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General Information
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Product Information
Installation
Operation
Troubleshooting
Worldwide Locations
Appendix
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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General Information
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
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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. 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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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.
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General Information
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. 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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Holes are worn through moving parts. Grooves greater than 1/16" (1.5mm) deep are worn in moving parts. Evidence of cracks is present in moving parts. 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. 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.
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General Information
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. Avoid performing maintenance or repairs while the equipment is in operation. Wear proper protective equipment during equipment installation, maintenance, or repair.
Replacing components
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Verify that all components (such as cables, hoses, etc.) are tagged and labeled during disassembly and reassembly of equipment. 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.
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Product Information
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
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Product Information
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:
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Bowl assembly Conveyor assembly Drive assembly Gearbox assembly Torque control assembly Casing assembly Main and sub frames
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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.
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.
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.
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:
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Power 'ON' light Start / stop button for the centrifuge Start / stop button for the feed pump
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.
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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) Drive pulley (motor) P80 P72 P64 P56 P48 P44 P44 P44 P44 P44 *Driven pulley (R/A) P44 P44 P44 P44 P44 P44 P48 P56 P64 P72 Centrifuge rpm 2636 2373 2109 1845 1582 1450 1329 1139 997 886 G-force 1382 1119 884 677 497 418 351 258 198 156 60 Hz motor (1750 rpm) Centrifuge rpm 3182 2864 2545 2227 1909 1750 1604 1375 1203 1069 G-force 2013 1630 1288 986 725 609 512 376 288 227
* 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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Product Information
Overall height ...................................... 42-5/16 in / 1075 mm Overall weight ...................................... 4800 lb / 2182 kg Power requirement .............................. 100 amps @ 480 volts, 60 Hz Bowl dimensions.................................. 14 in x 49 in / 350 mm x 1260 mm Conveyor / pitch................................... 4-1/4 in / 110 mm lagging conveyor *Bowl speeds....................................... 886 to 3182 rpm *G-force ............................................... 156 to 2013 Gearbox type ....................................... 2 stage planetary Gearbox ratio....................................... 52:1 Gearbox output torque......................... 23,500 in-lbs / 270 kgf.m (max) * 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: 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:
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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%.
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*Expected throughputs
Feed rate at various mud weight values Bowl speed G-force 608 1097 1672 9 ppg 125 gpm 125 gpm 125 gpm 12 ppg 88 gpm 84 gpm 66 gpm 15 ppg 30 gpm 22 gpm 17 gpm 18 ppg 22 gpm 13 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
Removing rotating assembly for machine installation. . . .3-4 Reinstalling rotating assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
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
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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.
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CHOICE OF HOOK POSITION WITH GEARBOX WITHOUT GEARBOX BOWL LIFTER BEAM CHOICE OF SLING POSITIONS PER MODEL LIFTING STRAP
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.
For frame installation, follow these guidelines: 1. Ensure that the foundation is carefully leveled to within 1/8 in (3.0 mm).
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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.
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.
SECURING SCREWS
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The shipping cradles are installed to prevent damage to the main bearings during transit.
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Installation
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.
Figure 3-3. Straight edge against pulley outer faces to check alignment
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Figure 3-5. Determining the amount of belt deflection per span distance
Figure 3-6. Clamping cap around feed tube with even gap, matching marks
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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. 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.
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).
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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!
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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
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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.
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.
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Speed, feed and pond depth adjustments . . . . . . . . . . . . . .4-2 Speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Speed range and pulley sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
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
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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.
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. 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.
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Operation
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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.
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
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1382 1119 884 677 497 418 351 258 198 156
2013 1630 1288 986 725 609 512 376 288 227
2590 2590 2590 2450 2450 2450 2450 2450 2590 2590
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Operation
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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.
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)
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Operation
Figure 4-1. Epicentric dams control the pond depth (volume of liquid in bowl)
Figure 4-2. Numbers on epicentric dams enable setting the pond depth
4-5
Operation
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.
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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.
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
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Operation
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.
c.
4-7
Operation
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. b. Introduce a wash liquid into the centrifuge bowl, and restart the machine. 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. c.
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Troubleshooting
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 Solids too dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
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Troubleshooting
Mechanical problems
Centrifuge problems and possible causes
Potential centrifuge problemsalong with possible causesare 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)
! ! ! ! ! ! ! ! ! ! ! ! ! ! !
5-1
Troubleshooting
! ! ! ! !
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Feed rate or concentration too high Incorrect setting of torque control Bowl plugged with solids Fault in conveyor bearings Defective gearbox
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
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:
! !
Pond depth within the centrifuge bowl Flow rate to the centrifuge
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!
Troubleshooting
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.
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)
5-3
Troubleshooting
! ! !
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Feed rate too high Conveyor flights worn Bowl speed too low
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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
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
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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
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
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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. 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.
