior to obtaining a solid, airless stream. A clear rubber hose may be inserted over the bleeder valve orifice and placed into a bottle for oil collection and visual observation.
5.
Tighten the small bleeder valve on the injector and turn the main starter control switch to the OFF position.
6.
Move to the next injector down stream, loosen the bleeder valve, and repeat steps 3, 4, and 5. Continue this procedure until all injectors have been bled.
CAUTION: Do not let the lubricator motor run continuously for extended periods of time in a dead headed condition. Heat build up within the pump can cause premature failure. 7.
Once the injectors are properly bled, ensure that the main starter control switch of the lubricator is in the OFF position.
8.
Open the timer enclosure cover and place the LINE PRIME/NORMAL RUN switch to the NORMAL RUN position. Close and secure the timer enclosure cover.
9.
To verify that the injectors are functioning properly, remove the inlet line to the motors from the couplings located at the top of each injector.
10.
Turn the main starter control switch to the ON position. The lubricator motor will now cycle at the interval dictated by the timer setting. Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
6
Removing Air from the System (cont.) 11.
Allow the system to cycle several times while monitoring oil flow. If any of the injectors DO NOT function properly, repeat this entire procedure. If any of the injectors malfunction a second time, replace the defective injectors and re-bleed the system.
12.
Turn the main starter control switch to the OFF position.
13.
Carefully replace the Teflon tape on the inlet line fitting. DO NOT cover the fitting opening. Reinstall the inlet line to the motor. Ensure that any contaminants are prevented from entering the system. Tighten and clean all connections.
14.
Turn the main starter control switch to the ON position.
15.
Allow the system to operate normally for several hours. Inspect all tubing, hoses and connections for oil leaks. Monitor drain bottles for oil accumulation.
16.
The system is now ready for Normal Operational use.
C. Remote Solid State Automatic Lubrication Sytsem The Derrick Solid State Remote Automatic Lubricator System requires bleeding after all tubing and fittings have been installed. CAUTION:
The following steps must be followed correctly - FAILURE TO DO SO MAY CAUSE BODILY HARM AND/OR EQUIPMENT FAILURE.
1.
Locate the injector closest to the lubricator and loosen the small bleeder valve to a point where it can further be loosened by hand.
2.
Open the timer enclosure cover and SET the ON DELAY RELAY (on the left) to ALL ZEROS (00.0). SET the OFF DELAY RELAY (on the right) to ALL NINES (999). Close and secure the timer enclosure cover.
3.
Turn the main starter control switch to the ON position. The lubricator motor will now run continuously until it is turned off.
4.
Follow the INJECTOR PRIMING INSTRUCTIONS (Drawing No. 8382-00) NOTE: A good deal of oil must be allowed to drain prior to obtaining a solid, airless stream. A clear rubber hose may be inserted over the bleeder valve orifice and placed into a bottle for oil collection and visual observation.
5.
Tighten the small bleeder valve on the injector and turn the main starter control switch to the OFF position. Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
7
Removing Air from the System (cont.) 6.
CAUTION:
Move to the next injector down stream, loosen the bleeder valve, and repeat steps 3, 4, and 5. Continue this procedure until all injectors have been bled. Do not let the lubricator motor run continuously for extended periods of time in a dead headed condition. Heat build up within the pump can cause premature failure.
7.
Once the injectors are properly bled, ensure that the main starter control switch of the lubricator is in the OFF position.
8.
Open the timer enclosure cover and SET the ON DELAY RELAY (on the left) to 5 MINUTES (05.0). SET the OFF DELAY RELAY (on the right) to 18 SECONDS (018). Close and secure the timer enclosure cover.
9.
To verify that the injectors are functioning properly, remove the inlet line to the motors from the couplings located at the top of each injector.
10.
Turn the main starter control switch to the ON position. The lubricator motor will now cycle at the interval dictated by the timer setting.
11.
Allow the system to cycle several times while monitoring oil flow. If any of the injectors DO NOT function properly, repeat this entire procedure. If any of the injectors malfunction a second time, replace the defective injectors and re-bleed the system.
12.
Turn the main starter control switch to the OFF position.
13.
Carefully replace the Teflon tape on the inlet line fitting. DO NOT cover the fitting opening. Reinstall the inlet line to the motor. Ensure that any contaminants are prevented from entering the system. Tighten and clean all connections.
14.
Turn the main starter control switch to the ON position.
15.
Allow the system to operate normally for several hours. Inspect all tubing, hoses and connections for oil leaks. Monitor drain bottles for oil accumulation.
16.
The system is now ready for Normal Operational use.
Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
8
OPERATION Initial Start Up A. Automatic Lubricator Systems The lubricator is powered whenever the vibrating motors are energized. At start up, after a new installation, the drain bottles should be closely monitored for oil accumulation. If levels observed are abnormal refer to TROUBLE SHOOTING SECTION for possible cause. B. Remote Standard Automatic Lubrication System The Derrick Standard Remote Automatic Lubrication System requires the following: NOTE: Ensure that the system has been properly bled. 1.
Open the timer enclosure cover and ensure that the LINE PRIME/NORMAL RUN switch is set to the NORMAL RUN position. a.
Set the RUN TIME dial of the timer assembly to 18 seconds (note the arrow on the label).
b. Set the INTERVAL dial of the timer assembly to 5 minutes, (again, note the locator arrow on the label). c.
Close and secure the timer enclosure.
NOTE: TIMER COVER MUST BE CLOSED AT ALL TIMES WHEN ENERGIZING THE SYSTEM, TO ENSURE EXPLOSIONPROOF INTEGRITY. 2.
The lubricator will now run for approximately 18 seconds every 5 minutes, as long as the power supply to the lubricator remains on. To be certain that the timer assembly is set up and functioning properly, manually time the system with a wrist watch and make necessary adjustments, if needed.
3.
Ensure each oil drain line is only inserted 1-1/2 to 2 inches into the top of a drain bottle. Note that this drain line also acts as a vent for the motor and must NOT be submerged in the discharged oil. If the line becomes submerged, there is danger of contaminated oil being sucked into the motor upon shutdown.
4.
Start up is complete and the system is ready for full operation.
Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
9
Initial Start Up (cont.) C. Remote Selectable Voltage Automatic Lubrication System The Derrick Selectable Voltage Remote Automatic Lubrication System requires the following: NOTE: Ensure that the system has been properly bled. 1.
Open the timer enclosure cover and ensure that the LINE/PRIME/NORMAL RUN switch is set to the NORMAL RUN position. Close and secure the timer enclosure. NOTE:
TIMER COVER MUST BE CLOSED AT ALL TIMES WHEN ENERGIZING THE SYSTEM, TO ENSURE EXPLOSION-PROOF INTEGRITY.
2.
The Selectable Voltage Remote Automatic Lubricator is factory set to run for approximately 18 seconds every 5 minutes, as long as the power supply to the lubricator remains on.
3.
Ensure drain line is only inserted 1-1/2 to 2 inches into the top of a drain bottle. Note that this drain line also acts as a vent for the motor and must NOT be submerged in the discharged oil. If the line becomes submerged, there is danger of contaminated oil being sucked into the motor upon shutdown.
4.
Start up is complete and the system is ready for full operation.
D. Remote Solid State Automatic Lubrication System The Derrick Solid State Remote Automatic Lubrication System requires the following: NOTE: Ensure that the system has been properly bled. 1.
Open the timer enclosure cover and set the ON DELAY RELAY (on the left) to 5 MINUTES (05.0). SET the OFF DELAY RELAY (on the right) to 18 SECONDS (018). Close and secure the timer enclosure cover.
2.
The lubricator will now run for approximately 18 seconds every 5 minutes, as long as the power supply to the lubricator remains on. To be certain that the timer assembly is set up and functioning properly, manually time the system with a wrist watch and make necessary adjustments, if needed.
3.
Ensure drain line is only inserted 1-1/2 to 2 inches into the top of a drain bottle. Note that this drain line also acts as a vent for the motor and must NOT be submerged in the discharged oil. If the line becomes submerged, there is danger of contaminated oil being sucked into the motor upon shutdown.
4.
Start up is complete and the system is ready for full operation. Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
10
Monitoring the System Regularly scheduled monitoring of the lubricator system will enable the Derrick vibrating motor to remain in service for many years. The following list details simple steps which will ensure long life of the vibrating motor. 1.
Daily-
Check pump output pressure by observing the gauge located near the lubricator motor. Set the red needle indicator on the gauge to 0; observe the actual reading, after the pump cycles. The acceptable range is between 850 - 1200 psi.
2.
Daily-
Check oil drain bottles to see if all bottles in the lubrication system are filling at approximately the same rate; some deviation may occur. If there is no sign of gradual draining into the bottle, the injectors must be inspected.
3.
Weekly-
Inspect the oil level sight gauge for water in the reservoir. If water is found, it should be drained via the reservoir drain, and the oil filter element changed.
4.
Weekly-
Check level in drain bottles and discard the oil. DO NOT REUSE OIL. If the system is functioning properly (supplying 4 - 4.5 oz per bearing per day), the drain bottles should be approximately two thirds full after 7 full days operation. If this is not the case, the interval timer must be adjusted (see Adjustments Section) .
