6 Centrifuge and Belt Press Maintenance

The Screening Dewatering The Screening Dewatering The Screening, Dewatering The Screening, Dewatering and Drying Expertsand Drying Expertsy g py g p

Centrifuge and Belt Press Centrifuge and Belt Press Centrifuge and elt Press Centrifuge and elt Press MaintenanceMaintenance

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Brian LentIntroduction

Western Regional Aftermarket Sales Manager

Experience

1976 1981 BIRD MACHINE Walpole MA

Based out of Boston MA

1981 1998 Humboldt Decanter -Norcross GA

Based out of San Ramon CA

1998 2006 BAKER PROCESS Walpole MA (Formerly BIRD)1998 2006 BAKER PROCESS Walpole MA (Formerly BIRD)


2006 to Present Andritz Separation Inc Arlington TX


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Long Term Maintenance of Dewatering Equipment

Belt Press

Centrifugeg

3 Individual footer (e.g. title of presentation, date, name of presenter): Arial 9 pt, gray, align center, max. 1 line


Dewatering Equipment like and other processing devices have there limits

Centrifuge and Belt Presses both have a solids loading and a liquidCentrifuge and Belt Presses both have a solids loading and a liquid loading limit

Belt Press units have a basic rule of thumb

100 gpm per meter of belt width100 gpm per meter of belt width

1000 #/hr per meter of belt width


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Centrifuges

Centrifuges are sized by the Optimal capacity of the bowl configuration and volume that can be put through it at that optimum loading

The solids loading is dependent on the feed solids THE HIGHER THE FEED SOLIDS THE LOWER THE FLOW to maintain the optimal performanceSOLIDS THE LOWER THE FLOW to maintain the optimal performance

The liquid loading is also dependent on the feed solids THE THINNER THE FEED THE HIGHER THE FLOW RATE to maintain the optimal performance

This is why in the market most companies have sizes that have similar sizes and geometry

The newer designs are pushing that curve to its limits

When these loadings are exceeded the optimal performance of these machines suffers drastically loss of % cake solids and flow through put

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How to calculate Throughput

Known: Flow RateFeed SolidsSpecific Gravity of Feed Slurry (use 1.0 if unknown)Specific Gravity of Feed Slurry (use 1.0 if unknown)

T = FR x 8.345 lbs/h x 60 minutes/h x FS% x SGSLSor simplified

T = 5 x FR x FS x SGSL

T --- Throughput in lbs/hr Dry SolidsFR --- Flow Rate in Gallons per MinuteFS --- Feed Solids in % Dry SolidsSGSL --- Specific Gravity of sludge or slurry (use 1.0 for municipal sludge)

Example: Flow Rate = 100 GPMFeed Solids = 2.5 % DSSG Sludge = 1.0

Throughput = 1 250 lbs/h DS

Slide No. 6Andritz Separation Inc.

Throughput = 1,250 lbs/h DS

SLUDGE FROM TYPICAL WASTEWATER TREATMENT

Slide No. 7Andritz Separation Inc.


From the simple sketch you can see that sludge is made up of waste andFrom the simple sketch you can see that sludge is made up of waste and that waste has the kitchen sink in it. The wastewater treatment plants try to remove the heavy particulate and screen most of the plastic and grit but a large amount still manages to get to the solids handling end of the plant where it is dewatered.

Contrary to popular thought not all Poop is the same each sludge has its own characteristics, chemical make up, grit levels, ash content, settling

t d th i di id l t thi k frates and any other individual component one can think of.

With that thought how do we protect our equipment

Most Belt Press units have

Protected and coated frames

Protected bearings and sealed housings

Protected rollers

Stainless steel fasteners and fittings

Plastic and protective housings and covers


Buenos Aires Plastic and protective housings and covers

Gear boxes and drives


Having said this EVERYTHING REQUIRES SOME DEGREE OFHaving said this EVERYTHING REQUIRES SOME DEGREE OF MAINTENANCE

The normal wear items for a Belt Press are

The Belts normal wear is 2000 to 3000 hours but this depends on the grit and pressure applied to the rollers

The Rollers the rollers have an normal life expectancy of 10 years again d di th it d li ddepending on the grit and pressures applied

