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Document No. TOC00221 Effective Date 25 May 07 Page No. TABLE OF CONTENTS DE-1000 CENTRIFUGE - GEARBOX DRIVE GENERAL INFORMATION .................................................. Section 1 Introduction .............................................................................. DER01019 Description and Operation ....................................................... DER01120 Equipment Specifications .........................................................
Document No.TOC00221 Page 2 of 2 TABLE OF CONTENTS Effective Date 25 May 07 The content of this document is subject to change at any time. Information provided does not cover all details or variations possible with DERRICK equipment, nor does it cover every contingency that Sep be met in conjunction with installation, operation, maintenance, or troubleshooting of the equipment.
Document No. DER01019 Effective Date 25 May 07 Page No. 1 of 5 INTRODUCTION DE-1000 CENTRIFUGE - GEARBOX DRIVE OVERVIEW This manual provides instructions for installing and operating the DE-1000 Gearbox Drive (GBD) centrifuge (Figure 1019-1). The manual is divided into several sections to assist the user in readily accessing the information. Instructions include description, theory of operation, safety, installation, and maintenance.
Document No. DER01019 INTRODUCTION Page 2 of 5 Effective Date 25 May 07 EQUIPMENT USE The DE-1000 GBD centrifuge is designed expressly to remove low specific gravity solids from slurries. In one type of processing, solids are removed and the liquid is returned for recirculation. In the other type of processing, solids are returned to the active system and the liquid is discarded. Derrick Corporation does not authorize any other use of this equipment.
INTRODUCTION Effective Date Document No. DER01019 25 May 07 Page 3 of 5 PRODUCT SUPPORT Derrick Corporation offers 24-hour per day, 7-day per week product support. Product support includes screen replacement / ordering information and repair / replacement parts and service for the entire product line. Refer to the following table for the parts / service center nearest you. PARTS SALES & SERVICE CALIFORNIA Bakersfield Woodland 800.999.2917 530.666.6475 COLORADO Denver 303.592.
Document No. DER01019 Page 4 of 5 INTRODUCTION Effective Date 25 May 07 HIGHLIGHTED INFORMATION Information considered important to safe and effective operation of the equipment is highlighted as illustrated below: Safety Issues WARNING! PRESENTS INFORMATION CRITICAL TO SAFE OPERATION AND/OR MAINTENANCE OF THE EQUIPMENT. FAILURE TO COMPLY WITH THIS INFORMATION MAY RESULT IN SERIOUS INJURY TO PERSONNEL AND/OR DEATH, OR MAJOR DAMAGE TO THE EQUIPMENT.
INTRODUCTION Effective Date Document No. DER01019 25 May 07 Page 5 of 5 HOW TO USE THIS MANUAL DER XX 000 Subsection Number (000 thru 999) Section Number: 01 GENERAL INFORMATION 02 SAFETY 03 INSTALLATION 04 OPERATING INSTRUCTIONS 05 MAINTENANCE 06 SCREEN TENSIONING SYSTEMS 07 VIBRATOR MOTORS 08 NOT ASSIGNED 09 DESANDER UNITS 10 DESILTER UNITS 11 REFERENCE DRAWINGS 12 SUPPLIER DATA Derrick Document The content of this document is subject to change at any time.
Document No. DER01120 Effective Date 25 May 07 Page No. 1 of 9 DESCRIPTION AND OPERATION DE-1000 CENTRIFUGE - GEARBOX DRIVE GENERAL The centrifuge is a high-speed electro-mechanical machine using a 50 HP electric motor to drive the bowl assembly and conveyor. The centrifuge receives slurry through a feed tube at the pulley end (solids discharge) of the machine. The slurry is dispersed into the rotating bowl, where centrifugal force is employed to separate liquid from the solids.
Document No. DER01120 DESCRIPTION AND OPERATION Page 2 of 9 Effective Date 25 May 07 OPERATING PRINCIPALS (CONT’D) During centrifuge operation, slurry is pumped through the feed tube into the center of the rotating conveyor (Figure 1120-1), where it splashes against the feed accelerator. The high velocity slurry is then dispersed out four feed nozzles mounted in the periphery of the conveyor cylinder.
DESCRIPTION AND OPERATION Effective Date 25 May 07 Document No. DER01120 Page 3 of 9 MAJOR COMPONENTS Major components of the centrifuge (Figure 1120-2) consist of the rotating assembly, gearbox drive assembly, fluid coupling, electrical control box, 50 HP electric motor, vibration switch, case, base assembly, and skid. The following paragraphs describe these components.
