Hs-3400 Manual m9252_r1 - Ms3400 Std Xp
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P.O. Box 2327 2800 N. Frazier Conroe, TX 77305-2327 936-756-4800 phone 936-441-0006 fax
Model HS-3400 Centrifuge Standard XP Standard Electric Drive Explosion Proof Installation, Operation, and Maintenance Manual
M9252 R1
General Information
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Product Information
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Installation
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Operation
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Troubleshooting
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Maintenance and Repair
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Parts and Drawings
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Worldwide Locations
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Appendix
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© Copyright 2003 Varco International, Inc. Brandt® is a registered trademark of Varco International, Inc. HS-3400™ is a trademark of Varco International, Inc. Royal Purple® is a registered trademark of Royal Purple, LTD. All other product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective owners. All rights reserved. This publication is the property of, and contains information proprietary to Varco International, nc. No part of this publication may be reproduced or copied in any form, or by any means, including electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Varco International, Inc. Information in this manual is subject to change without notice.
Warranty Brandt warrants that, for a period of one year from the date of delivery equipment of Brandt manufacture, the Equipment shall be free of defects in materials and workmanship under normal use and service, and provided the Equipment is used and maintained in accordance with instructions supplied by Brandt. This is Brandt's sole and exclusive warranty. If a defect in the Equipment appears within one year from the date of shipment, and Purchaser has given written notice of such defect within thirty days from the discovery thereof, Brandt will repair or replace the part, at its option, by shipping a similar part FOB shipping point or, at its option, refund an equitable portion of the purchase price. Brandt may require the return, to a designated Brandt location, of the defective part, transportation prepaid to establish Purchaser's claim. No allowance will be made for repairs undertaken without Brandt's written consent or approval. This warranty applies only to equipment manufactured by Brandt. Warranties on equipment manufactured by others, if any, are assigned to Purchaser by Brandt (without recourse) at time of delivery. Any description of Equipment, drawings, specifications, and any samples, models, bulletins, or similar material, used in connection with this sale are for the sole purpose of identifying the Equipment and are not to be construed as an express warranty that the Equipment will conform to such description. Any field advisory or installation support is advisory only. The foregoing warranties are in lieu of all other warranties, whether oral, written, express, implied or statutory. Implied warranties or merchantability and fitness for a particular purpose will not apply. Brandt's warranty obligations and purchaser's remedies thereunder are solely and exclusively as stated herein. Purchaser's sole and exclusive remedy, whether based upon warranty, contract or tort, including negligence, will be to proceed under this warranty. All liability of Brandt shall terminate one year from the date of delivery of the Equipment.
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Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Notes, cautions, and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Safety requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Safe area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Centrifuge safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Safety issues from corrosion, erosion and pitting. . . . . . . . . . . . . . . 1-3
Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Recommended tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 General system safety practices. . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Replacing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Proper use of equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Model HS-3400 Centrifuge Standard XP
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General Information
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Brandt
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Intended audience This manual is intended for use by field engineering, installation, operation, and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. Brandt®, a Varco company, will not be held liable for errors in this material, or for consequences arising from misuse of this material.
Conventions Notes, cautions, and warnings Notes, cautions, and warnings appear throughout this manual to provide you with additional information, and to advise you to take specific action to protect personnel from potential injury or lethal conditions. They may also inform you of actions necessary to prevent equipment damage or conditions that may void your warranty. Please pay close attention to these advisories.
Notes The note symbol indicates that additional information is provided about the current topic.
Cautions The caution symbol indicates potential risk of damage to equipment or injury to personnel. Follow instructions explicitly and take extreme care. A caution symbol may also indicate a condition that voids your equipment warranty.
Warnings The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to observe and follow proper procedures is likely to result in serious or fatal injury to personnel, significant property loss, or significant equipment damage.
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Illustrations Figures provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale.
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For more specific component information pertinent to your rig configuration, see the technical drawings included with your Varco documentation.
Safety requirements Brandt equipment is installed and operated in a controlled drilling rig environment involving hazardous operations and situations. Proper service and repair is important for safe and reliable operation. Operation and service procedures provided by Brandt manuals are the recommended methods of performing those operations. To avoid injury to personnel or equipment damage, carefully observe the following safety requirements.
Safe area The Brandt HS-3400™ Standard Electric Drive, Explosion Proof (Standard XP) centrifuge is a high speed / high G-force decanting type unit used for the continuous, controlled removal of solids from contaminated fluids. As this is a high-speed machine that can generate forces in excess of 2000G, particular emphasis should be given to the safety section contained within this manual. It is strongly recommended that a Brandt technician be in attendance during installation, start-up and commissioning phases. The Brandt technician will give full training instructions in operation, application and maintenance of the HS-3400 Standard XP centrifuge, which, if followed, should ensure long, trouble-free operation of unit. For concerns regarding the safety or process suitability of the HS-3400 Standard XP centrifuge, please contact any of the Brandt service centers listed in section 8, “Worldwide Locations.” Brandt has a team of experienced Service Engineers available on a 24 hour basis should further assistance be required.
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Centrifuge safety precautions Study this section carefully before attempting start-up, operation, repair or maintenance to the centrifuge. Unsafe practices can cause conditions hazardous to personnel and equipment.
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1. Do not remove guards or attempt to repair any rotating parts unless power is safely isolated and machine is at rest. 2. Adequate walkways and guardrails should be installed around the machine if mounted in an elevated position. 3. Do not operate the centrifuge until it is securely mounted and assembled correctly. 4. Do not operate the centrifuge unless all guards are securely fitted and the bowl lid is bolted in position. 5. Do not attempt to rotate the centrifuge by pulling on the drive belt as fingers are easily trapped. 6. Always use recommended tools and lifting appliances detailed in this manual when attempting repair, assembly or dismantling of the centrifuge or its components. 7. Never mechanically or otherwise block the tripping action of the torque overload mechanism. 8. Never attempt to decelerate the rotating assembly by using wooden blocks or other braking devices. Severe equipment and/or personnel damage can occur. 9. Do not operate the centrifuge if unusual noise or vibration exists. Consult Brandt if in any doubt. 10. If undertaking electric welding on any part of the centrifuge, ensure that no earthing current passes through the bearings. 11. Do not operate the HS-3400 centrifuge until start-up and shutdown procedures are fully understood. 12. Do not attempt to use the centrifuge for applications other than that stated in the purchase order. Do not exceed maximum recommended speeds or process specific gravity. 13. Do not interchange bowl parts, since specific parts are balanced as a unit. 14. Follow recommended oil level check procedure and recommended greasing procedures and schedules. 15. Running the equipment in the wrong direction can cause severe damage. The centrifuge should always rotate in a clockwise direction when viewed on the driven pulley.
Safety issues from corrosion, erosion and pitting To ensure a high factor of safety under operating conditions, high speed centrifugal equipment manufactured by Brandt is designed after a careful stress analysis has been made of highly stressed parts. A thorough control of metallurgical properties is maintained throughout manufacture and all material is warranted as free from defects at time of shipment. The equipment is designed and built for a long useful life.
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It should be recognized that equipment subjected to severe erosive or corrosive environments might deteriorate over a period of time depending upon the severity of exposure and/or possible misuse. Users of high-speed centrifugal equipment should be aware of this fact and also those extremely high forces that are brought into play when their equipment is in operation. Any weakening of highly stressed members by misuse, erosion, corrosion, chemical pitting or stress cracking must be guarded against to prevent possible metal failure.
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In the interest of longer and safer operation of customer equipment, Brandt recommends that the customer maintain a periodic (monthly) inspection on highly stressed moving parts such as bowls, shaft, spindles, etc., which are subjected to corrosive or erosive wear. The following points should be noted and the recommended action taken: !
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Do not operate equipment when: !
Holes are worn through moving parts.
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Grooves greater than 1/16" (1.5mm) deep are worn in moving parts.
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Evidence of cracks is present in moving parts.
Observe chemical pitting: !
All cases of chemical pitting, even under 1/16" (1.5mm) depth, should be watched carefully. This action is almost always due to the breakdown of the passive film on stainless bowl shell walls in the presence of chlorides. This can occur under heel cake that has not been cleaned from the bowl wall. High temperature and high acidity accelerate the action.
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Contact the Brandt Service Department regarding the repair or replacement of pitted bowl shells or other parts.
Personnel training All personnel performing installation, operations, repair, or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation, and maintenance. During installation, maintenance, or repair of equipment, personnel should wear protective gear.
Contact the Brandt training department for more information about equipment operation and maintenance training.
Recommended tools Service operations may require the use of tools designed specifically for the purpose described. When stated, use only these tools.
General system safety practices Local codes may apply. Please consult them prior to performing any operation.
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The presence of a Brandt representative at the site does not relieve the owner/ operator of responsibility to follow published installation, operation, and maintenance instructions. The equipment discussed in this manual may require or contain one or more utilities, such as electrical, hydraulic, pneumatic, or cooling water. Before installing or performing maintenance or repairs on equipment, read the following instructions to avoid endangering exposed persons or damaging equipment.
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Isolate all energy sources before beginning work.
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Avoid performing maintenance or repairs while the equipment is in operation.
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Wear proper protective equipment during equipment installation, maintenance, or repair.
Replacing components !
Verify that all components (such as cables, hoses, etc.) are tagged and labeled during disassembly and reassembly of equipment.
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Replace failed or damaged components with Brandt certified parts. Failure to do so could result in equipment damage or personal injury.
Maintenance Equipment must be maintained on a regular and routine basis. See the service manual for maintenance recommendations. Failure to conduct routine maintenance could result in equipment damage or injury to personnel.
Proper use of equipment Brandt equipment is designed for specific functions and applications, and should be used only for its intended purpose.
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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Purpose and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Description overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
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Main components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Bowl assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Conveyor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Gearbox assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Torque control assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Casing assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Main frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Sub frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Alternative feed pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Bowl and conveyor speeds. . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Technical details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
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Description Purpose and functions The Brandt HS-3400 Standard XP centrifuge is a high speed / high G-force decanting type unit used for the continuous, controlled removal of solids from contaminated fluids. The functions of solids sedimentation, separation and draining are all combined in the Brandt HS-3400 centrifuge.
Description overview To provide a complete description of all the systems that comprise a complete centrifuge installation, this section describes the following: !
Main components of the centrifuge, which include the following: !
Bowl assembly
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Conveyor assembly
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Drive assembly
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Gearbox assembly
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Torque control assembly
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Casing assembly
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Main and sub frames
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Feed pump
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Control panels
This section also provides technical details, or specifications for the Brandt HS-3400, along with operational data to describe the normal throughputs of mud volumes for the centrifuge (in gallons per minute, or gpm) based on varying mud weight values and bowl speeds.
Main components The Brandt HS-3400 centrifuge consists of the following units and assemblies that are identified in the general assembly drawings.
Bowl assembly This assembly is made up of four main components, these being the cylindrical and tapered bowl sections, and the front and rear hubs. The rear hub is fitted with a pulley that rotates the complete assembly about its horizontal axis. The rear hub is fitted at the tapered (or beach) end of the bowl and provides 360° discharge of solids. The front hub is fitted with adjustable plates, through which the clarified liquor discharges and which regulate the pond depth of slurry within the bowl. The outboard ends of the hubs are mounted in pillow blocks that are fixed to the main frame.
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Conveyor assembly This unit is enclosed within the bowl assembly and is driven through the hollow front hub by the splined output shaft of the gearbox. The conveyor is rotated about the same horizontal axis and in the same direction as the bowl, but at a slightly lower speed. The function of the conveyor is to scroll settled solids to the rear end of the bowl and discharge these solids through the solids discharge porting at the tapered end of the bowl. Conveyors are supplied with tungsten carbide tiles to minimize wear on the flights.
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Drive assembly The bowl drive consists of a 40 horsepower (hp) explosion proof electric motor mounted horizontally on a sliding base, which in turn forms part of the centrifuge sub frame. The motor belt drives the centrifuge bowl using a pulley and fluid coupling mounted on the motor output shaft. The fluid coupling ensures a ‘soft’ start-up of the centrifuge. Bowl speed changes are effected by changing the motor pulley. The sliding base on which the motor is mounted provides for belt adjustment.
Gearbox assembly This unit consists of a two stage planetary gearbox that is bolted directly to the front hub of the bowl assembly. Differential drive is transmitted to the conveyor via a splined output shaft in same direction of rotation as the bowl with a ratio of 51 turns of the conveyor to 52 turns of the bowl. Gearbox reaction torque is transmitted via a pinion shaft protruding from outer end of gearbox to a torque control assembly mounted on centrifuge frame.
Torque control assembly This assembly, bolted to the centrifuge main frame, provides the reaction force to the sun gear torque and automatically trips at a preset value in the event of a gearbox overload. In the event of an overload and subsequent tripping of this device, the conveyor and bowl will rotate at same speed. A limit switch fitted to this assembly detects the trip condition and automatically stops both the pump and centrifuge drive motors.
Casing assembly This unit encloses the bowl and directs the liquid and solids streams to two separate outlets positioned in the lower section of the casing. The casing is fitted with internal baffles to ensure both streams remain segregated. The top half of the casing is hinged to allow easy access to the bowl for inspection and maintenance. In operation, a gasket is fitted between the lid and lower casing, and both parts are securely bolted together.
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Main frame This rigid fabricated unit supports both the main bearings and casing assembly, and is in turn bolted to the sub frame. The bearing housings are accurately aligned and dowel pinned to ensure proper operation.
Sub frame This unit carries the main frame and drive assembly. The sub frame has five shock mounts fitted to the underside that can be bolted directly to a prepared foundation for permanent installation or left bolted to the transportation frame for mobile installations.
Feed pump Unless requested otherwise, the feed pump assembly provided by Brandt is a PDP-60A positive displacement progressive cavity pump. The PDP-60A feed pump is driven by a 10 hp explosion proof electric motor via a variable speed gearbox. The assembly is mounted on a skid with a lifting eye. Included with the PDP-60A feed pump, unless specified otherwise, is 75 feet of ship board duty electrical cable for connection to the control panel. When operating the feed pump, observe these precautions: •
Do not operate the feed pump dry, or the feed pump stator will wear excessively.