Tracking and tensioning systems (either pneumatic or hydraulic) have a life cycle also there life is dependent on the pressure, operating cycles and

l h k i f th itgeneral housekeeping of the unit

Drives / gear boxes there life cycle depends on lubrication changes, alignment and general housekeeping

Bearings and seals these are the only items that require constant attention as far a grease and housekeeping

The frame and ancillary equipment requires attention when it fails or is

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y q p qdamaged


Belt press lubrication

5.3.1 Lubricant Specification

REFERENCE SYMBOLMOBILSHELLTEXACOA - GreaseMobilith SHC 460- - - -- - - -B - OilMobilgear 630Shell Omala Oil 220Meropa 220C - GreaseMobilux EP2Shell Alvania Grease R3Multifak EP2

5.3.2 Lubrication ScheduleFrequency Lubricant

1. Grease bearings monthly A2. Grease tracking device 1 month A3. Grease thrust rods on tensioning device 6 months A4. Check oil level in drive gearbox 80 hours B5 Ch il i d i b 10 000 h (2 ) B5. Change oil in drive gearbox 10,000 hours (2 years) B6. Repack bearings in drive gearbox 20,000 hours (4 years) C7. Grease bull gear & drive pinion gear 1 month A

5.3.3 Lubrication Location*Graphics may differ from actual machine*Graphics may differ from actual machine

All equipment should have a simple grease chart that can be followedIt is up to the customer to log these lubrication events

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g


C t if h i il d i t i tCentrifuges have similar wear and maintenance points

Most centrifuges in the market these days are outfitted with the following g y gstandards

Bowls, bowl heads, conveyors and hard components are 316 SS or made from a casting type duplex Stainless Steel

The feed compartments, feed ports, cake ports and conveyor tips are protected or made from a Tungsten Carbide or similar material

Most have SS liners or covers protecting the solids and liquids dischargeMost have SS liners or covers protecting the solids and liquids discharge points

Most have bearings are designed for L10 ratings and the seals are Buna or better depending on servicebetter depending on service

Most bases are carbons steel with powder coating or epoxy coatings

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Centrifuge Maintenance Requirements

5.3.1 Lubricant Specification

LUBRICANT LISTLUBE TYPE SKF Mobil Shell BPA. Grease SKF LGMT2 Mobilux EP2 Alvania EP2 Energrease LS EP2Centrifuge A. Grease SKF LGMT2 Mobilux EP2 Alvania EP2 Energrease LS EP2B. Grease SKF LGMT3

C. Grease EXCLUSIVELYEnergrease PR EP 00

D. Oil Mobil SHC X100 30 BP Super visco static627 20w50

5.3.2 Lubrication ScheduleInnovative

CentrifugeTechnology

Quality

Frequency Lubricant Quantity1. Grease bearing - feed end 200 hours A 20 Gr2. Grease bearing - drive end 200 hours A 15 Gr3. Grease thrust bearing - feed end 4000 hours B 100 Gr4. Change grease in drive speed inducer 4000 hours C 3000 Gr5. & 6. Grease electric motor bearings 3000 hours A see Vendor info

Reliability

High Performance

5.3.3 Lubrication Location


Maintenance Service Intervals

Most suppliers have a standard chart that is used as a guide for theMost suppliers have a standard chart that is used as a guide for the customers to logically project the maintenance of a particular size centrifuge (the parts cost and labor vary by size) but they all have a specific repair interval.

These type of charts can be used as guides for projected maintenance costs.

The frequency of the intervals is dependent on the operating hours perThe frequency of the intervals is dependent on the operating hours per day, week and year.

The first few years of a 4000 operating hour centrifuge is obviously less than a unit that is in service 24/7/365 unitthan a unit that is in service 24/7/365 unit

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Andritz Centrifuge Features12 Centrifuge Maintenance Requirements12 Centrifuge Maintenance Requirements