Document No. DER01120 Page 4 of 9 DESCRIPTION AND OPERATION Effective Date 25 May 07 Conveyor The conveyor assembly is a hollow, cylindrical auger that receives the inlet slurry into its interior, disperses it through nozzles to the bowl assembly, and transports the solids to the solids discharge outlet. Rotated by a differential gearbox, the conveyor turns in the same direction but at a slower rate than the bowl.
DESCRIPTION AND OPERATION Effective Date Document No. DER01120 25 May 07 Page 5 of 9 Figure 1120-3 Overload Release Assembly FLUID COUPLING The rotating assembly is driven by the 50 HP electric motor through the fluid coupling mounted on the motor shaft. Rotary motion of the motor shaft is transmitted to the inner hub of the fluid coupling. The outer hub of the coupling is connected to the sheave, which is rotated by the pressure of fluid contained within the coupling.
Document No. DER01120 DESCRIPTION AND OPERATION Page 6 of 9 Effective Date 25 May 07 ELECTRICAL CONTROL BOX (CONT’D) Figure 1120-4 Electrical Control Box 50 HP DRIVE MOTOR The 50 HP, 460 Vac 60 Hz or 380 Vac 50 Hz, three-phase, explosion-proof electric motor is connected to the liquid bowl assembly by a sheave and drive belt. Motion is transmitted to the sheave by a fluid coupling, which is attached directly to the motor shaft.
DESCRIPTION AND OPERATION Effective Date 25 May 07 Document No. DER01120 Page 7 of 9 The vibration switch is mounted on the centrifuge frame in an orientation that is most affected by out-of-balance vibration of the bowl assembly. Clogging of the conveyor or worn bearings may produce sufficiently high vibration to trip the switch.
Document No. DER01120 DESCRIPTION AND OPERATION Page 8 of 9 Effective Date 25 May 07 ELECTRICAL CONTROL SYSTEM OPERATION The following paragraphs describe operation of the electrical control system. This information is provided as an aid to understanding the centrifuge operation, which will facilitate operating the equipment as well as for troubleshooting. The following paragraphs describe operation of the drive motor and feed pump control circuits.
DESCRIPTION AND OPERATION Effective Date 25 May 07 Document No. DER01120 Page 9 of 9 Vibration Tripping the vibration switch due to excessive vibration of the centrifuge will also cause a shutdown, as the switch interrupts power flow to centrifuge run relay CR1. After removing the cause of unusual vibration, pressing the external button on the switch housing returns the switch contacts to the magnetically latched condition to restore power.
Document No. DER01220 Effective Date 25 May 07 Page No. 1 of 1 EQUIPMENT SPECIFICATIONS DE-1000 CENTRIFUGE - GEARBOX DRIVE Equipment specifications are presented below for the DE-1000 gearbox drive (GBD) centrifuge. Refer to Section 11 - Reference Drawings for additional information and specifications. Dimensions (Approx.) 115” L x 58-1/2” H x 75” W (2921mm x 1483mm x 1908mm) Weight (Approx.
Document No. DER01320 Effective Date 10 Oct 08 Supersedes Page No. 25 May 07 1 of 1 SERVICES & UTILITIES REQUIRED DE-1000 CENTRIFUGE - GEARBOX DRIVE GENERAL To achieve optimum performance and reliability from your Derrick equipment, the services and utilities described below must be available at the installation site. ELECTRIC POWER For electrical service requirements, refer to the voltage label inside the electrical junction box.
Document No. DER01420 Effective Date 25 May 07 Page No. 1 of 3 EQUIPMENT HANDLING PROCEDURES DE-1000 CENTRIFUGE - GEARBOX DRIVE RECEIVING THE EQUIPMENT Immediately upon receipt of the Derrick equipment, examine contents for damaged and/or missing components. All equipment is sold FOB Derrick Corporation, Buffalo, New York.
Document No. DER01420 EQUIPMENT HANDLING PROCEDURES Page 2 of 3 Effective Date 25 May 07 MOVING/POSITIONING THE EQUIPMENT (CONTINUED) Four reinforced lifting lugs are built into the equipment frame to allow attachment of an overheadlifting device (Figure 1220-1). Lifting points are labeled “LIFT HERE ONLY”. DO NOT attempt lifting equipment by attaching slings or similar lifting aids to the 50 HP electric motor or other nondesignated portions of the unit. Use of spreader bars is recommended.