•
Only change the speed of the feed pump gearbox when the feed pump is running.
Alternative feed pump type If the feed pump is not supplied by Brandt, we strongly recommend using a variable speed eccentric screw pump. Use of a different type of pump (i.e., a type other than variable speed eccentric screw type) can cause less efficient separation within the centrifuge. For example, using a centrifugal pump, which normally requires flow regulated by valves, results in increased turbulence within the casing. The increased turbulence then causes further breakdown of particles that the centrifuge may not be able to remove.
Control panels Three explosion proof control panels are located on the centrifuge skid for starting and stopping both the centrifuge and feed pump. The panels are wired together. Cabling is provided to connect the feed pump to the control panel. The control panels have the following components: !
Power disconnect switch
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Power 'ON' light
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Start / stop button for the centrifuge
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Start / stop button for the feed pump
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Start and stop functions are interlocked to ensure that the pump cannot start unless the centrifuge is running. Interlocks are also included to shut down the pump and centrifuge in the event of torque overload.
2 Bowl and conveyor speeds Changing the drive or driven pulley or both can alter the operating speed of the centrifuge to provide the speeds and G-forces tabulated below. Dividing the centrifuge speed by 52, the ratio of the standard gearbox, arrives at the differential speed. Note that figures quoted in the table below are non-slip speeds. Actual operating speeds may be slightly lower than those quoted and will depend on several factors, including volume of oil in the fluid coupling, centrifuge speed, type of duty, etc., but are generally in the range of 1% to 5% lower than quoted.
G-forces and centrifuge rotation speeds resulting from pulley sizes and nominal motor rotation speed 50 Hz motor (1450 rpm)
60 Hz motor (1750 rpm)
Drive pulley (motor)
*Driven pulley (R/A)
Centrifuge rpm
G-force
Centrifuge rpm
G-force
P80
P44
2636
1382
3182
2013
P72
P44
2373
1119
2864
1630
P64
P44
2109
884
2545
1288
P56
P44
1845
677
2227
986
P48
P44
1582
497
1909
725
P44
P44
1450
418
1750
609
P44
P48
1329
351
1604
512
P44
P56
1139
258
1375
376
P44
P64
997
198
1203
288
P44
P72
886
156
1069
227
* The belt guard must be field modified to use any size larger than P44 on the rotating assembly (R/A).
Technical details Specifications
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Overall length ...................................... 98-7/16 in / 2500 mm
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Overall width........................................ 68-7/8 in / 1750 mm
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Overall height ...................................... 42-5/16 in / 1075 mm
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Overall weight ...................................... 4800 lb / 2182 kg
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Power requirement .............................. 100 amps @ 480 volts, 60 Hz
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Bowl dimensions.................................. 14 in x 49 in / 350 mm x 1260 mm
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Conveyor / pitch................................... 4-1/4 in / 110 mm lagging conveyor
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*Bowl speeds....................................... 886 to 3182 rpm
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*G-force ............................................... 156 to 2013
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Gearbox type ....................................... 2 stage planetary
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Gearbox ratio....................................... 52:1
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Gearbox output torque......................... 23,500 in-lbs / 270 kgf.m (max)
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* Max bowl speed of 4000 rpm (and G-force of 3180) is only run when solids SG is 2.1 SG or less. Max bowl speed is decreased (from 4000 rpm) when solids SG increases, as determined by the following formula:
Max bowl speed (rpm)
4000 = ------------------------solids SG -------------------2.1
For example, if solids SG is 3.5 SG, then max bowl speed is 3100 rpm.
Operating data Maximum feed rate to the centrifuge is dependent on many variables including: !
Liquid and solids properties of input fluid
!
Desired output properties of end products in terms of separation efficiency, dryness, etc.
In addition, centrifuge settings in terms of bowl speed, differential speed and pond depth will also affect the ultimate optimum feed rate. The following table provides some information on expected throughputs. Figures in this table have, for the most part, been derived from separation of drilled solids from
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drilling mud in oil and gas well drilling operations. Where solids concentration is low, these figures can increase up to 50%.
*Expected throughputs Feed rate at various mud weight values
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Bowl speed
G-force
9 ppg
12 ppg
15 ppg
18 ppg
1750 rpm
608
125 gpm
88 gpm
30 gpm
22 gpm
2350 rpm
1097
125 gpm
84 gpm
22 gpm
13 gpm
2400 rpm
1672
125 gpm
66 gpm
17 gpm
9 gpm
* Throughput and product quality can also be affected by the pond depth of the slurry in bowl, which is varied by changing the setting of the epicentric dams. To change the dam settings, loosen the securing screws, rotate to the new settings, and tighten. The higher the setting number, the deeper the pond depth.
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Transportation and handling . . . . . . . . . . . . . . . . . . . . . . . .3-1 Unpacking the centrifuge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Mounting the centrifuge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Frame installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
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Removing rotating assembly for machine installation. . . .3-4 Reinstalling rotating assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Installing the drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Installing the feed tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Connecting feed, solids and effluent discharge lines . . . .3-7 Connecting the feed line to the feed tube . . . . . . . . . . . . . . . . . . .3-7 Connecting the solids discharge line . . . . . . . . . . . . . . . . . . . . . .3-7 Connecting the effluent discharge line . . . . . . . . . . . . . . . . . . . . .3-7
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 Precautions for electrical installation. . . . . . . . . . . . . . . . . . . . . . .3-8 Procedure for electrical installation . . . . . . . . . . . . . . . . . . . . . . . .3-8
Feed pump installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
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Transportation and handling The equipment is packaged to afford protection from rust and corrosion for a period of twelve months if stored indoors. If the equipment is not to be installed immediately, Brandt strongly recommends that it be stored in the original factory packing. If the equipment is to be used for only short periods of time, resulting in prolonged periods of shutdown, take measures to protect the equipment and prevent exposure of the equipment to outside elements for long periods of time. Examples of this scenario include seasonal operation or uncrating the equipment followed by an extended period of nonuse. Upon arrival and unpacking, each piece of equipment should be carefully inspected, and any damage should be reported promptly.
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Unpacking the centrifuge The centrifuge may be shipped completely assembled or with the rotating assembly removed and packed separately. In either situation, carefully unpack the equipment and ensure that no damage is sustained. The rotating assembly should be handled with particular care to avoid damaging any of the surfaces.
Mounting the centrifuge When selecting a location for the centrifuge, the following basic requirements should be considered: !
Foundation for weight support - The foundation for the frame / sub base and motor should be level and capable of supporting the entire weight of the centrifuge (see "Frame installation" next in this section).
!
Headroom for lifting - Sufficient headroom must be available to allow the rotating assembly to be lifted from the frame with the aid of a suitable hoist of 1 ton capacity (for a drawing of overall dimensions and necessary clearances, see drawing "HS-3400 centrifuge installation - P10849" on page 7-8). It must be possible to position the hoist so that the centerline of the hook can traverse the longitudinal centerline of the bowl (see Figure 3-1, below).
!
Floor space and walkway - Sufficient clear floor space or walkway must be provided around the centrifuge to allow easy manipulation and setting down of components and assemblies that are removed from the machine. This is particularly important where two or more units are group installed. Space should also be provided for disassembling and cleaning at each end of the machine for removal of the feed tube and gearbox.
!
Underside clearance - Sufficient clearance is necessary beneath the centrifuge to accommodate solids and liquid discharge chutes.
HS-3400 Centrifuge Standard XP
3-1
Installation
M9252
R1
CHOICE OF HOOK POSITION WITH GEARBOX WITHOUT GEARBOX BOWL LIFTER BEAM CHOICE OF SLING POSITIONS PER MODEL LIFTING STRAP
3
Figure 3-1. Hoist support points for installing the centrifuge
Frame installation The centrifuge can be mounted on a concrete floor, a concrete pedestal or a structural steel support. For permanent installations, it is recommended that a composite foundation of concrete and structural steel be used. This will provide greater strength and will aid noise suppression. It is nevertheless essential that sub base and vibration isolators be used between the centrifuge frame and the foundation.
The transportation base provided may be used as a mounting base.
For frame installation, follow these guidelines: 1. Ensure that the foundation is carefully leveled to within ± 1/8 in (3.0 mm).
3-2
Brandt
M9252
Installation
R1
2. Set the bolts for securing the vibration mounts to the foundation as shown on the installation drawing for specific contract. If a concrete foundation is used, grout the bolts in place and allow the grout to harden thoroughly. 3. Install the vibration mounts and level the top surface to within ± 1/32 in (.8 mm) i.e., 1/16 in (1.6 mm) total corner to corner, using an engineer's level. 4. Install the centrifuge complete with its sub base on the vibration mounts and secure with nuts and washers. If the frame and sub base are not level to within the limits stated above, distortion will be introduced into the frame which may cause rubbing of the bowl and casing, rubbing of the feed tube against the rotating assembly, and bearing failure.
3
Where the centrifuge has been supplied complete with transportation base, the above procedures have already been carried out in relation to that base. Therefore the machine can be mounted via the transportation base to a level foundation as per step 1, above.
5. After installation of the centrifuge is complete, remove the shipping cradles, where fitted, from the bowl / casing (see Figure 3-2, below). Then secure the pillow blocks to the frame as described in "Installing the rotating assembly" on page 6-15.
REMOVE SHIPPING CRADLES
SECURING SCREWS
Figure 3-2. Shipping cradles protect rotating assembly during transit
HS-3400 Centrifuge Standard XP
3-3
Installation
M9252
R1
Removing rotating assembly for machine installation If the centrifuge has been delivered as a complete unit, but handling equipment capable of lifting the weight of the complete machine is not available, the rotating assembly may be removed to reduce the overall weight. For procedures on how to remove the rotating assembly, see "Removing the rotating assembly" on page 6-12. Before the rotating assembly can be removed from an uninstalled or partially installed centrifuge, the shipping cradles must be removed. (See Figure 3-2, above.) The shipping cradles are installed to prevent damage to the main bearings during transit.
3
Reinstalling rotating assembly If removing the rotating assembly is necessary, as described above, see procedures for reinstalling the rotating assembly afterwards. For procedures on how to reinstall the rotating assembly, see "Installing the rotating assembly" on page 6-15.
Installing the drive belt After installing and / or re-securing the rotating assembly into the frame and prior to fitting the feed tube, install the drive belt. To install the drive belt: 1. Ensure the motor and centrifuge pulleys have not sustained nicks or burrs during handling. 2. Check that the pulleys have not been contaminated with dirt, oil, rust, etc., all of which can damage drive belts. 3. Check the alignment of the pulley by holding a straight edge against the pulley outer faces (see Figure 3-3). Any evidence of pulley wobble will make pulley alignment impossible. 4. Ensure that the drive belt is clean, dry and in good condition. If grease or oil has contaminated the belt, clean thoroughly with a suitable non-flammable cleaning agent. 5. Install the belt on the motor and centrifuge pulleys, and turn the belt adjusting screw(s) to ensure correct belt tension, as described in the next step (see Figure 3-4). 6. To correctly adjust belt tension, proceed as follows: a. Ensure that both pulleys are in alignment. b.
3-4
Measure the span in inches or meters.
Brandt
M9252
Installation
R1 c.
Adjust the tension in the belt to permit 1/64 inch deflection per inch (16 mm per meter) of span, measured at the center of the span, when a force of 3 to 4 lb (1.5 to 2.0 kg) is applied at 90° to the belt by a hand-held scale. (See Figure 3-5.) There will normally be a drop in belt tension during the first 10 to 12 hours of operation. During this run-in period, the belts tend to seat fully and the initial stretch takes place. After the first 10 to 12 hours of running, the drive should be stopped and another check made for correct tension.
3
Figure 3-3. Straight edge against pulley outer faces to check alignment
Figure 3-4. Location of the adjusting screws for belt tension
HS-3400 Centrifuge Standard XP
3-5
Installation
M9252
R1
Figure 3-5. Determining the amount of belt deflection per span distance
3
Installing the feed tube To install the feed tube, proceed as follows: 1. Remove the four screws securing the feed tube clamping cap to feed tube bracket (see Figure 3-6) and withdraw the cap. The feed tube bracket and its clamping cap are both marked with matching alignment numbers or marks on the face or side of the bracket. When refitting the cap, these numbers or marks must coincide. 2. Ensure that the feed tube clamping surfaces are thoroughly cleaned. 3. Insert the feed tube into the bowl until the collar on the tube contacts the face of the bracket. 4. Assemble the clamping cap to the feed tube bracket ensuring screw holes are aligned. 5. Insert the four fixing screws and tighten evenly so that the clearance between the cap and the bracket is even on both sides of the tube. 6. Install the belt guard and secure to the frame.
Figure 3-6. Clamping cap around feed tube with even gap, matching marks
3-6
Brandt
M9252
Installation
R1
Connecting feed, solids and effluent discharge lines Connecting the feed line to the feed tube Follow these precautions when making a feed line connection to the feed tube: •
Do NOT use rigid pipe as a feed line. Always use flexible hose when connecting a feed line to the feed tube.
•
Do NOT hang heavy weight on the feed tube.
Failure to observe either of the above precautions may cause deflection of the inner end of the feed tube. This condition can result in the feed tube rubbing against the inside of the conveyor, followed by premature failure of the feed tube.
3
The feed line from the pump should always be connected to the end of the feed tube by means of a flexible hose. Brandt can provide a hose adapter for the end of the feed tube if required.
Connecting the solids discharge line Ensure that the chute or adapter hung off the rectangular solids discharge flange weighs less than 100 lb (45 kg). Brandt can provide an adapter for this flange to use in conjunction with a sloping chute. Alternatively a flexible, lightweight bellows can be connected directly into a conveyor or chute. Any sloping gravity chute that is connected to the solids outlet should be inclined at the steepest possible angle to prevent build-up of solids on the chute. (Excessive solids build-up on the discharge chute can lead to solids packing off the inside of the centrifuge. This can lead to shutdown of the centrifuge through overload.) When possible, a line should be connected to the centrifuge casing flushing point, which is provided to assist on the removal of solids from both the casing and solids removal chute.