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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 Centrifige main bearings Centrifuge conveyor Centrifuge gearbox Torque control assembly Pump variable speed gearbox Lubricant Aeroshell 14 grease, P/N 001-108-100 Aeroshell 14 grease, P/N 001-108-100 Royal Purple GT220 Synfilm Oil, P/N 46BJ Aeroshell 14 grease, P/N 001-108-100 TD-22 Synthetic Traction Oil, P/N 46BC Frequency One shot every day. Purge every 1500 hours or every 2 months. Purge every 2 weeks. Check every 2 weeks. Change once every 12 months or 4000 hours. Grease every 4 weeks Check every 2 weeks. Change once every 20000 hours.
Centrifuge gearbox Conveyor bearings Main bearings Figure 6-1. Centrifuge lubrication points (see previous table for schedule)
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Centrifuge lubrication
For the centrifuge, periodic lubrication is needed for these two bearing sets:
! !
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.) 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.
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Figure 6-2. Fill gearbox casing to upper level plug with oil syringe
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.
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.
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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.
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c.
4. Reinstall the guard securely after greasing and before starting the machine.
PULLEY
Excess grease passes back through a parallel escape channel in the bowl hub extension wall and discharges within the casing seal holder.
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c.
4. Reinstall the guard securely after greasing and before starting the machine.
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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.
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63 61
62 61
.008/.020 GAP
61 62 63
Flinger cover End plate, drive end End plate, gearbox end
Figure 6-6. Main bearing end plate can be removed to eliminate excess grease
6-9
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1 5 6 2
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. 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 dilutantwhether regularly or otherwisealways 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.
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6-11
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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.
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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. Repeat the operation on each of the dowels.
Figure 6-10. Extract dowel pins
c.
6-13
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c.
d. Extract the dowel sleeve by impact of the sliding hammer against the stop nut at the top of the shaft.
e. Repeat the operation on each of the dowel sleeves. 11. Unscrew and remove the pillow block securing screws together with lockwashers.
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.
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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
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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. c. With the pillow block and frame holes accurately aligned, lower the rotating assembly further until the pillow blocks just touch the frame pads. 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. 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.
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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).
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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.)
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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.
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c.
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. 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.
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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 arm removal and installation Torque control disassembly and assembly
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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.
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6-23
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APPLY PRESSURE
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). b. Apply tension from the spring scale to the arm in a clockwise direction, at 90 to the pad face. (See Figure 6-18.) Steadily increase the tension until the control trips.
c.
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
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a. Reset the torque control lever. b. c. Screw the spring adjusting nut inwards. 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.
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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).
5. To correctly adjust belt tension, proceed as follows: a. Ensure that both pulleys are in alignment. b. c. Measure the span in inches or meters. 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
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Figure 6-21. Determining the amount of belt deflection per span distance
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 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.
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SIZE No.4 No.5 No.6 No.8 No.10 1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1 8 11 14 26 39 92 190 336 540 820 1627 2894 4543 6804
TORQUE lbf.in.
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6-30
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HS-3400 Standard XP spare parts . . . . . . . . . . . . . . . . . . . .7-1 Centrifuge spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 Feed pump spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