EQUIPMENT HANDLING PROCEDURES Effective Date 25 May 07 Document No. DER01420 Page 3 of 3 EQUIPMENT STORAGE General If equipment is not being installed immediately, it should be stored in a dry environment (50 percent relative humidity or less). A dry environment will ensure that the machine remains in the same condition as when it was received. If unit is stored outdoors, cover with a UV-resistant tarpaulin (tarp) or UV-resistant shrink-wrap. Install vents when using shrink-wrap.
Document No. DER02020 Effective Date 25 May 08 Page No. 1 of 3 WARNINGS SUMMARY DE-1000 CENTRIFUGE - GEARBOX DRIVE GENERAL This section contains a summary of WARNINGS presented throughout the manual. The WARNINGS are grouped according to the following categories: • Electrical Hazards • Equipment Handling • Operation • Maintenance • Storage SOUND WARNING! TO PROTECT AGAINST HEARING LOSS, HEARING PROTECTION SHOULD BE WORN AT ALL TIMES WHEN WORKING ON OR NEAR DERRICK MACHINES.
Document No. DER02020 WARNINGS SUMMARY Page 2 of 3 Effective Date 25 May 08 EQUIPMENT HANDLING WARNING! USE SPREADER BARS TO PREVENT DAMAGE WHEN LIFTING THE EQUIPMENT. WARNING! TO ENSURE PROPER BALANCE AND ORIENTATION WHEN UNIT IS RAISED AND PREVENT DAMAGE TO COMPONENTS, ATTACH LIFTING SLING ONLY AT DESIGNATED LIFT POINTS. DO NOT ATTEMPT LIFTING BY ATTACHMENT TO MOTOR OR ANY OTHER LOCATION.
WARNINGS SUMMARY Effective Date 25 May 08 Document No. DER02020 Page 3 of 3 MAINTENANCE WARNING! HIGH VOLTAGE MAY BE PRESENT. ALWAYS OPEN FUSED DISCONNECT SUPPLYING ELECTRIC POWER TO THE EQUIPMENT, AND LOCK OUT AND TAG OUT POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE AND/OR ADJUSTMENTS OF EQUIPMENT. STORAGE WARNING! CENTRIFUGE MAY BE DAMAGED BY STORING IN A HIGH HUMIDITY ENVIRONMENT (GREATER THAN 50% RH). EQUIPMENT MUST BE STORED IN A LOW-HUMIDITY ENVIRONMENT.
Document No. DER02889 Effective Date 22 May 08 Supersedes 15 Jun 07 Page No. 1 of 1 MATERIAL SAFETY DATA SHEETS (MSDSs) DE-1000 CENTRIFUGE - GEARBOX DRIVE Material Safety Data Sheets (MSDSs) for exterior finish products are included in this section to advise personnel of the properties and any possible hazards associated with these materials. Emergency first aid procedures, special precautions, emergency telephone number, and other relevant data are contained in the MSDSs.
Document No. DER02889 Page 2 of 2 MATERIAL SAFETY DATA SHEETS (MSDSs) Effective Date Supersedes 22 May 08 15 Jun 07 The content of this document is subject to change at any time. Information provided does not cover all details or variations possible with DERRICK equipment, nor does it cover every contingency that may be met in conjunction with installation, operation, maintenance, or troubleshooting of the equipment.
(ANSI Section 4) FIRE-FIGHTING MEASURES (ANSI Section 5) Fire extinguishing media : Dry chemical or foam water fog. Carbon dioxide. Closed containers may explode when exposed to extreme heat or fire. Vapors may ignite explosively at ambient temperatures. Vapors are heavier than air and may travel long distances to a source of ignition and flash back. Vapors can form explosive mixtures in air at elevated temperatures. Closed containers may burst if exposed to extreme heat or fire. Dust explosion hazard.
TOXICOLOGICAL INFORMATION (ANSI Section 11) Supplemental health information : Contains a chemical that is moderately toxic by ingestion. Contains a chemical that is toxic by inhalation. Contains a chemical that may be absorbed through skin. Free diisocyanate may cause allergic reaction in susceptible persons. Notice - reports have associated repeated and prolonged occupational overexposure to solvents with permanent brain and nervous system damage.