Connecting the effluent discharge line Ensure that the liquid effluent discharge line connection: !
Weighs less than 100 lb (45 kg) and
!
Provides a flexible connection.
Brandt recommends a 6 inch discharge line for a single centrifuge installation and 8 inch discharge line for a dual centrifuge installation. The rate of fall for the liquid effluent discharge line should be no less than 0.25 inch per foot (20 mm per meter).
HS-3400 Centrifuge Standard XP
3-7
Installation
M9252
R1
Electrical installation Precautions for electrical installation The following precautions are very important for electrical installation. Failure to observe them can result in severe physical injury or death.
Follow Lockout / Tagout procedures prior to performing maintenance on this unit. Disconnect power to the electrical circuit before beginning any work on the electrical controls or motor settings. Failure to do so may result in severe physical injury or death!
3 Power leads may be hot. DO NOT perform any operation unless proper Lockout / Tagout procedures are in place.
Never start the motor without the belt and gearbox guards and upper casing securely in place.
Before attempting to start the centrifuge, ensure the following: •
Bowl cradles have been removed
•
Bowl rotates freely
•
Pillow blocks are securely attached to the frame
•
Centrifuge is securely mounted
Procedure for electrical installation Proceed as follows to complete the electrical installation for the centrifuge: 1. Ensure that the correct size pulleys are fitted to the motor and centrifuge. 2. Select supply cable wire size that is in accordance with local electrical codes. 3. Connect supply cable to the main disconnect in the control panel as per wiring diagram provided. Use temporary connections at first to verify correct phase as follows: a. Make temporary wiring connections to the motor at first, and momentarily start the motor to ensure that the motor fan rotates in clockwise direction when viewed from the pulley end of the motor. b.
3-8
If rotation is incorrect, have qualified electrical personnel reverse the phase for the control panel.
Brandt
M9252
Installation
R1
4. When the direction of rotation is correct, make permanent connections to the control panel. 5. Connect the feed pump cable to the control panel as per wiring diagram provided. All interlocks, alarms, etc. necessary for safe start-up, operation and shutdown are incorporated within the control panels. In wet and / or humid atmospheres, it is recommended that electric motor anti-condensation heaters be wired back to panel. Provided that power is left on to main control panel, the heaters will be activated when motors are not being run.
3
Feed pump installation For feed pump installation, follow these guidelines: !
Type of pump - Use the feed pump supplied by Brandt or an available variable speed, positive displacement eccentric screw pump as described in section 2, "Alternative feed pump type" (see page 2-3).
!
Best location - Ideally, locate the feed pump at a location below the feed slurry level to provide flooded suction for the pump.
!
Alternative location - If the feed pump must be located above the feed slurry level, provide a priming point for the suction line, with foot valve fitted to the end of the suction hose.
!
Pipe alignment without stress - If the feed pump is fitted with rigid suction and feed lines, ensure there are no undue stresses placed upon the centrifuge casing caused by pipe misalignment. When operating the feed pump, observe these precautions: •
Do not operate the feed pump dry, or the feed pump stator will wear excessively.
•
Only change the speed of the feed pump gearbox when the feed pump is running.
HS-3400 Centrifuge Standard XP
3-9
Installation
M9252
R1
3
3-10
Brandt
M9252
Operation
R1
Pre-startup check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Checklist for pre-startup check . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Startup procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Speed, feed and pond depth adjustments . . . . . . . . . . . . . .4-2 Speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 Speed range and pulley sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Feed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4
Pond depth adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 Effect of pond depth on centrifuge output. . . . . . . . . . . . . . . . . . . . . 4-4 Epicentric dams set to regulate pond depth . . . . . . . . . . . . . . . . . . . 4-4 Guidelines for setting pond depth. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Procedure for adjusting pond depth . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Shut down procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Guidelines for centrifuge shut down . . . . . . . . . . . . . . . . . . . . . . .4-6 Brief interruptions in slurry processing . . . . . . . . . . . . . . . . . . . . . . . 4-6 Shut down for less than 24 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Shut down for 24 to 72 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Shut down for more than 72 hours . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Resetting the torque control mechanism . . . . . . . . . . . . . .4-7
HS-3400 Centrifuge Standard XP
4-A
Operation
M9252
R1
4
4-B
Brandt
M9252
Operation
R1
Pre-startup check After the centrifuge and associated equipment have been installed, it is strongly recommended that prior to initial start-up, the following checks be carried out. As each item is checked and proved satisfactory, the item number on the list should be marked off. This will prevent oversights that could cause delay in start-up, damage to the equipment or injury to personnel.
Checklist for pre-startup check Completed
1. Centrifuge sub base and frame level and securely mounted. 2. Anti vibration mounts secure on foundation. 3. Motor and motor sliding base properly installed and secure. 4. Pulleys in good condition and aligned. Belt properly tensioned.
4
5. Belt guard correctly fitted and secure. 6. Gearbox guard correctly fitted and secure. 7. Upper casing closed and secured to the lower casing. 8. Certified wiring and dimension drawings and recommended installation drawings re-examined per latest revisions. 9. Electrical connections safely and correctly installed and motor wired for correct rotation. 10. Feed system interlocked. Pump adjusted to lowest setting. 11. Rinse/"Floc" connection installed (if supplied). 12. Torque control trip point correctly set. 13. All fasteners secure and tightened to the correct torque figure. 14. Correct capacity hoist available with sufficient overhead clearance to maneuver equipment. 15. Machine correctly lubricated. 16. Shipping cradle (where fitted) removed from bowl, pillow blocks or bearing clamps secured to frame and bowl free to rotate. Shock mount isolation brackets (where fitted) removed from transport mounting base. 17. Ensure correct pulley combination is fitted. Do not exceed max speed on nameplate. 18. All supplementary equipment correctly installed. 19. Safety instruction read in detail and implemented.
HS-3400 Centrifuge Standard XP
4-1
Operation
M9252
R1
Startup procedure The following startup procedure is typical for a Brandt centrifuge fitted with fluid coupling and controlled by an explosion proof electrical control panel. 1. Make sure the machine installation has been checked and verified as per prestartup checks listed on previous page. 2. Switch on power to control panel. 3. Press centrifuge start button. 4. Allow the centrifuge to come to full speed (approximately 1 minute). 5. Turn on water flush to solids discharge (if fitted). 6. Check that feed pump inlet and outlet valves are open. 7. On heavyweight muds, open bypass line (if fitted). 8. After centrifuge has been allowed to run for approximately 5 minutes, press the start button for feed pump. Pump will not start if centrifuge is not running. 9. Slowly close bypass valve, and increase mud pump feed rate until desired feed is obtained.
4
Speed, feed and pond depth adjustments Speed adjustment The reason for changing speed is to modify the G-force imparted to the slurry in the centrifuge. Generally, increasing speed will improve clarification of effluent and dryness of solids. Operating at high speed, however, also can cause lower throughput, higher wear rates and higher maintenance cost. For example, doubling the speed of the centrifuge will increase the G-force by a factor of 4. Doubling the speed also increases the wear rate by a factor of 8 and lowers maximum throughput by up to 50%. G-force for any decanting centrifuge at any given speed can be calculated as follows: G = .0000142 x (rpm)2 x bowl diameter (inches) G-force for the HS-3400 centrifuge, with a known bowl diameter, is calculated as follows: G = .00001988 x (rpm)2
Applicable to all centrifuges, do not exceed the maximum design speed given for any particular specific gravity of slurry. Refer to nameplate on the machine or the purchase order acknowledgement for specified duties. If in any doubt, please refer to Brandt for advice.
4-2
Brandt
M9252
Operation
R1
Speed range and pulley sizes Centrifuge speed can be altered by changing the motor pulley, centrifuge pulley or a combination of both. Change of the pulleys may also require change of the drive belt. Refer to the charts below for the correct pulley and belt part numbers to attain the desired speed. If changing the main drive motor pulley, refer to the fluid coupling removal and installation procedure in the appendix section of this manual. If changing the centrifuge pulley, it is desirable to elevate the rotating assembly prior to removal of pulley. Changing out the pulley in this situation involves removal of the feed tube support bracket, which may require application of an alignment fixture during reinstallation. Refer to section "Rotating assembly repair and overhaul" on page 6-12 of this manual for procedure.
Centrifuge speeds, pulley sizes and belt sizes 50 Hz motor (1450 rpm)
60 Hz motor (1750 rpm)
Drive pulley (motor)
Driven pulley (R/A)
Centrifuge rpm
G-force
Centrifuge rpm
G-force
Belt size
P80
P44
2636
1382
3182
2013
2590
P72
P44
2373
1119
2864
1630
2590
P64
P44
2109
884
2545
1288
2590
P56
P44
1845
677
2227
986
2450
P48
P44
1582
497
1909
725
2450
P44
P44
1450
418
1750
609
2450
P44
P48
1329
351
1604
512
2450
P44
P56
1139
258
1375
376
2450
P44
P64
997
198
1203
288
2590
P44
P72
886
156
1069
227
2590
4
Pulley sizes and part numbers Pulley size
Part number
Pulley size
Part number
P44-14M-40
09-546
P64-14M-40
09-533
P48-14M-40
09-534
P72-14M-40
09-532
P56-14M-40
09-459
P80-14M-40
09-531
Belt sizes and part numbers Belt size
Part number
2450
09-409
2590
09-563
HS-3400 Centrifuge Standard XP
4-3
Operation
M9252
R1
Feed adjustment The feed pump can be adjusted by rotation of the handwheel mounted on side of the pump gearbox. Only change the speed of the feed pump gearbox when the feed pump is running.
In some case, especially when processing slurries with high specific gravity, the minimum pump feed rate may be in excess of the centrifuge capacity. Under these circumstances, a tee should be fitted in the pump delivery line with a shut off valve, which will allow a proportion of the feed volume to be bypassed and returned to suction tank.
Pond depth adjustment Effect of pond depth on centrifuge output
4
The degree of sedimentation which takes place in the centrifuge bowl for any specific application is a function of centrifugal force applied and the average retention time of the liquid phase in the bowl. Centrifugal force changes are effected by changes to speed while retention time changes can be achieved by either adjusting the feed rate or altering the volume of liquid in bowl. Regulating the pond depth can alter the volume of liquid in the bowl. Normally maximum clarification is achieved at deep pond depth, although there are special cases where the reverse is the result. Deep pond depths usually result in wetter solids and reduced scrolling torque levels.
Epicentric dams set to regulate pond depth The settings on the epicentric dams, located around the end of the centrifuge bowl, are used to regulate pond depth (see Figure 4-1 and Figure 4-2). The epicentric dams have numbers that indicate pond depth:
4-4
!
Low numbers for shallow pond depth (example: 2.5)
!
Medium numbers for standard pond depth (example: 3.7)
!
High numbers for deep pond depth (example: 4.9)
Brandt
M9252
Operation
R1
Figure 4-1. Epicentric dams control the pond depth (volume of liquid in bowl)
4
Figure 4-2. Numbers on epicentric dams enable setting the pond depth
Guidelines for setting pond depth The following table provides guidelines for setting the pond depth: Highest priority
Lower priority
Use deepest pond setting if...
Maximum clarification of liquid phase
Moisture free content of solids discharge
Use shallowest pond setting if...
Maximum dryness of the solids discharge
Clarification of liquid phase
Procedure for adjusting pond depth To adjust pond depth by setting the epicentric dams, proceed as follows: 1. Shut off power to machine. Observe the following precautions: •
Power leads may be “hot.” DO NOT perform any operation unless proper Lockout / Tagout procedures are in place.
•
Ensure that the bowl has stopped rotating.
HS-3400 Centrifuge Standard XP
4-5
Operation
M9252
R1
2. Open the upper casing lid. 3. Loosen the screws securing one of the dams to the front hub. 4. Rotate to the desire setting indicated by numbers on the dam. a. If the slot will not allow the dam to rotate to the desired setting, remove the screws and reposition the dam. b.
IMPORTANT: Do not drop any of the screws into the liquid discharge line.
5. Repeat the procedure for all four dams.
All the dams must have the same setting or bowl imbalance will occur.
6. Check that both sets of casing gasket are in place, then close the upper casing and secure with screws. 7. The machine can now be restarted.
4
Shut down procedure 1. Turn the variable speed control on pump to the lowest setting. 2. Press the feed pump 'Stop' button on the control panel on the centrifuge skid. 3. If available, send flush water through to clean the lines and the bowl. 4. Press the centrifuge 'Stop' button on the control panel. 5. Allow the bowl to come to a complete stop. 6. Switch off water flush to solid discharge (if fitted). IMPORTANT SAFETY NOTE: Aways remember that the bowl will continue to rotate for a few minutes after centrifuge ‘stop’ button is pressed. Do NOT open the centrifuge casing lid until bowl rotation has completely stopped.
Guidelines for centrifuge shut down The following are guidelines for maintaining proper care of the centrifuge and the centrifuge feed and discharge lines, in case of the following interruptions or shut down periods: !
Brief interruptions in slurry processing
!
Shut down for less than 24 hours
!
Shut down for 24 to 72 hours
!
Shut down for more than 72 hours
Brief interruptions in slurry processing If further slurry is to be processed through the centrifuge within a short period, the centrifuge can be left running with no detrimental effects.
4-6
Brandt
M9252
Operation
R1
In many circumstances, it is less harmful to leave the centrifuge running continuously, rather than switch the unit on and off several times per day.
Shut down for less than 24 hours If the centrifuge is to be shut down even for relatively short periods, it is desirable to continue running the centrifuge unit for 10 to 15 minutes after the feed pump is shut down prior to stopping the centrifuge unit. This helps in cleaning the solids from the bowl.