DESCRIPTION 200 HRS

3000 HRS

4000 HRS

6000 HRS

8000 HRS

9000 HRS

12000 HRS

15000 HRS

18000 HRS

24000 HRS

1. * Lubricate both support bearings EVERY 200 hrs X

12. Centrifuge Maintenance Requirements12. Centrifuge Maintenance Requirements

2. Renew grease in cyclo & thrust brg. X X X X X X 3. General inspection X X X X X 4. Inspect scrapers, deflector rings (D7L only) X X X X X 5. Inspection of drive belts X X X X 6. Mechanical inspect of feed brg. block X X 7. Inspection of nozzles X X 8. Renew grease in REDEX pulley after 1st 200 hrs X X X X X X X X 9. Inspection of bearings & seals X X 10. Inspect / dismantle of reducer X X 11. Inspect / overhaul of torque limiter X X 12. Inspect deflector X X 13. Inspect feed & discharge ports ( where applicable) X X X X X 14. Inspect drive belt tension X X 15. Inspect vibration isolators (shock absorbers) X 16. Inspect elastic coupling X 17. Inspection of feed tube X X X X X 18. Replacement of drive belts, support brgs., & seals X 19. Replacement of deflectors, scrapers (D7L), & nozzles X 20. General complete mechanical overhaul & inspection X

* E t it 1 th i t l b f b i i ti * Except item 1, the intervals above are from beginning operation. When 24000 hrs is reached, revert back to beginning of chart.

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Simple rules of thumb for operating any piece of equipment

The Harder you run it the more it will cost you to maintain it

The Faster you operate and unit (above its performance optimum speed)The Faster you operate and unit (above its performance optimum speed) the more wear you will have

The more solids you put through a unit (above its optimum performance range) the more wear you will have in the unitrange) the more wear you will have in the unit

The more grit or non biological particulate you have in the sludge the more wear and plugging that will occur

Th l h k i f i f i t t f t thThe less housekeeping you perform on a piece of equipment to faster the surfaces and housing will deteriorate

The less Electrical upkeep that is performed on the controls and electrical components of a s stem the faster the ill failcomponents of a system the faster they will fail

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YES - I SAID CONTROLSHow many times have you heard Its a Mechanical problem when the motor wont start or the panel does not functionmotor wont start or the panel does not function.

Electrical components have a shelf life and in todays market they have a Factory support life as well

Most PLC units are good for 10 years

OIT or HMI units are about the same or a little less

Instrumentation seems to have a better cycle if taken care ofInstrumentation seems to have a better cycle if taken care of

VFD drives are supported by the factory for 10 years but some parts can be recycled to extend the life by a few years

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Andritz Centrifuge Features11 Centrifuge Control System11 Centrifuge Control System11. Centrifuge Control System11. Centrifuge Control System

NEMA 4X Stainless SteelNEMA 4X Stainless Steel 316L Control Panel withColor Touch Screen

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CONTROL PANELS

This is the heart of the operation if the controls are poor then the machine operation and performance are poorp p p

If the Control Panels are left open and allowed to have a poor quality air into the panel the wiring, instruments and controls can prematurely fail.

If the conduits into the panels are not sealed off then what ever can getIf the conduits into the panels are not sealed off then what ever can get into the conduits is inside the panels

If the air conditioners (and most do have them if they have VFDs) filters and inlets are not serviced and the efficiency of the conditioned air isand inlets are not serviced and the efficiency of the conditioned air is affected the heat generated inside the panel can reach 150 deg F and the function of the PCL and HMI (along with other controls) can fault.

If the controls on the machines are SO cord with plastic grommet fittingsIf the controls on the machines are SO cord with plastic grommet fittings they are in direct contact with the operating atmosphere, possible damage and the big feet of most Maintenance people (OPS) these need to be inspected at timely intervals for damage and wear.

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GENERAL NOTES

General Housekeeping is never a bad thing

All lubes and oils should be changed at least twice a year regardless ofAll lubes and oils should be changed at least twice a year regardless of operating hours

Filters are always changed with the oils - these include air, oil, water and screens.screens.

Never operate a unit that one does not feel comfortable operating if a guard is missing or left off after a service report it and correct it

If thi i h i i f i i l it d tIf something is showing signs of wear, erosion or corrosion replace it do not operate it

Motors need love too they have lubrication intervals or life cycles (sealed bearings) and the loads on the shafts req ire alignment and the sho ld bebearings) and the loads on the shafts require alignment and they should be checked during required service

Belts the forgotten band belts do not last until the break they should be checked for cracks and replaced ar specified intervals

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QUESTIONS:

There are NO dumb questions


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6 Centrifuge and Belt Press Maintenance

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