Chemical Hazard Data Common Name diisobutyl ketone ethyl orthoformate butyl acetate phthalo green pigment xylene titanium dioxide acrylic polymer aliphatic polyisocyanate formaldehyde yellow iron oxide tert-butyl acetate pigment yellow 74 light aromatic solvent naphtha n-butanol ethyl 3-ethoxypropionate barium sulfate castor oil, raw hexamethylene diisocyanate oxo-heptyl acetate pseudocumene anti-settling agent rheological additive Footnotes: C=Ceiling - Concentration that should not be exceeded, even insta
(ANSI Section 3) (ANSI Section 4) Inhalation : Remove to fresh air. Restore and support continued breathing. Get emergency medical attention. Have trained person give oxygen if necessary. Get medical help for any breathing difficulty. Skin contact : Wash thoroughly with soap and water. If any product remains, gently rub petroleum jelly, vegetable or mineral/baby oil onto skin. Repeated applications may be needed. Remove contaminated clothing. Wash contaminated clothing before re-use.
Carcinogenicity : The international agency for research on cancer (IARC) has evaluated ethylbenzene and classified it as a possible human carcinogen (group 2b) based on sufficient evidence for carcinogenicity in experimental animals, but inadequate evidence for cancer in exposed humans. In a 2 year inhalation study conducted by the national toxicology program (NTP), ethylbenzene vapor at 750 ppm produced kidney and testicular tumors in rats and lung and liver tumors in mice.
Document No. DER03020 Effective Date 10 Oct 08 Supersedes 25 May 07 Page 1 of 7 INSTALLATION INSTRUCTIONS DE-1000 CENTRIFUGE - GEARBOX DRIVE GENERAL This section describes the recommended installation procedure for the Derrick equipment defined by the model number and drawing number associated with your equipment. The centrifuge is shipped fully assembled, except for the rotating assembly. For safety during shipment, this assembly is supported by shipping blocks.
Document No. DER03020 INSTALLATION INSTRUCTIONS Page 2 of 7 Effective Date 10 Oct 08 INSTALLATION SEQUENCE Following is the sequence of steps for installing the centrifuge. The sequence presented may vary depending on the user’s facilities and previous experience with this type of equipment. 1. Read and understand all safety information in Warnings Summary DER02020 in Section 2 before installing and operating this equipment. 2.
INSTALLATION INSTRUCTIONS Effective Date 10 Oct 08 Document No. DER03020 Page 3 of 7 Figure 3020-1 Centrifuge Leveling SHIPPING COMPONENTS Note! Do not discard rotating assembly support shipping brackets after removal. These brackets must be re-installed whenever the machine is moved. These components prevent damage to the rotating assembly bearings during transit. Following final positioning and leveling of the centrifuge, the shipping brackets and covers (Figure 3020-2) must be removed.
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INSTALLATION INSTRUCTIONS Effective Date 10 Oct 08 Document No. DER03020 Page 5 of 7 FEED PUMP The customer must supply a positive-displacement feed pump of up to 15HP for delivering slurry to the centrifuge. The pump must be connected to the centrifuge’s electrical control system as described in this document so that its operation can be supervised by the centrifuge. ELECTRIC POWER CONNECTIONS Three-phase line power and ground connections are required.
Document No. DER03020 INSTALLATION INSTRUCTIONS Page 6 of 7 Effective Date 10 Oct 08 ELECTRIC POWER CONNECTIONS (CONT’D) Figure 3020-5 Electric Power and Feed Pump Connections MACHINE STARTUP Refer to Section 4 of this manual for initial startup and operating procedures for the centrifuge. WARNING! DO NOT ATTEMPT TO OPERATE MACHINE WITH SHIPPING COMPONENTS INSTALLED. The content of this document is subject to change at any time.
Document No. DER04097 Effective Date 27 Nov 07 Supersedes 25 May 07 Page No. 1 of 7 OPERATING INSTRUCTIONS DE-1000 CENTRIFUGE - GEARBOX DRIVE GENERAL This section includes initial and normal startup, operation, shutdown, and emergency shutdown procedures for the centrifuge. These procedures are for use only by trained personnel who are qualified to operate high-speed rotating equipment. The centrifuge is designed to be operated only for the purpose specified at the time of purchase.
Document No. DER04097 OPERATING INSTRUCTIONS Page 2 of 7 Effective Date 27 Nov 07 INITIAL STARTUP Perform the initial startup procedure when the centrifuge is being started for the first time following installation or after the machine has been relocated. Before beginning the procedure, verify the following: 1. All tools, documents, and shipping components have been removed and there are no obstructions to operation. 2. All personnel are clear of equipment.