Shut down for 24 to 72 hours If centrifuge is to be shut down for periods longer than 24 hours, the feed pump and delivery lines should be flushed to remove the solids in the lines. (Some processes may require flushing through the feed pump and delivery lines for shut down periods that are much shorter than this.)
Shut down for more than 72 hours If centrifuge is to be shut down for periods longer then 72 hours, the upper casing should be opened, and all traces of solids and slurry should be washed out of the upper and lower casing sections. This should be done in addition to flushing out the pump and delivery lines, as discussed in the previous paragraph.
4
If centrifuge is to be shut down for periods of 4 weeks or more, consider refitting the shipping cradles (referred to in section 3, Installation) to prevent damage to bearings. If this is not possible, the bowl and motor need to be rotated periodically, either manually or by applying power to the motor.
Resetting the torque control mechanism The torque control mechanism provides the reaction force to the gearbox torque arm and automatically trips at a preset value in the event of transmission overload. In the event of an overload and subsequent trip, both the feed pump and main drive motors will be automatically shut down. The motors cannot be restarted until the torque control mechanism in reset. To reset the torque control, proceed as follows: 1. Shut off power to the drive motor. Lock the starter in the 'OFF' position. 2. Ensure that the bowl has stopped rotating. 3. Remove the screws securing the gearbox guard and withdraw the guards. 4. Before resetting the torque control make the following checks. a. Try turning the torque arm by hand in a clockwise direction. b.
If the torque arm turns without obstruction and the gearbox remains stationary, the conveyor is not blocked or stalled within the bowl. (See step d, below.)
c.
If the gearbox rotates when the torque arm is turned, a blockage in the conveyor is indicated.
HS-3400 Centrifuge Standard XP
4-7
Operation
M9252
R1
d. If the torque arm turns and the gearbox remains stationary (as determined in step b, above), try rotating the gearbox casing by hand. If the gearbox will not rotate, a blockage in the gearbox casing is indicated. Open and clean the gearbox casing. 5. If the centrifuge has cleared itself, reset the torque control by applying sufficient hand pressure to the torque control lever in the anti-clockwise direction to overcome the pressure of the compression link assembly, and set the lever over-center against the stop pin. When resetting the torque control, protect your hands with strong industrial gloves, especially if a high trip setting is in use. Alternatively, a simple reset bar may be manufactured. 6. Replace the casing bolts and gearbox guard. 7. If the centrifuge has not cleared itself, follow these steps: a. Reset the torque control mechanism as described above.
4
b.
Introduce a wash liquid into the centrifuge bowl, and restart the machine.
c.
Continue washing until all solids are cleared. The bowl will usually free itself of solids during the period of acceleration when the centrifugal force is at a lower value than at full speed.
d. As soon as the bowl is clear, the feed can be restarted.
4-8
Brandt
M9252
Troubleshooting
R1
Mechanical problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Centrifuge problems and possible causes . . . . . . . . . . . . . . . . . .5-1 Centrifuge vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Torque overload trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Motor overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Motor will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Process problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 Factors that influence centrifuge fluid processing. . . . . . . . . . . . .5-2 Achieving better separation (cut point) . . . . . . . . . . . . . . . . . . . . .5-3 Troubleshooting various process problems . . . . . . . . . . . . . . . . .5-3 Insufficient capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Insufficient separation (cut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Solids too wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5
Solids too dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
HS-3400 Centrifuge Standard XP
5-A
Troubleshooting
M9252
R1
5
5-B
Brandt
M9252
Troubleshooting
R1
Mechanical problems Centrifuge problems and possible causes Potential centrifuge problems—along with possible causes—are organized and listed below in these problem categories: !
Centrifuge vibration
!
Torque overload trips
!
Motor overload
!
Motor will not start
Centrifuge vibration Slight periodic vibration is normal in a machine of this type because of the speed differential between the bowl and the conveyor. However, if vibration is severe, always investigate the cause. Possible causes for centrifuge vibration are as follows: !
Machine not properly lubricated
!
Liquid discharge funnel not centrally located at casing outlet and amplifying normal vibration
!
Feed slurry plugging bowl and conveyor
!
Casing filled with solids
!
Worn or unbalanced conveyor
!
Worn or unbalanced bowl shell
!
Pulleys misaligned or belt incorrectly adjusted
!
Loose fasteners
!
Misalignment of feed tube
!
Spindle or conveyor bearings worn or damaged
!
Gearbox adapter bent
!
Main bearings or conveyor bearings worn or damaged
!
Main bearing misaligned
!
Centrifuge frame warped or twisted through incorrect shimming
!
Anti-vibration mounts worn or damaged
!
Possible fault within gearbox
!
Hard piping used to centrifuge (i.e., no flexible couplings)
5
Torque overload trips Possible causes for torque overload trips are as follows: !
Conveyor overloaded
!
Conveyor bearings or gearbox not properly lubricated
HS-3400 Centrifuge Standard XP
5-1
Troubleshooting !
Feed rate or concentration too high
!
Incorrect setting of torque control
!
Bowl plugged with solids
!
Fault in conveyor bearings
!
Defective gearbox
M9252
R1
Motor overload Possible causes for motor overload are as follows: !
Accumulation of solids in casing dragging on bowl
!
Machine not properly lubricated
!
Defective motor bearings
!
Excessive feed rate drawing high current
!
Defective centrifuge main bearings
Motor will not start Possible causes for the motor not starting are as follows:
5
!
Torque arm tripped (investigate cause)
!
Motor thermistor protection relay tripped. (Allow time for motor windings to cool before restarting)
!
Accumulation of solids in lower casing
!
Fluid coupling incorrectly filled or fusible plug blown
!
Faulty wiring connections
!
Machine not properly lubricated. (Check manually that assembly rotates freely before restarting)
Process problems Factors that influence centrifuge fluid processing Centrifuge handling capacity (throughput), dryness of solids discharge and cut point (size of particles removed) will vary according to these variables in fluid properties and centrifuge operation: Variables in fluid properties: !
Viscosity of the mud
!
Particle size distribution within the mud
Variables in centrifuge operation:
5-2
!
Pond depth within the centrifuge bowl
!
Flow rate to the centrifuge
Brandt
M9252
Troubleshooting
R1 !
Rotational speed of the centrifuge
To adjust pond depth within the centrifuge bowl, make adjustments to the epicentric dams so they are set within these ranges (see also, in Operation section 4, "Pond depth adjustment" on page 4-4.): !
Deep pond depth ..................... dams set to 4.9
!
Standard pond depth ............... dams set to 3.7
!
Shallow pond depth ................. dams set to 2.5
To adjust the flow rate to the centrifuge, make adjustments to the variable speed drive on the feed pump. To adjust the rotational speed of the centrifuge bowl, use different pulley sizes.
Achieving better separation (cut point) At a given speed, better separation (cut point) is achieved by longer retention time within the centrifuge. Longer retention time is achieved by: !
Slower feed rate
!
Deeper pond
Deeper pond will, however, generally give a wetter solid product.
Troubleshooting various process problems
5
Potential centrifuge fluid processing problems—along with possible causes—are organized and listed below in these problem categories: !
Insufficient capacity
!
Insufficient separation (cut)
!
Solids too wet
!
Solids too dry
Tuning the centrifuge, in order to troubleshoot or solve these fluid processing problems, is a process of trade-offs. Setting up the centrifuge may require various compromises to yield acceptable discharge of solids and liquid, in both quantity and condition, for any given situation.
Insufficient capacity Possible causes for insufficient solids output are as follows: !
Pond depth too shallow
!
Torque arm incorrectly set (NOTE: On very heavy mud, dilution may assist total volume processed by reducing viscosity)
Insufficient separation (cut) Possible causes for insufficient separation (cut) are as follows: !
Pond depth too shallow
HS-3400 Centrifuge Standard XP
5-3
Troubleshooting !
Feed rate too high
!
Conveyor flights worn
!
Bowl speed too low
M9252
R1
Solids too wet !
Pond depth too high
!
Feed rate too high
Solids too dry !
Pond depth too shallow
!
Insufficient feed rate
5
5-4
Brandt
M9252
Maintenance and Repair
R1
Periodic checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Maintenance checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Lubrication schedule for centrifuge . . . . . . . . . . . . . . . . . . . . . . . .6-2 Centrifuge lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3 Gearbox lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3 Conveyor bearings lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 Lubricating the conveyor front bearing (gearbox end) . . . . . . . . . . . 6-5 Lubricating the conveyor rear bearing (pulley end) . . . . . . . . . . . . . 6-6
Main bearings lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 Repacking main bearings with grease . . . . . . . . . . . . . . . . . . . . . . . 6-7 Main bearing operating temperatures. . . . . . . . . . . . . . . . . . . . . . . . 6-8
Torque control lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
6
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 Centrifuge bowl cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Rotating assembly repair and overhaul . . . . . . . . . . . . . . .6-12 Removing the rotating assembly. . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Installing the rotating assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Gearbox repair and overhaul . . . . . . . . . . . . . . . . . . . . . . .6-17 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Disassembling the gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Removing the gearbox pinion shaft bearing . . . . . . . . . . . . . . . . . . 6-19 Installing the gearbox pinion shaft bearing . . . . . . . . . . . . . . . . . . . 6-20
HS-3400 Centrifuge Standard XP
6-A
Maintenance and Repair
M9252
R1
Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Torque control repair and overhaul . . . . . . . . . . . . . . . . . . 6-21 Torque arm removal and installation . . . . . . . . . . . . . . . . . . . . . 6-21 Removing the torque arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Installing the torque arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Torque control disassembly and assembly . . . . . . . . . . . . . . . . 6-22 Disassembling the torque control. . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Assembling the torque control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Installing the drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Tightening torque recommendations . . . . . . . . . . . . . . . . 6-27 UNC / UNF, high tensile steel, grade 12.9 . . . . . . . . . . . . . . . . . 6-28 UNC / UNF, stainless steel, etc., grade 8.8 . . . . . . . . . . . . . . . . 6-28 Metric, high tensile steel / stainless steel . . . . . . . . . . . . . . . . . . 6-29
6
6-B
Brandt
M9252
Maintenance and Repair
R1
Periodic checks The following operation checklist details checks that should be made at the beginning of each shift or at intervals decided by plant engineering or management staff. It is strongly recommended that all operators become familiar with the list and perform the checks regularly. This will increase efficiency by preventing oversights that can cause delay or costly damage to the equipment. Ideally the list should be reproduced as a chart which could be hung up at the workstation and marked off as each check is completed.
Maintenance checklist Completed
1 Read and digest all safety precautions. 2 Ensure that lubricant levels are maintained. Do not operate centrifuge without adequate lubricant. 3 Ensure that only recommended lubricants are used. 4 Maintain cleanliness of centrifuge, noting oil spills or leaks. 5 Maintain cleanliness of service area, including catwalks or ladders to prevent accidents. 6 Note any unusual noise or vibration. 7 Note excessive vibration and record readings. 8 Ensure that safety guards and upper casing are secured in place and in good condition. 9 Ensure that all fasteners are secure.
6
10 Ensure that all mountings are in good condition. 11 Check condition of drive belt. 12 Check the drive belt tension. 13 Check that automatic shutdown interlocks are operational. 14 Ensure that torque control trips at the desired setting. Lubricate the linkage and test at least once per month. 15 Inspect areas around seals and bearings of conveyor and gearbox spindle for leakage. 16 Check that electrical connections are secure and in good condition.
HS-3400 Centrifuge Standard XP
6-1
Maintenance and Repair
M9252
R1
Lubrication Lubrication schedule for centrifuge Ensure only recommended lubricants are used.
The following table lists the lubrication points, recommended lubricants, and lubrication schedule for the centrifuge. (See Figure 6-1, below, for locations.) Location
Lubricant
Frequency
Centrifige main bearings
Aeroshell 14 grease, P/N 001-108-100
One shot every day. Purge every 1500 hours or every 2 months.
Centrifuge conveyor
Aeroshell 14 grease, P/N 001-108-100
Purge every 2 weeks.
Centrifuge gearbox
Royal Purple® GT220 Synfilm Oil, P/N 46BJ
Check every 2 weeks. Change once every 12 months or 4000 hours.
Torque control assembly
Aeroshell 14 grease, P/N 001-108-100
Grease every 4 weeks
Pump variable speed gearbox
TD-22 Synthetic Traction Oil, P/N 46BC
Check every 2 weeks. Change once every 20000 hours.
���
���
6
���
���
��� ��� ���
���
Centrifuge gearbox Conveyor bearings Main bearings
Figure 6-1. Centrifuge lubrication points (see previous table for schedule)
6-2
Brandt
M9252
Maintenance and Repair
R1
Centrifuge lubrication For the centrifuge, periodic lubrication is needed for these two bearing sets: !
Main bearings
!
Conveyor bearings
Quick procedures for lubricating the main and conveyor bearings are next. Later sections provide more details. Main bearings lubrication, quick procedure: 1. Bearings are located in front and rear pillow blocks. 2. Grease while the unit is running. 3. At each of the pillow blocks, remove the plug from the bearing housing opposite the grease nipple on the other side. 4. With the unit running, pump one shot of grease in each pillow block every 24 hours. 5. After greasing, allow the unit to run for some time before refitting plug. 6. Periodically clean away the excess grease that will accumulate around the base of the pillow block. (For more details, see "Main bearings lubrication" on page 6-7.) Conveyor bearings lubrication, quick procedure: 1. Front conveyor bearing is located at the gearbox end. Rear conveyor bearing is located at the pulley end. 2. Grease while unit stopped. 3. Ensure that the grease escape hole is not plugged. Avoid injecting grease too fast or with excessive pressure. (See note below.)
6
4. Grease very slowly, and rotate the torque arm forwards and backwards to distribute grease. 5. Continue greasing until clean grease emerges from the escape channel. (For more details, see "Conveyor bearings lubrication" on page 6-5.) Grease applied under pressure or too fast to the front conveyor bearing at the gearbox end can result in damage to the gearbox seal. This may result in oil loss from the gearbox. Therefore, when lubricating each of the conveyor bearings, always: •
Ensure the grease escape hole is not plugged.