5.
Weekly-
Check oil for discoloration. If the oil in one drain bottle appears considerably darker than the others, it may be necessary to increase the oil input to the bearings in order to flush out impurities. Refer to ‘Initial Set up’ and decrease the ON DELAY RELAY setting to less than 5 MINUTES (05.0). NOTE: Oil consumption will increase with shortened ‘off’ intervals.
6.
6 Months- Change the lubricator filter element. To remove old filter element, unscrew the filter bowl and remove the internal filter element by hand. (The element simply slides on and off a fitted sleeve). Reach inside the filter case to remove and clean the magnetic strip provided which traps any bits of metal present in the oil. Reinstall the magnetic strip and set the new filter element in place. Do not over-tighten filter bowl.
Should any irregularities be noted during any of the above inspections, refer immediately to Trouble Shooting for probable causes and solutions.
Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
11
Approved Oil for Use in Derrick Vibrating Motors Selecting the appropriate lubricating oil for the anticipated environmental and operating conditions will result in many years of reliable service from a Derrick vibrating motor. Listed below are those oils which are approved for use by Derrick Corporation. (Please note that the oils are not listed in order of preference.) Failure to use a lubricating oil approved by Derrick Corporation may void any warranty. Refer to Oil Testing Data sheet at the end of this section for information specific to each of the oils listed below. No.
Manufacturer
Oil
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Amoco................................................... Amokon 68 Arco....................................................... Duro 68 Ashland ................................................. Valvoline R & O 30 BP.......................................................... Turbinol 68 BP Gulf ................................................. Harmony 68 Chevron................................................. GST ISO 68 Turbine Clearlube ............................................... Clearlube 68F (FDA Approved) Conoco .................................................. Turbine ISO 68 Conoco .................................................. 6000 ISO 68 Conoco .................................................. Syncon 68 (synthetic) Esso Canada.......................................... Terresso 68 Lyondell ................................................ Ideal 68 Mobil..................................................... DTE Heavy Medium Mobil..................................................... SHC 626 (synthetic) Monolec ................................................ 6403 Turbine Oil Pennzoil................................................. Pennzbell Turbine 68 Petro Canada......................................... Super Turboflo 68 Shell....................................................... Turbo T Oil 68 Teresstic ................................................ Teresstic 68 Texaco .................................................. Regal R & O 68 Unocal ................................................... Turbine XD 68 Unocal ................................................... Triton 68 (synthetic)
Note that several synthetic lubricating oils are included in the above list. Under normal conditions, the use of the more costly synthetic lubricants is not necessary. Some synthetic lubricants may contain additives which could adversely affect motor life. However, synthetic lubricants are usually preferred, when wide variations in temperature are anticipated. NOTE:
DO NOT USE OILS CONTAINING EXTRA PRESSURE OR ANTI-WEAR (AW) ADDITIVES.
This document supersedes drawing #3852-00. pg. 2 of 2
Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
12
Recommended Oils for Extreme Temperature Duty Hot Duty Where ambient temperatures are expected to routinely exceed 104 °F (40 °C), the following oils from the Approved Oil for Use in Derrick Vibrating Motors list are recommended. Note that even though a plant's ambient temperatures may not be in this range, screening a hot product may raise the temperature in the vicinity of the vibrating motor. In some "hot duty" installations it may also be advantageous to decrease the interval timer setting to increase the amount of oil delivered to the bearings. This increased lubrication can effectively reduce the operating temperature of the motor by flushing the bearings with cool oil. No.
Manufacturer
Oil
1. 2. 6. 9. 10. 12. 14. 22.
Amoco................................................... Amokon 68 Arco....................................................... Duro 68 Chevron................................................. GST ISO 68 Turbine Conoco .................................................. 6000 ISO 68 Conoco .................................................. Syncon 68 (synthetic) Lyondell ................................................ Ideal 68 Mobil..................................................... SHC 626 (synthetic) Unocal ................................................... Triton 68 (synthetic)
Cold Duty Where ambient temperatures are expected to routinely remain below 20 °F (-6 °C), or where the vibrating motor may be subjected to extreme cold when not running, the following oils from the Approved Oil list are recommended. No.
Manufacturer
2. 3. 6. 10. 14. 22.
Arco....................................................... Duro 68 Ashland ................................................. Valvoline R & O 30 Chevron................................................. GST ISO 68 Turbine Conoco .................................................. Syncon 68 (synthetic) Mobil..................................................... SHC 626 (synthetic) Unocal ................................................... Triton 68 (synthetic)
NOTE:
Oil
DO NOT USE OILS CONTAINING EXTRA PRESSURE OR ANTI-WEAR (AW) ADDITIVES.