OPERATING INSTRUCTIONS Effective Date 27 Nov 07 Document No. DER04097 Page 3 of 7 OPERATION Monitor the liquid and solids discharges continually to determine operating status of the centrifuge. Take corrective action if any anomaly is detected such as insufficient solids discharge and/or repetitive tripping of the overload release assembly. Note that any change in feed rate or adjustment of pond depth will not produce an immediate response from the centrifuge.
Document No. DER04097 OPERATING INSTRUCTIONS Page 4 of 7 Effective Date 27 Nov 07 Pond Depth Pond depth can only be adjusted with the centrifuge fully stopped and locked out and tagged out. For this reason, pond depth is usually adjusted after the feed rate is adjusted. The factory pond depth setting of 3.4 is usually satisfactory when used in conjunction with feed rate adjustment. However, if desired results cannot be achieved by adjusting the feed rate, changing the pond depth may be helpful.
OPERATING INSTRUCTIONS Effective Date Document No. DER04097 27 Nov 07 Page 5 of 7 Bowl and Conveyor Speeds The faster the bowl speed, the faster solids are conveyed out of the centrifuge, but faster processing results in wetter solids discharge. To reduce wetness, the slurry must remain in the bowl longer, subjecting it to the settling process for a longer duration before being conveyed out the solids discharge.
Document No. DER04097 Page 6 of 7 OPERATING INSTRUCTIONS Effective Date 27 Nov 07 Overload Release Clutch Torque Frequent overload tripping that cannot be corrected by feed rate and/or pond depth adjustments may be due to an incorrect torque setting of the overload release assembly. To check and adjust overload release assembly torque, refer to DER05104. AUTOMATIC SHUTDOWNS The centrifuge has built-in safety features to protect the equipment.
OPERATING INSTRUCTIONS Effective Date Document No. DER04097 27 Nov 07 Page 7 of 7 NORMAL SHUTDOWN The normal shutdown procedure is to be used for controlled stopping of operation. Normal shutdown is performed for routine activities such as cleaning, lubrication, inspection, or adjustment. WARNING! CENTRIFUGE MUST BE FLUSHED OUT THOROUGHLY AT THE END OF THE DAY. UNLESS WASHED OUT, PROCESS MATERIAL WILL SAG AND DRY OUT CAUSING SEVERE OUT OF BALANCE.
Document No. DER05017 Effective Date 25 May 07 Page No. 1 of 12 BEARING REPLACEMENT DE-1000 CENTRIFUGE GENERAL This procedure describes replacement of the main bearings installed in the pillow blocks as well as the conveyor bearings located inside the conveyor. Excessive noise or vibration during centrifuge operation may indicate defective bearings. If such conditions are evident, the bearings should be inspected for looseness and replaced if necessary.
Document No. DER05017 Page 2 of 12 BEARING REPLACEMENT Effective Date 25 May 07 Liquid End Pillow Block Bearing(Cont’d) 4. Remove Rotodiff / gearbox from liquid bowl head (Figure 5017-1) as follows: a. Scribe a line across Rotodiff / gearbox and flange to ensure correct positioning upon installation. Using a 14mm hex wrench, remove six screws securing Rotodiff / gearbox to flange. b. To ensure correct placement of shim(s), mark location of shim(s) between flange and Rotodiff / gearbox.
BEARING REPLACEMENT Effective Date Document No. DER05017 25 May 07 Page 3 of 12 5. Turn flange (Figure 5017-2) until large access holes in flange align with retaining screws for outboard flinger cover. Remove screws securing outboard flinger cover to pillow block, and lift and remove flinger cover. 6. Remove screws securing flange to liquid bowl head, and loosen set screw securing flange to liquid bowl head. Figure 5017-2 Rotodiff / Gearbox Flange Attachment 7.
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BEARING REPLACEMENT Effective Date Document No. DER05017 25 May 07 Page 5 of 12 Figure 5017-4 Liquid End Cross Section Solids End Pillow Block Bearing With liquid end pillow block bearing previously removed and rotating assembly remaining suspended, remove the solids end pillow block bearing (Figure 5017-5) as follows: 1. Remove screws securing inboard and outboard flinger covers to pillow block, and lift and remove inboard flinger cover. 2.