•
Apply grease slowly.
Gearbox lubrication The gearbox is normally supplied ready filled with lubricant, but the oil should still be checked before initial startup. It should subsequently be checked every 2 weeks, unless otherwise specified, and changed every 12 months.
HS-3400 Centrifuge Standard XP
6-3
Maintenance and Repair
M9252
R1
Mild EP type synthetic oil, such as Royal Purple® GT220, is required which must be of a non-corrosive nature. Any additives should be such that they will not separate out under continuous centrifuging. To check and fill the gearbox, proceed as follows: 1. Shut off the power to the drive motor and lock the starter in 'OFF' position. 2. Ensure that the bowl has stopped rotating. 3. Remove the screws securing the gearbox guard and withdraw the guards. 4. Rotate the gearbox until the filler plug in the side of the gearbox casing is in the topmost position. This will set the two 1/8 inch pipe plugs in the front face of the gearbox in vertical alignment (see Figure 6-2, below).
Figure 6-2. Fill gearbox casing to upper level plug with oil syringe
6
5. Thoroughly clean the gearbox casing in the area of the filler and level plugs. Remove the filler plug and the upper level plug. Check that the oil level is slightly below the upper level plug. If not, add oil of the recommended grade to bring up the level using the gearbox oil syringe.
Exercise care to prevent dirt or chips from entering the gearbox.
6. If consistent loss of oil is evident, check the pinion shaft seal (i.e., where the backdrive is attached to the gearbox). Also check the gearbox adapter area (i.e., where the gearbox is attached to the bowl hub). 7. If leakage occurs from the pinion shaft seal, the seal may be replaced, as described later in section 6, "Disassembling the gearbox" on page 6-19. If leakage is evident around the gearbox adapter, the complete gearbox must be returned to the Brandt Service Department for factory repair. 8. If no further lubrication is necessary, reinstall and secure gearbox guard.
6-4
Brandt
M9252
Maintenance and Repair
R1
Conveyor bearings lubrication The front and rear conveyor bearings are lubricated at the factory before shipment and must be lubricated at least once every 2 weeks of operation. Failure to follow this schedule will cause solidification of grease, which can lead to bearing failure. If the centrifuge application necessitates frequent washing and/or steam cleaning, the conveyor bearings must be lubricated on each occasion after steam cleaning and prior to returning the machine to service. Steam cleaning and high-pressure water cleaning should not be applied in the immediate vicinity of the pillow blocks. If any doubts exist relative to cleaning or to frequency of lubrication, contact the Brandt Service Department.
Lubricating the conveyor front bearing (gearbox end) Grease introduced through the grease fitting situated in the wall of the gearbox adapter (see Figure 6-3, below) passes along the bore of the hub extension to the spline bushing and into the conveyor bearings. GEARBOX ADAPTOR
SEAL HOLDER
CONVEYOR BEARING
6
Figure 6-3. Conveyor front bearing grease channel
Excess grease passes back through an escape channel in the bowl hub extension that terminates in an aperture through the extension wall within the casing seal holder. To lubricate the conveyor front bearing: 1. Inject grease of the recommended grade slowly into the grease fitting until clean grease emerges from the escape channel.
HS-3400 Centrifuge Standard XP
6-5
Maintenance and Repair
M9252
R1
2. During greasing, remove the gearbox guard and rotate the pinion shaft forward and backwards alternately. This will distribute the grease and reduce the risk of possible rupture of the grease seals. 3. Take note if any of these symptoms of a mechanical problem occur: a. If any resistance to the input of grease is experienced, this will indicate plugged channels. In this event, greasing should be stopped immediately to prevent possible damage to the seals. The escape channel must then be cleared, if necessary by removing the pillow block assembly and clearing with a suitable rod or wire. b.
If during greasing, dirt or centrifuge product emerges from the escape channel, this will indicate that the bearing seals are damaged and in need of replacement. (Contact Brandt for service procedures.)
c.
If during greasing, metal chips emerge with the old grease, this will indicate bearing deterioration that should be checked. (Contact Brandt for service procedures.)
4. Reinstall the guard securely after greasing and before starting the machine.
Lubricating the conveyor rear bearing (pulley end) Grease introduced through the grease fitting situated in the pulley hub adjacent to the rear pillow block (see Figure 6-4) passes directly along a channel in the bowl hub extension to the conveyor bearing. CONVEYOR BEARING
SEAL HOLDER
PULLEY
6
Figure 6-4. Conveyor rear bearing grease channel
Excess grease passes back through a parallel escape channel in the bowl hub extension wall and discharges within the casing seal holder.
6-6
Brandt
M9252
Maintenance and Repair
R1
To lubricate the conveyor rear bearing: 1. Inject grease of the recommended grade into the grease fitting until clean grease emerges from the escape channel. 2. During greasing, remove the gearbox guard and rotate the pinion shaft forward and backwards alternately. This will distribute the grease and reduce the risk of possible rupture of the grease seals. 3. Take note if any of these symptoms of a mechanical problem occur: a. If any resistance to the input of grease is experienced, this will indicate plugged channels. In this event, greasing should be stopped immediately to prevent possible damage to the seals. The escape channel must then be cleared, if necessary by removing the pillow block assembly and clearing with a suitable rod or wire. b.
If during greasing, dirt or centrifuge product emerges from the escape channel, this will indicate that the bearing seals are damaged and in need of replacement. (Contact Brandt for service procedures.)
c.
If during greasing, metal chips emerge with the old grease, this will indicate bearing deterioration that should be checked. (Contact Brandt for service procedures.)
4. Reinstall the guard securely after greasing and before starting the machine.
Main bearings lubrication The main bearings, situated in the front and rear pillow blocks, are lubricated at the factory before shipment and require one shot of the recommended grease to each pillow block every 24 hours. Periodically clean away the excess grease that will accumulate around the base of the pillow block.
Repacking main bearings with grease
6
To repack main bearings with grease, proceed as follows: 1. Refer to "Lubrication schedule for centrifuge" on page 6-2 for type of lubricant. 2. Ensure that the drive belt and gearbox guards are securely in place. 3. Ensure that the upper casing is closed and secured to the lower casing. 4. Remove the grease plugs from the front and rear pillow blocks (see Figure 6-5).
HS-3400 Centrifuge Standard XP
6-7
Maintenance and Repair
M9252
R1
��� ��� ��� ��� ���
Grease plug Pillow block Grease fitting
��� Figure 6-5. Grease points for 1 of 2 main bearings
5. If required, insert a grease fitting into one of the holes in each pillow block that was vacated by the grease plug. 6. Run the machine so that the bowl is rotating at normal speed, and inject grease in small amounts at intervals sufficient to allow the grease temperature to rise gradually. 7. If the grease escape hole is plugged with hardened grease, insert the grease fitting into the plugged aperture and inject grease in the reverse direction. 8. When front and rear main bearings have been lubricated successfully remove the grease fittings and run the machine for approximately 10 hours with all four holes open to allow excess grease and trapped air to exhaust through the apertures. 9. After the requisite setting period, install the grease plugs securely.
6
Main bearing operating temperatures The normal running temperature of the pillow blocks is less than 120° F (50° C) when the machine is running and slurry is not being fed, or the slurry feed is cool. When the bearings are first filled with grease, however, the temperature will rise above normal running temperature for a short period of time. Temperature should not be in excess of 165° F (75° C). If excessive temperature is encountered, remove the bearing end plate, and remove sufficient grease to leave the cavity approximately half full. (See Figure 6-6, below, items 61 through 63, which include the bearing end plates. The figure is a portion of drawing "Rotating assembly - SA11684" on page 7-10.)
6-8
Brandt
M9252
Maintenance and Repair
R1
63
62
61
61
SET 0.62 FLINGER 0.63
0.70 SET 0.71 FLINGER
.008/.020 GAP
.008/.020 GAP
61
Flinger cover
62
End plate, drive end
63
End plate, gearbox end
Figure 6-6. Main bearing end plate can be removed to eliminate excess grease
Torque control lubrication The inside of the female-spring compression link and the outside of the male-spring compression link projection are lubricated at the factory before shipment and should normally be greased every 4 weeks. On certain applications, however, shorter intervals between greasing may be necessary.
6
To lubricate the torque control, proceed as follows: 1. Refer to "Lubrication schedule for centrifuge" on page 6-2 for type of lubricant. 2. Shut off the power to the drive motor, and lock the starter in 'OFF' position. 3. Ensure that the bowl has stopped rotating. 4. Remove the screws securing the gearbox guard, and withdraw the guard. 5. Using industrial protective gloves, or suitable setting bar, manually trip the torque control by turning torque control lever in clockwise direction until it snaps over center and rests against the stop pin. (See Figure 6-7, below.)
HS-3400 Centrifuge Standard XP
6-9
Maintenance and Repair
M9252
R1
1 5 6 2
4
3
��� ��� ���
Torque control level Lock nut Cotter / split pin
��� ��� ���
Pivot pin Compression link assembly Compression spring
Figure 6-7. Lubrication at compression link assembly of torque control
6. Loosen lock nut and turn adjusting nut out all the way. 7. Remove split pin from pin, and remove the pin from compression link. Slide the male compression link from female compression link. 8. Apply the appropriate grease to the inside of the female compression link and the outside of the projection of the male compression link, and reassemble the two parts. 9. Reconnect the male link to the torque control lever with pin and split pin. Ensure that the drain hole in the male compression link is positioned at the bottom.
6
10. Adjust and reset the torque control as described under "Assembling the torque control" on page 6-23.
Cleaning If it is necessary to clean and flush the centrifuge bowl with hot water, caustic or other dilutant—whether regularly or otherwise—always perform this type of cleaning before shutting down the centrifuge. For this type of cleaning, it also advisable to divert the flow of flushing medium in order to prevent contamination of the effluent. Conveyor flights, etc. are equipped with tungsten carbide tiles that are designed to protect them from abrasive wear. These tiles are by nature not as corrosion resistant as the stainless steels used in construction of the centrifuge. To reduce the risk of chemical damage, consult Brandt prior to using any cleansing, rinsing, washing or bacteria killing agents in the centrifuge.
6-10
Brandt
M9252
Maintenance and Repair
R1
Centrifuge bowl cleaning To clean the centrifuge bowl, follow these steps: 1. Shut off flow of feed slurry. 2. Shut off rinsing (if in use). 3. Operate flush/feed diverter control (if fitted). 4. Introduce flushing liquor. 5. After requisite flushing period, shut off the centrifuge but continue flushing after the bowl has stopped rotating. This flushing will deliver flushing liquid and some solids into the liquid discharge ports. 6. Lock the starter in 'OFF' position, but continue flushing. 7. Ensure that the bowl has stopped rotating. 8. Remove the screws of the gearbox guard and withdraw the guard. 9. Rotate the bowl forwards and backwards by rotating the gearbox several turns alternately in each direction by hand while the flushing continues. When flushing is complete, shut off supply of flushing liquid. The action of rotating and contra-rotating the bowl will displace a proportion of the solids into the liquid discharge. If this procedure is unacceptable, arrangements should be made to divert this discharge to waste during the cleaning period. 10. Remove the screws that secure the upper casing to the lower casing. Ensure that the screws in both sides and ends of the casing are removed. Swing the upper casing back on its hinge or remove as applicable. 11. Flush out the upper and lower casings with steam, hot water or solvent.
6
Take necessary safety measures to prevent possible injury from cleaning medium. Steam cleaning and high-pressure water cleaning should not be applied in the immediate vicinity of the pillow blocks (main bearings). 12. Check that both sections of the casing gasket are in place, then close and secure the upper casing with screws. 13. If this method of cleaning does not remove all the deposits, the bowl must be disassembled, and each part must be cleaned individually. 14. After cleaning, reassemble the bowl, etc. Close and secure the casing, and securely refit the gearbox guard and belt guard.
HS-3400 Centrifuge Standard XP
6-11
Maintenance and Repair
M9252
R1
Rotating assembly repair and overhaul Removing the rotating assembly To remove the centrifuge rotating assembly, proceed as follows: 1. Shut off power to the drive motor, and lock the starter in 'OFF' position. 2. Ensure that the bowl has stopped rotating. 3. Remove the screws securing the belt guard, and remove the guard. 4. Remove the screws securing the gearbox guard to main frame, and withdraw the guard. 5. If the rotating assembly is to be disassembled, remove the gearbox. (See procedure in this section, "Removing the gearbox" on page 6-17.) 6. Remove the screws that secure the upper casing to the lower casing. Ensure that the screws on both sides and ends of the casing are removed. Swing the upper casing back on its hinge, or remove as applicable. 7. Ensure that the feed tube clamping cap is marked for reassembly, then remove the screws securing the cap to the feed tube bracket (see Figure 6-8). Remove the cap, and withdraw the feed tube.
6
Figure 6-8. Remove the screws securing the cap to the feed tube
8. Loosen the motor securing nuts. Turn the belt adjusting screws to move the drive motor and sliding base towards the centrifuge (see Figure 6-9). Remove the drive belt.
6-12
Brandt
M9252
Maintenance and Repair
R1
Figure 6-9. Loosen motor securing and belt adjusting screws
9. Remove the pillow block dowel pin protector caps, then withdraw dowels, as follows, by using the shaft and sliding hammer portion of the dowel sleeve extractor tool (see Figure 6-10): a. Assemble the sliding hammer to the shaft portion of the dowel sleeve extractor. Engage the female thread in the end of the shaft over the protruding thread of the dowel pin, and screw home securely. b.
Withdraw the dowel by impact of the sliding hammer against the stop nut at the top of the shaft.
c.
Repeat the operation on each of the dowels.
6 Figure 6-10. Extract dowel pins
HS-3400 Centrifuge Standard XP
6-13
Maintenance and Repair
M9252
R1
10. Extract the dowel pin outer sleeves, as follows, by using the complete dowel sleeve extractor tool (see Figure 6-11): a. Assemble the sliding hammer to the shaft portion of the extractor, and attach the lifter assembly to the female thread in the end of the shaft. b.