Derrick Corporation 590 Duke Road Buffalo, New York 14225 (716) 683-
Derrick Automatic & Remote Automatic Lubrication System
MAINTENANCE Trouble Shooting If the lubrication system is not functioning properly, the following items may be of assistance in determining the problem. Problem (if applicable)
Recommended Action
1. The starter is in reset position
Turn starter to "OFF" and then "ON" again.
2. The power supply has been interrupted
Check power supply, circuit breaker, or fuse.
3. The motor starter switch is inoperative
Replace switch.
4. The cycle length timer (OFF DELAY RELAY) has not allowed sufficient time to achieve required charge pressure
Increase run time.
5. One of the timers is defective
Replace defective timer assembly. Refer to Appendix A.
6. There is a leak in the hydraulic tubing
Locate leak. Repair/replace components and bleed the line. Test for correct pressure.
7. There is air in the hydraulic tubing
Bleed all injectors.
8. There is a blockage or kink in the hydraulic tubing.
Replace hydraulic tubing. Check for leaks and bleed. Test for correct pressure.
13
Derrick Automatic & Remote Automatic Lubrication System
Trouble Shooting (cont.)
Problem
9. Motors not draining, running excessively hot
Recommended Action
a. Check drain hoses for kinks or obstructions b. Verify drain hoses are not excessively long, 4 ft. maximum. c. Ensure hoses penetrate drain bottle cap only 1 1/2”- 2” and are NOT submerged. d. Ensure vent hole in drain bottle cap is clean and open to atomospheric pressure.
10. The injector is defective
Replace injector. Check for leaks and bleed. Test for correct pressure.
11. Pump pressure is low
Check for and correct any of the following: a. A leak in the hydraulic tubing b. Low oil reservoir c. A blockage or kink in the hydraulic tubing d. Air in the hydraulic tubing e. Lubricator cycle length has not permitted adequate time for pressure to build up f. Faulty injector(s)
14
Derrick Automatic & Remote Automatic Lubrication System
15
Injector Specifications All injector exposed surfaces consist of corrosion resistant stainless steel. Inlet and bleed screw openings are 1/4” NPTF, with the outlet in the metering screw being 1/8” NPTF. (see 13566-00-001) Minimum pressure to activate injector ......................... 725 psi Maximum operating pressure........................................ 3000 psi Minimum time to charge (pressurized)......................... 15 seconds Minimum time to reset (at 0 psi)................................... 30 seconds Displaced volume per stroke: Standard output .....................................0.4 cc High output ...........................................0.8 cc Injector life and operation are typically maintenance free, and primarily depend on cleanliness of oil being metered.
Adjustments Derrick recommends the following lubrication quantities for its vibrating motors: MOTOR TYPE
OIL PER 24 HOUR PERIOD
K, L, M, R
4.0 - 4.5 oz (115.0 - 130.0 cc)
A, D
8.0 - 9.0 oz (230.0 - 260.0 cc)
This normally is accomplished with the lubricator interval timer set to cycle every five (5) minutes. If slight modification of lubrication quantities is deemed neccesary, cycle frequency can be changed by adjusting the ‘ON DELAY RELAY’ timer. Shorter time interval = increased oil output Longer time interval = decreased oil output CAUTION:
Consult a local Derrick representative if delay times of less than three (3) minutes or greater than six (6) minutes are thought to be desireable.
SECTION 8 - REFERENCE DRAWINGS WET SCREENING MACHINES
This section contains Derrick engineering drawings for your equipment. These drawings are included to provide assistance in troubleshooting, repair, and parts ordering. Number
Title
11213-00-002 - General Arrangement 8221-00-005 - Parts List for 2L48-90W-3 12048-00 - Sealing Rapid Change Draw Bolt 11897-00 - Lubricator, Model 151-15-240-50 11622-00 - Lubricator Wiring Diagram
15 Nov 16
8-1
SECTION 9 - INSTALLATION AND MAINTENANCE LOG WET SCREENING MACHINES
PURPOSE This section should be used by operating and maintenance personnel to record historical information gathered during the installation and operation of the Derrick equipment. If properly kept, the log will be useful for altering maintenance intervals and intercepting trends that may indicate the need for changing operating procedures. Each entry in the log should be dated for future reference and tracking. If required, additional pages may be added to the log by copying a blank page or simply inserting ruled paper at the rear of the section.
Installation and Maintenance Notes:
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