Document No. DER05017 Page 6 of 12 BEARING REPLACEMENT Effective Date 25 May 07 Solids End Pillow Block Bearing (Cont’d) 5. Remove flathead screws securing outboard pillow block cover to pillow block, and remove cover. Separate O-ring from pillow block cover and discard O-ring. 6. Remove flat head screws securing inboard pillow block cover to pillow block, and slide pillow block and bearing outer race and rollers off solids bowl head. 7. Loosen set screw securing inboard flinger to solid bowl head. 8.
BEARING REPLACEMENT Effective Date Document No. DER05017 25 May 07 Page 7 of 12 Cleaning, Inspection, and Repair 1. Clean all components with a suitable cleaner/degreasing agent, and blow dry with filtered compressed air. Remove any corrosion to facilitate inspection. 2. Inspect bowl heads for scratches, nicks, burrs, or deformation that may affect suitability for returning to service. Blend out any minor surface defects.
Document No. DER05017 Page 8 of 12 BEARING REPLACEMENT Effective Date 25 May 07 Liquid End Pillow Block Bearing (Cont’d) 7. Slide assembled pillow block and bearing outer race onto inner race previously installed on bearing journal. 8. Install new O-ring against shoulder of outboard pillow block cover, slide pillow block cover onto shaft, and rest against pillow block. 9. Orient inboard pillow block cover so that flat edge is aligned with bottom of pillow block. 10.
BEARING REPLACEMENT Effective Date Document No. DER05017 25 May 07 Page 9 of 12 5. Install new small cross-section O-ring against shoulder of inboard pillow block cover, and slide pillow block cover onto shaft. 6. Apply sufficient quantity of bearing grease listed in customer specification to completely cover bearing rollers. 7. Slide assembled pillow block and bearing outer race onto inner race previously installed on bearing journal. 8.
Document No. DER05017 Page 10 of 12 BEARING REPLACEMENT Effective Date 25 May 07 Solids End Pillow Block Bearing (Cont’d) 14. Apply a light coat of grease to surface of bowl shaft where sheave mounts. 15. Heat sheave to 200°F. While handling with insulated gloves, orient notch in sheave with key on solid bowl head shaft and install sheave on shaft. Secure sheave with screws. 16. Slide inboard and outboard pillow block flingers close to pillow block covers, leaving about 1/16-in.
BEARING REPLACEMENT Effective Date Document No. DER05017 25 May 07 Page 11 of 12 b. Remove retaining ring securing seal within seal housing. Remove and discard seal and Oring from seal housing. c. Extract bearing from bearing housing, and discard bearing. d. Remove retaining ring securing seal within bearing housing, and remove and discard seal. e. Remove wave spring from solid bowl head shaft. Cleaning, Inspection, and Repair 1.
Document No. DER05017 Page 12 of 12 BEARING REPLACEMENT Effective Date 25 May 07 Installation (Cont’d) 2. To install the solids end conveyor bearing, proceed as follows: a. Insert new seal into seal housing (Figure 5017-5), and secure with retaining ring. b. Install new O-ring into external groove of seal housing. c. Insert new seal into bearing housing, and secure with retaining ring. d. Insert new bearing into bearing housing, and fully seat against shoulder. e.
Document No. DER05018 Effective Date 15 Oct 07 Supersedes Page No. 25 May 07 Page 1 of 6 HARDWARE TORQUE SPECIFICATIONS DE-1000 CENTRIFUGE GENERAL Use only hardware that is approved by Derrick® Corporation. The use of potentially inferior, nonDerrick approved hardware may result in serious injury to personnel and/or damage to equipment. Additionally, any warranty in force, whether written or implied, may be voided by use of unapproved hardware.
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HARDWARE TORQUE SPECIFICATIONS Effective Date DER05018 Document No. 15 Oct 07 Page 3 of 6 Solid End Hardware Installation No. Description Qty Lubricant Torque Location 6 1/4 x 1-1/4 Pin 4 Loctite 680 252 in-lbs Sol. End Bowl Hd 7 5/16-18 x 1/2 Set Screw 2 Loctite 262 N/A Sol. End Bowl Hd 8 1/8 NPT x 3/4 Gr. Fitting 4 N/A N/A Sol. End Bowl Hd 9 Plastic Cap 2 N/A N/A Sol. End Bowl Hd 10 3/8-16 x 1 Hx Skt Hd 8 Anti-Seize 252 in-lbs Sol.