Having first removed the dowel pin, slide the eccentric sleeve along the lifter until it contacts the cap.
c.
Holding the extractor assembly upright, insert the lifter down through the bore of the dowel sleeve as far as possible. Then push the eccentric sleeve down into the bore of the dowel sleeve to lock the lifter into the dowel sleeve recess.
d. Extract the dowel sleeve by impact of the sliding hammer against the stop nut at the top of the shaft.
Figure 6-11. Extract dowel sleeves
e. Repeat the operation on each of the dowel sleeves. 11. Unscrew and remove the pillow block securing screws together with lockwashers.
6
12. Attach the bowl lifter to a hoist, and position it centrally over the bowl. The hoist hook or shackle should be connected to the specific aperture on the bowl lifter marked 'WITH GEARBOX' or 'WITHOUT GEARBOX' as applicable. (See Figure 6-12.) 13. Pass the two bowl lifting straps beneath the bowl. Form each strap into a noose, and connect the free end of each strap to the correct hook on the bowl lifter. Ensure that the bowl lifter and straps are securely placed and that no personnel are at risk in the event of accidental release of the lifting gear.
6-14
Brandt
M9252
Maintenance and Repair
R1
14. Lift the complete rotating assembly clear of the frame and secure it in the Bowl Cradle or lay it horizontally on blocks to keep it from rolling. Disconnect the bowl lifter.
CHOICE OF HOOK POSITION WITH GEARBOX WITHOUT GEARBOX BOWL LIFTER BEAM CHOICE OF SLING POSITIONS PER MODEL LIFTING STRAP
6 Figure 6-12. Rotating assembly lifted clear of the frame
Installing the rotating assembly To install the rotating assembly, proceed as follows: 1. Check that the mounting faces of the pillow blocks and mating surfaces of the frame are free of obstruction. If necessary, smooth these surfaces with a file or sandpaper. 2. Connect the bowl lifter and lifting straps to the hoist and bowl. (See Figure 612.) 3. Lift the rotating assembly and suspend it centrally over the centrifuge frame. Take great care when guiding the rotating assembly into the frame that hands, fingers, clothing, etc. are not vulnerable in the event of accidental release of lifting gear.
HS-3400 Centrifuge Standard XP
6-15
Maintenance and Repair
M9252
R1
4. Carefully lower the assembly until the mounting faces of the pillow blocks are just clear of the top face of the frame pads, then insert the dowel pin outer sleeves through the pillow blocks and into the frame as described in the next step. The importance of the pillow block dowels and sleeves should not be underestimated. Correct and careful assembly is essential to the safety and smooth running of the centrifuge. Loose, cracked, distorted or missing dowels or sleeves can cause: •
Serious misalignment of the pillow blocks.
•
Premature failure of main bearings.
•
Extreme vibration.
•
Friction between the rotating assembly and casing baffles causing heat and possible fire hazard.
•
Fracture of pillow blocks and frame pads.
•
Loosening and fracture of pillow block securing screws.
5. To insert dowel pin outer sleeves, proceed as follows: a. Align the pillow block dowel holes with those in the frame pads by inserting a suitable length of steel rod (slightly smaller in diameter than the holes) through one of the dowel holes in each of the pillow blocks and into the frame. b.
With the pillow block and frame holes accurately aligned, lower the rotating assembly further until the pillow blocks just touch the frame pads.
c.
Press one dowel sleeve into the vacant hole in each pillow block. Use only hand pressure, and ensure that the recessed end of the sleeve enters the hole first. Do not force the sleeves by hammering, as this will damage the sleeves and the frame.
6
If more than hand pressure is necessary to position the sleeve fully against the shoulder at the bottom of the hole, carefully tap into place with a soft faced mallet. d. Remove the two locating rods and insert the remaining two sleeves. 6. Continue lowering the hoist. 7. With the mounting faces of the pillow blocks fully in contact with the frame, insert the tapered portion of each dowel pin, and tap it fully home with a light soft faced hammer. 8. Install the dowel pin protector caps. 9. Insert the pillow block securing bolts, complete with washers, and tighten securely. 10. Disconnect the bowl lifter. 11. If the gearbox was removed from the rotating assembly, install as described in "Installing the gearbox" on page 6-20. 12. Install the drive belt, and adjust tension as described in "Installing the drive belt" on page 6-25.
6-16
Brandt
M9252
Maintenance and Repair
R1
13. Install the feed tube as described in section 3, under "Installing the feed tube" on page 3-6. Ensure that the feed tube clamping surfaces are thoroughly cleaned. 14. Check that the two sections of the casing gasket are in place, then close and secure the upper casing to the lower casing. 15. Check for freedom of bowl rotation. 16. Lubricate the assembly as described in "Lubrication" on page 6-2. 17. Re-install and secure all guards.
Gearbox repair and overhaul Removing the gearbox To remove the centrifuge gearbox, proceed as follows: 1. Shut off power to the drive motor and lock the starter in 'OFF' position. 2. Ensure that the bowl has stopped rotating (wait at least 10 minutes). 3. Remove the screws securing the gearbox guard, and withdraw the guard. 4. If the machine is equipped with a torque control assembly, perform these steps: a. Slacken the lock nut and the locking screw that secures the torque arm to the gearbox pinion shaft. (The locking screw must clear the location flat on the shaft.) b.
Withdraw the torque arm.
c.
Trip the torque control.
5. If the gearbox is to be disassembled (see "Disassembling the gearbox" on page 6-19), drain the lubricant as described in the section "Gearbox lubrication" (see page 6-3). 6. Support the gearbox with a sling attached to a hoist so that the spline shaft will not be damaged when it is withdrawn from the spline bushing in the conveyor. (See Figure 6-13).
HS-3400 Centrifuge Standard XP
6-17
6
Maintenance and Repair
M9252
R1
Figure 6-13. Support the gearbox with a sling for removal
7. Match mark the gearbox and adapter. 8. Remove the screws securing the gearbox to the adapter. 9. Insert the two special hardened jacking screws into the tapped holes in the gearbox adapter. Screw the jacking screws in evenly, and jack the gearbox clear. (See above, Figure 6-13.) a. Gearbox removal jacking screws are available as Brandt part number 001203-0805. b.
As a substitute for the Brandt part, use two 8 mm x 30 or 35 hex head bolts. (Do NOT use a 10 mm bolt as a substitute. The alignment of the tapped holes of 10 mm size in the gearbox adapter will allow the bolt to scar the mating groove between the gearbox adapter and gearbox.)
10. Ensure that the sling is supporting the full weight of the gearbox, and carefully withdraw the gearbox from the machine. (See Figure 6-14.)
6
Figure 6-14. Support weight of gearbox while withdrawing shaft
11. Remove the jacking screws from the gearbox adapter.
6-18
Brandt
M9252
Maintenance and Repair
R1
Disassembling the gearbox Permissible disassembly extends only as far as replacement of the pinion shaft, the pinion shaft oil seal, gasket and bearing. If other parts are damaged, the entire assembly must be replaced with a new or rental gearbox, and the damaged gearbox must be returned to Brandt for repair.
Removing the gearbox pinion shaft bearing Removing the gearbox pinion shaft bearing can be performed with the gearbox in place or out of the machine. 1. If the removal of the pinion shaft is to be undertaken when the gearbox is in the machine, perform steps 1 through 5 for "Removing the gearbox" (see page 617). 2. If the removal of the pinion shaft is to be undertaken while the gearbox is out of the machine, perform all of the steps for "Removing the gearbox" (see page 617). 3. Refer to Figure 6-15, below, which illustrates the disassembly / assembly of parts for removing the gearbox pinion shaft bearing.
6
Figure 6-15. Assembly / disassembly of parts for gearbox pinion shaft bearing
4. Unscrew pinion shaft oil seal housing screws. 5. Withdraw the seal housing, complete with oil seal, and remove the gasket. 6. Extract oil seal from the seal housing. 7. Withdraw the pinion shaft and bearing from the gearbox. 8. Inspect all parts for wear and damage.
HS-3400 Centrifuge Standard XP
6-19
Maintenance and Repair
M9252
R1
a. The gear teeth on the pinion shaft must be free of pits, cracks or flaws of any nature. b.
Check the bearing for damage or wear by carefully contra-rotating the inner and outer rings while holding them with the tips of the fingers. Any roughness indicates damage.
Installing the gearbox pinion shaft bearing To install the gearbox pinion shaft bearing, refer to Figure 6-15, and proceed as follows: 1. If bearing replacement is necessary, mount the pinion shaft and bearing assembly on an arbor press, and press the bearing from the shaft. Using a suitable length of clean steel tubing, press the new bearing by the inner race onto the pinion shaft. 2. Insert the pinion shaft into the gearbox. Take care to mesh the gear teeth on the first stage planet gears, and note these details: a. The inner end of the pinion shaft is supported by a bearing within the gearbox and must enter the bearing within the gearbox as the shaft is inserted. b.
If the pinion outer bearing (pressed on the shaft) does not enter the recess in the gearbox front cover completely, agitate the shaft slightly to enter it in the bearing.
c.
Once entered, the pinion shaft may be pushed fully into place allowing the outer bearing to seal fully in the recess in the front cover.
3. Press a new pinion shaft oil seal into oil seal housing. 4. Insert screws into the oil seal housing. 5. Assemble a new oil seal gasket to the oil seal housing by locating it on the screws.
6
6. Apply an even film of mineral oil to the bore of the oil seal. 7. Install the oil seal housing assembly to the gearbox front cover. Secure in place with screws. 8. If replacement of the pinion bearing was undertaken with the gearbox out of the machine, assemble the unit to the machine as described in the section "Installing the gearbox" (see page 6-20). 9. If replacement of the pinion shaft bearing was undertaken with the gearbox on the machine, refill the gearbox with the correct grade of oil to the correct level as described in the section "Gearbox lubrication" (see page 6-3). 10. Reinstall and secure the gearbox guard.
Installing the gearbox To install the centrifuge gearbox, proceed as follows: 1. Ensure that the mating surfaces of the gearbox and the adapter are free of obstruction. Smooth with a file or sandpaper. Alignment of the gearbox and smooth running of the machine depend on true fitting of these surfaces. 2. Support the gearbox with a sling attached to a hoist.
6-20
Brandt
M9252
Maintenance and Repair
R1
3. Raise the gearbox and suspend it level with the axis of the bowl. 4. Align the gearbox spline shaft with the adapter, and carefully enter the shaft through the adapter and front hub into the spline bushing in the conveyor. Note these details: a. To facilitate engagement of the shaft and bushing, rotate the gearbox pinion shaft to align the male and female splines, while simultaneously pushing the gearbox into engagement with the gearbox adapter. b.
Prior to the full entry of the gearbox spigot into the adapter, align the match marks on the adapter with those on the gearbox.
5. Insert and tighten the gearbox-to-adapter screws securely. 6. Rotate the gearbox pinion shaft to position the torque arm location flat at the top. 7. Ensure that the torque arm locking screw is clear of the bore and assemble the arm to the pinion shaft. 8. Tighten the torque arm locking screw securely onto the location flat, and lock in place with the lock nut. 9. Reset the torque control as described in "Assembling the torque control" on page 6-23. 10. If previously drained, refill the gearbox with the correct grade of oil to the correct level as described in the section "Gearbox lubrication" on page 6-3. 11. Reinstall and secure the gearbox guard.
Torque control repair and overhaul This section provides procedures for: !
Torque arm removal and installation
!
Torque control disassembly and assembly
6
Torque arm removal and installation Removing the torque arm To remove the torque arm, proceed as follows: 1. Shut off power to the drive motor, and lock the starter in the 'OFF' position. 2. Ensure that the bowl has stopped rotating. 3. Remove the screws securing the gearbox guard to the main frame. 4. Slacken the lock nut and the locking screw that secures the torque arm to the gearbox pinion shaft. The screw must clear the location flat in the shaft. 5. Withdraw the torque arm. 6. Check the condition of the arm to ensure that the bore is not worn or corroded and that no cracks exist.
HS-3400 Centrifuge Standard XP
6-21
Maintenance and Repair
M9252
R1
Installing the torque arm To install the torque arm, proceed as follows: 1. Rotate the gearbox pinion shaft to position the torque arm location flat at the top. 2. Ensure that the torque arm locking screw is clear of the bore, and assemble the arm to pinion shaft. 3. Tighten the locking screw securely onto the location flat, and lock in place with the lock nut.
Torque control disassembly and assembly Disassembling the torque control To disassemble the torque control, proceed as follows: For references to item numbers listed in the following steps, see drawing "Torque control assembly - 034-8SD-006" on page 7-18 . 1. Using industrial protective gloves, or a suitable setting bar, manually trip the torque control by turning torque control lever in clockwise direction until it snaps over center and rests against the stop pin (see Figure 6-16).
6
Figure 6-16. Manually tripping the torque control
2. Loosen lock nut (802/11), and turn adjusting nut (802/6) out all the way. 3. Remove split pin (802/19) from pin (802/9), and remove the pin from male compression link (802/8). 4. Remove split pin (802/19) from pivot pin (802/4), and withdraw the compression link assembly. 5. Place the compression link assembly on as clean working surface, and slide male compression link (802/8) from female compression link (802/5). Remove spring (802/6). 6. Remove retaining ring (802/16) from pivot shaft (802/12), and withdraw torque control lever (802/13). 7. Clean and inspect all parts for wear and renew as necessary.