HS-3400 centrifuge installation - P10849 . . . . . . . . . . . . . . .7-8 HS-3400 centrifuge installation - P10849 (continued) . . . . . . . . .7-9
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40 4 4 4 4 4 1 1* 1*
* Denotes spare parts recommended for remote locations. Consult with your Brandt Sales Representative to determine your particular needs.
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Electrical 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
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Part # 001-020-1395 001-201-1007 001-201-1010 001-201-0816 001-020-1245 034-018-000 001-570-216 034-015-000 001-211-0802 001-012-017 034-016-000 001-041-393 001-041-492 001-201-0803 001-098-702 001-201-0810 001-014-393 001-014-369 001-014-315 001-020-0745 034-021-000 001-271-1003 034-022-001 034-023-000 001-020-1745 001-211-9005 001-020-0545 034-024-000 034-025-000 034-026-00 034-027-000 034-028-000 034-029-000
Description 'O' ring, BS 1395-30 Screw, Soc. HD CAP, M10 x 35 Screw, Soc. HD CAP, M10 x 50 Screw, Soc. HD CAP, M8 x 80 'O' ring, BS 1245-30 Lip seal Lip seal, 80 x 100 x 10 Holder, rear seal Screw, Soc. SET, M8 x 10 Bearing, ball (85 x 130 x 22) 6017 Housing, rear bearing and seal Circlip, spiral (rear seal holder) Circlip, spiral (front seal holder) Screw, Soc. HD CAP M8 x 15 Fibre washers Screw, SOC. HD CAP M8 x 50 Sleeve-speedi 99393 Sleeve-speedi 99369 Sleeve-speedi 99315 'O' ring, BS 0745-30 Liner - feed zone SCR-Button HD M10 x 15 Feed cone Nozzle assembly - feed 'O' ring BS 1745-30 SCR-SOC Set cone PT M10 x 25 'O' ring BS 0545-30 Pillow block End plate Flinger cover (outer) End plate (drive end outer) End plate (gearbox end outer) Flinger
54 55 56 57* 58 59 60 61 62 63 64
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Part # 001-012-415 001-012-2153 034-030-000 001-150-000 001-223-1005 001-201-0820 001-211-0602 001-151-202 034-032-000 034-033-000 034-034-000 034-035-000 001-020-1793 001-014-399 001-201-0812 001-221-0604 034-041-000 22VF 034-014-002 Description
Qty 1 1 1 2 8 6 4 2 2 2 2 4 2 2 8 12 ** "3 2
Bearing, roller (75 x 130 x 31) NU2215 Bearing, ball (75 x 130 x 25) 6215 Stabilizer ring Nipple, grease 1/8" BSP, straight Screw, Soc. HD CSK, M10 x 25 Screw, Soc. HD CAP, M18 x 100 Screw, Soc. Set, M6 x 10 Plug, 1/8" BSP Seal, holder (drive end, gearbox end) Seal, end cover Seal, spacer Seal, rulon 'O' ring, BS 1793 Sleeve-speedi 99399 Screw, Soc. HD CAP, M8 x 60 Screw, Flat SOC. HD, M6 x 20 Bowl liner HHCS 1/2" 13-UNC x 2 1/2 Stabilizer ring
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Item # 33 34 35 36 37 38 39 40 41 42
Part # 001-050-6006 001-223-0502 001-044-260 001-043-295 001-012-0127 001-570-114 001-012-204 001-043-245 001-051-5810 001-050-0604
Description Pin dowel 10 x 30mm SHCS CSK M5 x 10 Circlip external 60mm dia Circlip internal 95mm dia Bearing ball 60 x 95 x 18 Seal rotary shaft 70 x 90 x 10 Bearing ball 20 x 47 x 14 Circlip internal 45mm dia Pin dowel 1/4" x 5/8 Pin dowel 6 x 20mm
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Worldwide Locations
International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-A
Worldwide Locations
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Worldwide Locations
International
Argentina San Martin 345 4to Piso Buenos Aires 1004 Argentina phone 54 114 394-3939 54 114 394-4599 54 114 394-6213 54 114 394-4499 Bolivia KM 6.5 Carretera Antigua Acochabamba (Al lado Casa Cotas) Santa Cruz del la Sierra 3813 Bolivia phone 591 33 553500 591 33 553501 591 33 554280 591 33 553501
fax
fax
Brazil Padre Guilherme Lago Castro 559 Barrio Cancela Preta Macae, Rio de Janeiro Brazil phone 55 222 773-5437 55 222 773-3115 55 222 773-4197 55 222 773-3986 55 222 763-9346 55 222 763-9343
Canada 6616 - 45th Street Leduc, Alberta T9E 7C9 Canada phone 780-986-6063
fax
fax
780-986-6362
Canada #1600 540-5thAvenue S.W. Calgary, Alberta T2P 0M2 Canada phone fax 403-264-9646 403-263-8488
Equador Luxemburgo 143 y Holanda Edificio Luxemburgo Depto. 7A Quito Ecuador phone fax 593 2-224-3212 593-2-224-3224 593 2-224-3212 593 2-224-3224 593 2-246-5359
The Netherlands De Hulteweg 3b 7741 LE Coevorden The Netherlands phone fax 31 524-582718 31 52-534814
Norway Gamie Forusvn 25 Staveanger N-4033 Norway phone fax 47 51-951460 47 51-951470
Scotland Badentoy Way Badentoy Park Portlethen, Aberdeen AB12 4YB Scotland phone fax 44 1224-787700 44 1224-784555
phone fax
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United States
California 7300 Downing Avenue Bakersfield, CA 93308 phone fax 661-588-8503 661-588-8506 Colorado 410 17th Street, Suite 1170 Denver, CO 80202 phone fax 303-592-9250 720-904-0693
Louisiana Advanced Wire Cloth 618 Hangar Drive P.O. Box 9188 (70562) New Iberia, LA 70560 phone fax 337-365-7700 337-365-0375
Louisiana 1515 Poydras Street Suite 1850 New Orleans, LA 70112 phone fax 504-636-3660 504-636-3670
Lousiana 1327 Eraste Landry P.O. Box 52252 (70505) phone fax 800-359-5935 337-235-3739
North Dakota 4965 2nd Street SW P.O. Box 326 (58602) Dickinson, ND 58601 phone fax 701-227-8608 701-227-8612
Oklahoma 3216 Aluma Valley Drive P.O. Box 95169 (73143-5169) Oklahoma City, OK 73121 phone fax 405-478-0047 800-725-4986 405-478-0177
Texas 426 Flato Road Corpus Christi, TX 78405 phone fax 361-289-7794 800-725-4974 361-289-9058
Texas 12950 West Little York Houston, Texas 77041 phone fax 713-256-4100 713-856-4133
Texas 4710 Andrews Hwy Odessa, TX 79762 phone fax 915-560-6802 888-563-0663 915-550-3190
Wyoming 6775 W. Yellowstone P.O. Box 2852 (82601) Casper, WY 82604 phone fax 307-237-9431 307-237-9441 307-237-6110
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Appendix
9-A
Appendix
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9-B
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