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HARDWARE TORQUE SPECIFICATIONS Effective Date DER05018 Document No. 15 Oct 07 Page 5 of 6 Liquid End Hardware Installation No. Description Qty Lubricant Torque Location 1 3/8-16 x 1-1/4 Hx Skt Hd 12 Anti-Seize 252 in-lbs Liq. End Bowl Hd 2* 5/16 x 1 Pin 4 Loctite 680 N/A Liq. End Bowl Hd 3 5/16 x 5/16 x 3 Key 1 N/A N/A Liq. End Bowl Hd 4 3/8-16 x 1-1/2 Hx Skt Hd 8 Anti-Seize 252 in-lbs Liq End Bearing Hsng 5 3/8-16 x 1 Hx Skt Hd 4 Anti-Seize 252 in-lbs Liq.
Document No. DER05018 Page 6 of 6 HARDWARE TORQUE SPECIFICATIONS Effective Date 15 Oct 07 The content of this document is subject to change at any time. Information provided does not cover all details or variations possible with DERRICK equipment, nor does it cover every contingency that may be met in conjunction with installation, operation, maintenance, or troubleshooting of the equipment.
Document No. DER05022 Effective Date 25 May 07 Page No. 1 of 10 PREVENTIVE MAINTENANCE DE-1000 CENTRIFUGE - GEARBOX DRIVE GENERAL Preventive maintenance consists of overall inspection, cleaning, and lubrication. Routine maintenance will ensure maximum life and trouble-free operation. While the maintenance schedule presented in this section is not rigid, modifications should be based on experience with operating the equipment at your facilities.
Document No. DER05022 Page 2 of 10 PREVENTIVE MAINTENANCE Effective Date 25 May 07 Figure 5022-1 Bearing Lubrication Points PARTS REPLACEMENT Defective parts should be replaced as soon as possible to prevent further damage to equipment. Refer to the general arrangement drawing, , rotating assembly drawing, and electrical drawings in Section 11 - Reference Drawings, for Derrick component locations and part numbers. Refer to Section 12 for supplier component information.
PREVENTIVE MAINTENANCE Effective Date Document No. DER05022 25 May 07 Page 3 of 10 MAINTENANCE PROCEDURES The following paragraphs describe maintenance procedures for centrifuge components and assemblies. Obvious procedures are omitted. WARNING! HIGH VOLTAGE MAY BE PRESENT. ALWAYS OPEN FUSED DISCONNECT SUPPLYING ELECTRIC POWER TO THE EQUIPMENT, AND LOCK OUT AND TAG OUT POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE PROCEDURES.
Document No. DER05022 PREVENTIVE MAINTENANCE Page 4 of 10 Effective Date 25 May 07 Drive Belt (Cont’d) 6. Tighten motor mount adjustment bolts to apply sufficient belt tension to permit deflection of 5/8” with 20 lbs. of pressure exerted at the midpoint of the belt. After correct tension is set, tighten motor mount bolts. 7. Install belt guard, and latch in place. 8. Insert feed tube into feed tube support until shoulder fully contacts support, and tighten screws to specification listed in DER05018.
PREVENTIVE MAINTENANCE Effective Date Document No. DER05022 25 May 07 Page 5 of 10 Figure 5022-3 Gearbox Removal 9. Note locations of all shims found between pillow blocks and base mounting pads, and remove and retain shims. 10. Apply protective coating to mating surfaces of pillow blocks and base. 11. Remove liquid bowl head assembly as follows: a.
Document No. DER05022 Page 6 of 10 PREVENTIVE MAINTENANCE Effective Date 25 May 07 Removal and Disassembly (Cont’d) b. Note locations of alignment marks on liquid bowl head to ensure proper orientation during reassembly. c. Remove 12 screws (Figure 5022-5) securing liquid bowl head to bowl assembly. d. Thread four jack screws into four threaded jack screw holes in bowl head, and tighten evenly until head has separated from bowl. e.
PREVENTIVE MAINTENANCE Effective Date Document No. DER05022 25 May 07 Page 7 of 10 12. Remove conveyor assembly as follows: a. Remove four screws securing liquid end seal housing to conveyor, and using jack screws to separate seal housing from bearing housing, remove seal housing. Discard seal. b. Position vertical lifting bracket on conveyor (Figure 5022-6), and secure with four screws. c. Attach a hoist capable of lifting at least 750 pounds to vertical lifting bracket. d.