6-22
Brandt
M9252
Maintenance and Repair
R1
8. Check the condition of the stop pin sleeve (802/7) and renew if damaged. 9. Check the condition of the microswitch.
Assembling the torque control To assemble the torque control, proceed as follows: For references to item numbers listed in the following steps, see drawing "Torque control assembly - 034-8SD-006" on page 7-18. 1. Assemble torque control lever (802/13) to pivot shaft (802/12), and secure in place with retaining ring (802/16). 2. Insert compression spring (802/13) into the bore of adjustment nut. 3. Apply the appropriate grease (see "Lubrication schedule for centrifuge" on page 6-2) to the inside of the female compression link and the outside of the projection of the male compression link, and reassemble the two parts. 4. Install the compression link assembly on pivot pin (802/4), and retain with split pin (802/19). 5. Reconnect the male link to the torque control lever with pin (802/9) and split pin. Ensure that the drain hole in the link wall is positioned at the bottom. 6. Set the torque control trip point, as described next. When resetting the torque control, protect your hands with strong industrial gloves, especially if a high trip setting is in use. Alternatively, a simple reset bar may be manufactured. 7. Set the torque control by applying sufficient hand pressure to torque control lever (802/13) in anti-clockwise direction to overcome the pressure of the compression link assembly and to set the lever over-center against the stop pin (see Figure 6-17).
HS-3400 Centrifuge Standard XP
6-23
6
Maintenance and Repair
TORQUE CONTROL LEVER
M9252
R1
APPLY PRESSURE
Figure 6-17. Resetting torque control in anti-clockwise direction
8. Turn spring adjusting nut (802/11) inwards to the approximate position it occupied prior to disassembly. 9. Determine the torque control tripping force, as follows: a. Engage a 50 Kg (110 lb) capacity spring scale at the upper (pad) end of torque control lever (802/13).
6
b.
Apply tension from the spring scale to the arm in a clockwise direction, at 90° to the pad face. (See Figure 6-18.)
c.
Steadily increase the tension until the control trips.
d. Note the force measured on the spring scale, and compare it to the “maximum allowable force on torque arm” (see next step).
Figure 6-18. Using a spring scale to determine torque control tripping force
6-24
Brandt
M9252
Maintenance and Repair
R1
10. If tripping occurs below the prescribed maximum allowable force (see the following note), then proceed as follows: Applicable to gearbox part number 034-805-000 / 1: •
Maximum allowable force on torque arm = 41 kg (90 lb)
a. Reset the torque control lever. b.
Screw the spring adjusting nut inwards.
c.
Trip the mechanism again using the spring scale, and note the tripping force.
d. Repeat the operation until the correct setting is obtained. 11. When a satisfactory trip figure has been achieved, tighten lock nut (802/11), and reset the torque control to operating position. Locking pin will prevent the control from being adjusted beyond the maximum allowable torque setting.
Operating at higher loads than those stated in the note above will result in premature gearbox failure. Never block the torque mechanism to prevent tripping out. 12. If microswitch (802/27) was removed during disassembly, re-install and lubricate arm and roller pivots. Ensure that the roller is correctly positioned relative to spring compression link (802/8) i.e., that the switch is actuated when the torque control trips. 13. Re-install and secure the gearbox guards.
Installing the drive belt After installing and / or re-securing the rotating assembly into the frame and prior to fitting the feed tube, install the drive belt by following these steps: 1. Ensure the motor and centrifuge pulleys have not sustained nicks or burrs during handling. Also check that the pulleys have not been contaminated with dirt, oil or rust etc, all of which can damage drive belt. 2. Check the alignment of the pulley by holding a straight edge against the pulley outer faces (see Figure 6-19); any evidence of pulley wobble will make pulley alignment impossible.
HS-3400 Centrifuge Standard XP
6-25
6
Maintenance and Repair
M9252
R1
Figure 6-19. Straight edge against pulley outer faces to check alignment
3. Ensure that the drive belt is clean, dry and in good condition. If grease or oil has contaminated belt, clean thoroughly with a suitable nonflammable cleaning agent. 4. Install the belt on the motor and centrifuge pulleys and turn the belt adjusting screw(s) to ensure correct belt tension, as described in the next step (see Figure 6-20).
6
Figure 6-20. Location of the adjusting screws for belt tension
5. To correctly adjust belt tension, proceed as follows: a. Ensure that both pulleys are in alignment.
6-26
b.
Measure the span in inches or meters.
c.
Adjust the tension in the belt to permit 1/64 inch deflection per inch (16 mm per meter) of span, measured at the center of the span, when a force of 3 to
Brandt
M9252
Maintenance and Repair
R1
4 lb (1.5 to 2.0 kg) is applied at 90° to the belt by a hand-held scale. (See Figure 6-21.) There will normally be a drop in belt tension during the first 10 to 12 hours of operation. During this run-in period, the belts tend to seat fully and the initial stretch takes place. After the first 10 to 12 hours of running, the drive should be stopped and another check made for correct tension.
Figure 6-21. Determining the amount of belt deflection per span distance
Tightening torque recommendations The following tables provide recommended tightening torque applications for socket head cap screws, non-plated lubricated assembly, as follows: !
UNC / UNF, High tensile steel, grade 12.9, sizes no. 4 to 1 inch
!
UNC / UNF, Stainless steel, etc., grade 8.8, sizes no. 4 to 1 inch
!
Metric, High tensile steel / Stainless steel, etc., sizes M3 to M24
6
Torque recommendations notes: •
Data derived from GKN Designers Handbook 1975.
•
Figures based on 100000 lbf/in2 induced tensile stress for Grade 12.9, and 60000 lb/in2 induced tensile stress for Grade 8.8.
•
Only stainless steel fasteners that are cold formed with rolled threads meet the requirements specified. Bar turned fasteners do not comply with the following charts.
•
Plated screws are not recommended.
HS-3400 Centrifuge Standard XP
6-27
Maintenance and Repair
M9252
R1
UNC / UNF, high tensile steel, grade 12.9 UNC TORQUE
UNF LOAD INDUCED
SIZE
lbf.in.
Nm
lbf
No.4
13
1.5
616
No.5
19
2.1
810
No.6
24
2.7
928
No.8
44
4.9
1420
No.10
65
7.3
1/4”
154
17.4
5/16”
316
357
3/8”
560
63
7/16”
900
101
1/2”
1368
5/8” 3/4”
TORQUE
LOAD INDUCED
lbf.in.
Nm
lbf
27
3.1
1030
1790
73
8.2
2030
3240
175
19.7
3680
5320
349
39.4
5870
7860
631
71
8860
10780
996
112
11980
154
14380
1536
173
16120
2721
306
22880
3060
345
25780
4824
545
33820
5352
604
37540
7/8”
7572
856
46715
8186
924
50420
1”
11340
1281
61115
12240
1382
65390
UNC / UNF, stainless steel, etc., grade 8.8 UNC
6
TORQUE
6-28
UNF LOAD INDUCED
SIZE
lbf.in.
Nm
lbf
No.4
8
0.9
370
No.5
11
1.2
486
No.6
14
1.6
556
No.8
26
2.9
852
No.10
39
4.6
1/4”
92
5/16” 3/8”
TORQUE
LOAD INDUCED
lbf.in.
Nm
lbf
16
1.9
618
1074
44
4.9
1218
10.4
1944
105
11.8
2208
190
21.4
3192
209
23.6
3522
336
38
4716
378
42
5316
7/16”
540
61
6468
597
67
7188
1/2”
820
92
8628
921
103
9672
5/8”
1627
183
13728
1836
207
15468
3/4”
2894
327
20292
3211
362
22524
7/8”
4543
513
28029
4911
554
30252
1”
6804
768
36670
7344
829
39558
Brandt
M9252
Maintenance and Repair
R1
Metric, high tensile steel / stainless steel HIGH TENSILE STEEL - GRADE 12.9 TORQUE
STAINLESS STEEL ETC. - GRADE 8.8
LOAD INDUCED
TORQUE
LOAD INDUCED
SIZE
lbf.in.
Nm
lbf
lbf.in.
Nm
Lbf
M3
21
2.4
936
12.6
1.4
561
M4
49
5.5
1632
29
3.3
279
M5
99
11.2
2640
59.4
6.7
1584
M6
168
19
3744
100
11.4
2246
M8
407
46
6804
244
27.6
4082
M10
804
91.2
10788
482
54.7
6472
M12
1404
159.1
15684
842
95.4
9410
M16
3492
394.8
29196
2095
236.8
17517
M20
6816
770.3
45576
4089
462.1
27345
M24
11784
1331.8
65652
7070
799
39391
6
HS-3400 Centrifuge Standard XP
6-29
Maintenance and Repair
M9252
R1
6
6-30
Brandt
M9252
Parts and Drawings
R1
HS-3400 Standard XP spare parts . . . . . . . . . . . . . . . . . . . .7-1 Centrifuge spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 Feed pump spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
HS-3400 Standard XP drawings . . . . . . . . . . . . . . . . . . . . . .7-3
Wiring diagram - PI10216 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 PI10216 parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
HS-3400 centrifuge assembly - A10849 . . . . . . . . . . . . . . . .7-6 A10849 parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
HS-3400 centrifuge installation - P10849 . . . . . . . . . . . . . . .7-8 HS-3400 centrifuge installation - P10849 (continued) . . . . . . . . .7-9
Rotating assembly - SA11684 . . . . . . . . . . . . . . . . . . . . . . .7-10 SA11684 parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7
Gearbox assembly - 034-805-001 . . . . . . . . . . . . . . . . . . . .7-14 034-805-001 parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Torque control assembly - 034-8SD-006 . . . . . . . . . . . . . .7-18 034-8SD-006 parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
HS-3400 Centrifuge Standard XP
7-A
Parts and Drawings
M9252
R1
7
7-B
Brandt
M9252
R1
Parts and Drawings
HS-3400 Standard XP spare parts Tables in the sections that follow list the spare parts for these major subassemblies of the HS-3400 Centrifuge Standard Electric Explosion Proof model: !
Centrifuge
!
Feed pump
7
HS-3400 Centrifuge Standard XP
7-1
Parts and Drawings
M9252
R1
Centrifuge spare parts
7
Qty.
Part no.
Description
3
001-020-3393
O-Ring #10
6
034-009-000
Gasket #22
3
001-020-2095
O-Ring #104
3
001-570-120
Lip Seal #107
3
001-012-716
Bearing #109, Conveyor Front
3
001-020-1395
O-Ring #100
3
001-020-1245
O-Ring #115
3
034-018-000
Lip Seal #116
3
001-570-216
Lip Seal #118
2
001-012-017
Bearing #122, Conveyor Rear
2
001-012-415
Bearing #307, Main Front Gear Box
3
001-012-2153
Bearing #308, Main Rear Drive
6
034-035-000
Seal #405
6
001-020-1793
O-Ring #406
3
001-012-2035
Bearing
4
001-570-003
Seal #405
3
034-117-000
Gasket Pinion
6
001-098-702
Gasket #128
3
034-036-000
Gasket #410 Casing
2
034-099-000
Feed Tube #202
2
034-049-000
Casing Liner
40
001-221-0803
Csk Screw 8 x 15 SS
4
001-014-399
Sleeve #407 Speedi
4
001-014-369
Sleeve Speedi
4
001-014-393
Sleeve Speedi
4
001-014-315
Sleeve Speedi
4
001-051-902
Dowel Pin w/Sleeve #518
1
034-023-000
Set (4) Nozzles #210
1*
034-8SD-001
Rotating Assembly
1*
034-805-000
Gearbox 52:1
* Denotes spare parts recommended for remote locations. Consult with your Brandt Sales Representative to determine your particular needs.
7-2
Brandt
M9252
Parts and Drawings
R1
Feed pump spare parts Qty.
Part no.
Description
1
167201
Stator
2
593597
Stator O-Ring
1
516401
Casting Seal
1
864301
Connecting Rod
2
854834
Connecting Rod Pin
2
594781
Connecting Rod Seal
4
517018
O-Ring Seal
2
512280
Retaining Snap Ring
1
862314
Pin Retainer
1
867937
Rotor
HS-3400 Standard XP drawings Drawings (and supporting parts lists) included in this section are as follows:
Electrical drawings !
Wiring diagram - PI10216
Assembly and installation drawings !
HS-3400 centrifuge assembly - A10849
!
HS-3400 centrifuge installation - P10849
!
Rotating assembly - SA11684
!
Gearbox assembly - 034-805-001
!
Torque control assembly - 034-8SD-006
HS-3400 Centrifuge Standard XP
7
7-3
Parts and Drawings
M9252
R1
Wiring diagram - PI10216
7
7-4
Brandt
M9252
R1
Parts and Drawings
PI10216 parts list (No part numbers listed in drawing PI10216.)
7
HS-3400 Centrifuge Standard XP
7-5
Parts and Drawings
M9252
R1
HS-3400 centrifuge assembly - A10849
7
7-6
Brandt
M9252
Parts and Drawings
R1
A10849 parts list Item #
Part #
Description
Qty
1
13811
Rotating assembly w/ 52:1 gearbox
1
2
13985
Base
1
3
034-031-000
Casing assembly
1
4
034-807-000
Bowl cradle assembly
2
5
10663
Transport skid
1
6
13991
Electrical sub assembly
1
7
034-090-000
Motor rails
2
8
001-230-1650
Slide rail adjusting screw
2
9
034-048-000
Gearbox cover
1
10
09-533
Sheave P64
1
11
09-563
Belt 2590-14M-40
1
12
8292
Main motor mount
1
13
5527
Liquid discharge connection
1
14
10AB
Gasket
1
15
8040
Belt guard
1
16
001-705-004
Shock mount
1
17
001-705-003
Shock mount
4
*18
13980
Hardware kit
1
19
1BF
Motor 40hp, 60Hz, 480v
1
20
034-020-001
Feed tube support
1
21
034-019-000
Feed tube
1
22
21BU
Collet
1
23
21AT
Fluid clutch
1
7
* Hardware kit parts listed on PI13980
HS-3400 Centrifuge Standard XP
7-7
Parts and Drawings
M9252
R1
HS-3400 centrifuge installation - P10849
7
7-8
Brandt
M9252
R1
Parts and Drawings
HS-3400 centrifuge installation - P10849 (continued)
7
HS-3400 Centrifuge Standard XP
7-9
Parts and Drawings
M9252
R1
Rotating assembly - SA11684
7
7-10
Brandt
M9252
Parts and Drawings
R1
SA11684 parts list Item #
Part #
Description
Qty
1
034-001-102
Bowl extension
1
2
13040
Bowl shell**
1
3
11683
Front hub
1
4*
001-203-0807
Screw, Soc. HD CAP, M8 x 35 Gr. 12.9
12
5
001-050-5606
Dowel, 6 dia. x 30
5
6
034-003-000
Flange, gearbox
1
7
09-546
Pulley, P44-14M-40
1
8
034-006-000
Rear hub
1
9*
001-203-0805
Screw, Soc. HD CAP M8 x 25 Gr. 12.9
8
10
001-020-3393
'O' ring BS 3393-57
2
11*
001-201-1005
SCR-SOC HD CAP M10 x 25
8
12
001-150-001
Nipple, grease, 1/4" UNF
2
13
034-029-000
Flinger - inner
2
14*
001-211-0602
Screw Soc SET M6 x 10
4
15
2030R821
Epicentric orifice
4
16*
001-201-0804
Screw,Soc. HD CAP , M8 x 20
16
17*
001-201-1007
Screw Soc CAP M10 x 35
24
18
034-001-103
Wear sleeve
8
19
034-008-101
Retainer wear ring
1
20*
001-221-0604
SCR-SOC CSK M6 x 20
8
21
001-211-1203
Screw, Soc. SET, M12 x 16
4
22
034-008-300
Insert carbide
1
23
6556
Sprocket adapter
1
24*
001-203-0805
Screw, Soc. HD CAP, M8 x 25 Gr. 12.9
12
25
034-011-000
Conveyor assembly
1
26
034-012-000
Spline bushing
1
27
001-020-2095
'O' ring, BS 2095-30
1
28
034-013-000
Holder, front seal
1
29*
001-211-0802
Screw, Soc. SET, M8 x 10
4
30*
001-570-120
Lip seal 100 x 125 x 12
2
31
001-012-716
Bearing, angular contact (80 x 140 x 26) 7216
2
HS-3400 Centrifuge Standard XP
7
7-11
Parts and Drawings
7
7-12
M9252
Item #
Part #
Description
Qty
32
001-020-1395
'O' ring, BS 1395-30
1
33*
001-201-1007
Screw, Soc. HD CAP, M10 x 35
4
34*
001-201-1010
Screw, Soc. HD CAP, M10 x 50
8
35*
001-201-0816
Screw, Soc. HD CAP, M8 x 80
6
36
001-020-1245
'O' ring, BS 1245-30
1
37
034-018-000
Lip seal
2
38
001-570-216
Lip seal, 80 x 100 x 10
2
39
034-015-000
Holder, rear seal
1
40*
001-211-0802
Screw, Soc. SET, M8 x 10
4
41
001-012-017
Bearing, ball (85 x 130 x 22) 6017
1
42
034-016-000
Housing, rear bearing and seal
1
43
001-041-393
Circlip, spiral (rear seal holder)
1
44
001-041-492
Circlip, spiral (front seal holder)
1
45*
001-201-0803
Screw, Soc. HD CAP M8 x 15
3
46
001-098-702
Fibre washers
3
47*
001-201-0810
Screw, SOC. HD CAP M8 x 50
4
48
001-014-393
Sleeve-speedi 99393
1
49
001-014-369
Sleeve-speedi 99369
1
50
001-014-315
Sleeve-speedi 99315
1
51
001-020-0745
'O' ring, BS 0745-30
4
52
034-021-000
Liner - feed zone
1
53
001-271-1003
SCR-Button HD M10 x 15
8
54
034-022-001
Feed cone
1
55
034-023-000
Nozzle assembly - feed
4
56
001-020-1745
'O' ring BS 1745-30
1
57*
001-211-9005
SCR-SOC Set cone PT M10 x 25
2
58
001-020-0545
'O' ring BS 0545-30
4
59
034-024-000
Pillow block
2
60
034-025-000
End plate
2
61
034-026-00
Flinger cover (outer)
2
62
034-027-000
End plate (drive end outer)
1
63
034-028-000
End plate (gearbox end outer)
1
64
034-029-000
Flinger
2
R1
Brandt
M9252
Parts and Drawings
R1
Item #
Part #
Description
Qty
65
001-012-415
Bearing, roller (75 x 130 x 31) NU2215
1
66
001-012-2153
Bearing, ball (75 x 130 x 25) 6215
1
67
034-030-000
Stabilizer ring
1
68
001-150-000
Nipple, grease 1/8" BSP, straight
2
69*
001-223-1005
Screw, Soc. HD CSK, M10 x 25
8
70*
001-201-0820
Screw, Soc. HD CAP, M18 x 100
6
71*
001-211-0602
Screw, Soc. Set, M6 x 10
4
72
001-151-202
Plug, 1/8" BSP
2
73
034-032-000
Seal, holder (drive end, gearbox end)
2
74
034-033-000
Seal, end cover
2
75
034-034-000
Seal, spacer
2
76
034-035-000
Seal, rulon
4
77
001-020-1793
'O' ring, BS 1793
2
78
001-014-399
Sleeve-speedi 99399
2
79*
001-201-0812
Screw, Soc. HD CAP, M8 x 60
8
80*
001-221-0604
Screw, Flat SOC. HD, M6 x 20
12
81
034-041-000
Bowl liner
**
82*
22VF
HHCS 1/2" 13-UNC x 2 1/2
"3
83
034-014-002
Stabilizer ring
2
* Hardware kit PI13922 ** 1 each called out in C13040
7
HS-3400 Centrifuge Standard XP
7-13
Parts and Drawings
M9252
R1
Gearbox assembly - 034-805-001
7
7-14
Brandt
M9252
Parts and Drawings
R1
034-805-001 parts list Item #
Part #
Description
Qty
1
034-100-000
Double annulus
1
2
034-102-000
Input cover
1
3
034-116-000
End cap
1
4
034-101-000
Sun gear shaft
1
5
034-117-000
Gasket
1
6
034-115-000
Spacer
1
7
034-105-000
Planet shaft (1st stage)
2
8
034-104-001
Planet carrier (1st stage)
1
9
034-107-000
Thrust washer
1
10
034-106-000
Planet gear (1st stage)
2
11
034-109-000
Planet gear (2nd stage)
3
12
034-110-000
Planet shaft (2nd stage)
3
13
034-111-000
Thrust washer (2nd stage)
1
14
034-112-001
Output shaft
1
15
034-113-001
Planet carrier (2nd stage)
1
16
034-108-001
Planet cover / sun gear
1
17
034-114-000
Retaining plate
1
18
001-203-0804
HHCS M8 x 20
33
19
001-012-007
Bearing ball 35 x 62 x 14
1
20
001-012-2035
Bearing ball 17 x 40 x 12
1
21
001-203-0503
HHCS M5 x 15
4
22
001-570-003
Seal rotary shaft 16 x 30 x 7
1
23
001-153-202
Plug hex HD 1/8" BSPT
2
24
001-050-5304
Pin dowel 3 x 20mm
5
25
001-155-204
Plug hex HD 1/4" BSP
1
26
001-094-004
Washer bonded DOWTY 1/4" BSP
1
27
001-020-830
O-ring BS830
2
28
001-050-5303
Pin dowel 3 x 15mm
5
29
034-103-000
Cover output
1
30
001-012-200
Bearing ball 10 x 30 x 9
1
31
001-031-030
Washer wave spring
5
32
001-050-5806
Pin dowel 8 x 30mm
2
HS-3400 Centrifuge Standard XP
7
7-15
Parts and Drawings
M9252
Item #
Part #
Description
Qty
33
001-050-6006
Pin dowel 10 x 30mm
1
34
001-223-0502
SHCS CSK M5 x 10
2
35
001-044-260
Circlip external 60mm dia
1
36
001-043-295
Circlip internal 95mm dia
1
37
001-012-0127
Bearing ball 60 x 95 x 18
1
38
001-570-114
Seal rotary shaft 70 x 90 x 10
1
39
001-012-204
Bearing ball 20 x 47 x 14
1
40
001-043-245
Circlip internal 45mm dia
1
41
001-051-5810
Pin dowel 1/4" x 5/8
"6
42
001-050-0604
Pin dowel 6 x 20mm
2
R1
7
7-16
Brandt
M9252
R1
Parts and Drawings
7
HS-3400 Centrifuge Standard XP
7-17
Parts and Drawings
M9252
R1
Torque control assembly - 034-8SD-006
7
7-18
Brandt
M9252
Parts and Drawings
R1
034-8SD-006 parts list Item #
Part #
Description
Qty
802/1
034-039-000
Torque arm
1
802/2
034-040-000
Locking screw
1
802/3
034-055-000
Bracket
1
802/4
034-056-000
Pivot pin
1
802/5
034-057-000
Link
1
802/6
034-058-000
Nut
1
802/7
034-059-000
Sleeve
1
802/8
034-060-000
Link, spring compression assembly
1
802/9
034-061-000
Pin
1
802/10
034-062-000
Stop pin
2
802/11
034-063-000
Locknut
1
802/12
034-064-000
Pivot shaft
1
802/13
034-065-000
Overload torque control lever
1
802/14
034-066-000
Thrust pad
1
802/15
001-030-121
Compression spring
1
802/16
001-044-220
Circlip, external, 20 mm dia.
1
802/17
001-052-302
Pin, spiral 3 x 10 mm
1
802/18
001-052-306
Pin, spiral 3 x 26 mm
4
802/19
001-056-401
Cotter/split pin
3
802/20
001-095-010
Washer, plain, M10
3
802/21
001-096-005
Washer, lock, M5
2
802/22
001-096-010
Washer, lock, M10
3
802/23
001-150-001
Nipple, grease
1
802/24
001-201-0510
Screw, soc. Hd cap, M5 x 50 mm
2
802/25
001-231-1004
Screw, hex Hd set, M10 x 20 mm
3
802/26
001-261-1001
Nut, lock, M10
1
802/27
001-355-001
Limit switch
1
HS-3400 Centrifuge Standard XP
7
7-19
Parts and Drawings
M9252
R1
7
7-20
Brandt
M9252
R1
Worldwide Locations
International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
United States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8
HS-3400 Centrifuge Standard XP
8-A
Worldwide Locations
M9252
R1
8
8-B
Brandt
M9252
Worldwide Locations
R1
International Argentina
Bolivia
San Martin 345 4to Piso Buenos Aires 1004 Argentina
KM 6.5 Carretera Antigua Acochabamba (Al lado Casa Cotas) Santa Cruz del la Sierra 3813 Bolivia
phone
54 114 394-3939 54 114 394-4599 54 114 394-6213
phone
591 33 553500 591 33 553501 591 33 554280
fax
54 114 394-4499
fax
591 33 553501
Brazil
Canada
Padre Guilherme Lago Castro 559 Barrio Cancela Preta Macae, Rio de Janeiro Brazil
6616 - 45th Street Leduc, Alberta T9E 7C9 Canada
phone
55 222 773-5437 55 222 773-3115 55 222 773-4197 55 222 773-3986
phone
780-986-6063
fax
55 222 763-9346 55 222 763-9343
fax
780-986-6362
Canada
Equador
#1600 540-5thAvenue S.W. Calgary, Alberta T2P 0M2 Canada
Luxemburgo 143 y Holanda Edificio Luxemburgo Depto. 7A Quito Ecuador
phone
403-264-9646
phone
593 2-224-3212 593-2-224-3224
fax
403-263-8488
fax
593 2-224-3212 593 2-224-3224 593 2-246-5359
The Netherlands
Norway
De Hulteweg 3b 7741 LE Coevorden The Netherlands
Gamie Forusvn 25 Staveanger N-4033 Norway
phone
31 524-582718
phone
47 51-951460
fax
31 52-534814
fax
47 51-951470
Scotland
United Arab Emirates
Badentoy Way Badentoy Park Portlethen, Aberdeen AB12 4YB Scotland
P.O. Box 22148 Dubai, UAE
phone
44 1224-787700
phone
971 4-482468
fax
44 1224-784555
fax
971 4-482340
HS-3400 Centrifuge Standard XP
8
8-1
Worldwide Locations
M9252
R1
United States
8
8-2
California
Colorado
7300 Downing Avenue Bakersfield, CA 93308
410 17th Street, Suite 1170 Denver, CO 80202
phone
661-588-8503
phone
303-592-9250
fax
661-588-8506
fax
720-904-0693
Louisiana
Louisiana
Advanced Wire Cloth 618 Hangar Drive P.O. Box 9188 (70562) New Iberia, LA 70560
1515 Poydras Street Suite 1850 New Orleans, LA 70112
phone
337-365-7700
phone
504-636-3660
fax
337-365-0375
fax
504-636-3670
Lousiana
North Dakota
1327 Eraste Landry P.O. Box 52252 (70505)
4965 2nd Street SW P.O. Box 326 (58602) Dickinson, ND 58601
phone
800-359-5935
phone
701-227-8608
fax
337-235-3739
fax
701-227-8612
Oklahoma
Texas
3216 Aluma Valley Drive P.O. Box 95169 (73143-5169) Oklahoma City, OK 73121
426 Flato Road Corpus Christi, TX 78405
phone
405-478-0047 800-725-4986
phone
361-289-7794 800-725-4974
fax
405-478-0177
fax
361-289-9058
Texas
Texas
4506B Britmore Houston, TX 77041
12950 West Little York Houston, Texas 77041
phone
713-896-1172
phone
713-256-4100
fax
713-466-1496
fax
713-856-4133
Texas
Wyoming
4710 Andrews Hwy Odessa, TX 79762
6775 W. Yellowstone P.O. Box 2852 (82601) Casper, WY 82604
phone
915-560-6802 888-563-0663
phone
307-237-9431 307-237-9441
fax
915-550-3190
fax
307-237-6110
Brandt
M9252
R1
Appendix
Pump manual . . . . . . . . . . . . . . . . . . . . . . . (separate package)
Fluid couplings (clutch) manual . . . . . . . . . . . . . . . (attached)
9
HS-3400 Centrifuge Standard XP
9-A
Appendix
M9252
R1
9
9-B
Brandt
View more...
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