Document No. DER05022 PREVENTIVE MAINTENANCE Page 8 of 10 Effective Date 25 May 07 Cleaning, Inspection, and Repair (Cont’d) 6. Inspect bowl interior and exterior for gouges, scratches, or other damage that may affect performance. 7. Check pillow block bearings and conveyor bearings for looseness, noise, or rubbing. Replace any defective bearings in accordance with procedure in DER05017.
PREVENTIVE MAINTENANCE Effective Date Document No. DER05022 25 May 07 Page 9 of 10 b. Insert six new hex head screws through gearbox flange and into threaded mounting holes of gearbox. Alternately turn each screw a few revolutions at a time to evenly draw the gearbox and flange together. Tighten the screws using a star pattern typical for circular bolt patterns. Refer to DER05018 for required torque values. 12.
Document No. DER05022 PREVENTIVE MAINTENANCE Page 10 of 10 Effective Date 25 May 07 Reassembly and Installation (Cont’d) 14. After completing gearbox installation, install top cover over gearbox. 15. Install drive belt, and apply adequate tension to prevent slippage. 16. Install feed tube and secure in its support. Tighten retaining screws in accordance with DER05018. 17. Close cover, and secure by tightening screws in accordance with torque specification in DER05018.
Document No. DER05102 Effective Date 25 May 07 Page No. 1 of 2 TOOLS AND EQUIPMENT DE-1000 CENTRIFUGE GENERAL The following tool list includes all tools and equipment supplied to facilitate maintenance of the DE-1000 Centrifuge. Each component is listed with its part number, quantity supplied, and use or application. TABLE 5102-1 DE-1000 CENTRIFUGE TOOL LIST PART NO.
Document No. DER05102 TOOLS AND EQUIPMENT Page 2 of 2 Effective Date 25 May 07 TABLE 5102-1 DE-1000 CENTRIFUGE TOOL LIST PART NO.
Document No. DER05103 Effective Date 25 May 07 Page No. 1 of 5 TROUBLESHOOTING DE-1000 CENTRIFUGE - GEARBOX DRIVE GENERAL Although equipment failure is unlikely, malfunctions due to operating error or other problem can result in unnecessary machine down-time and should be corrected as soon as possible. The troubleshooting procedures presented in this section will assist technicians in isolating and correcting malfunctions.
Document No. DER05103 TROUBLESHOOTING Page 2 of 5 Effective Date 25 May 07 CHECK FOR CLOGGED CONVEYOR Troubleshooting should begin with determining if the conveyor is clogged. To check for a clogged conveyor, proceed as follows: 1. Shut down and lock out and tag centrifuge. 2. Remove overload release assembly from gearbox, and attempt to turn gearbox pinion shaft while restraining bowl from rotating. If pinion can be turned independently of bowl, conveyor is not clogged. 3.
TROUBLESHOOTING Effective Date Document No. DER05103 25 May 07 Page 3 of 5 TROUBLESHOOTING CENTRIFUGE - FULL HYDRAULIC DRIVE Possible Cause Isolation Procedure & Corrective Action Failure Mode 3: Centrifuge Has Automatically Shut Down (Cont’d) Vibration switch tripped. Press and hold vibration switch reset button, and attempt to re-start centrifuge (refer to Section 4 - Operation). If machine fails to start or shuts down soon after starting, continue troubleshooting.
Document No. DER05103 TROUBLESHOOTING Page 4 of 5 Effective Date 25 May 07 TROUBLESHOOTING CENTRIFUGE - FULL HYDRAULIC DRIVE Possible Cause Isolation Procedure & Corrective Action Failure Mode 4: Feed Pump Fails to Start Feed pump motor overheated due to excessive current draw. Allow sufficient time for motor to cool, and then press PUMP ON button to attempt re-start of feed pump. If pump starts, adjust feed rate to avoid overloading pump and monitor operation until confident of no recurrence.
TROUBLESHOOTING Effective Date 25 May 07 Document No. DER05103 Page 5 of 5 The content of this document is subject to change at any time. Information provided does not cover all details or variations possible with DERRICK equipment, nor does it cover every contingency that may be met in conjunction with installation, operation, maintenance, or troubleshooting of the equipment.
Document No. DER05104 Effective Date 25 May 07 Page No. Page 1 of 4 ADJUSTMENTS DE-1000 CENTRIFUGE - GEARBOX DRIVE GENERAL This section contains procedures for adjusting the overload release assembly torque and removal and replacement of the motor sheave. These procedures should be attempted only by skilled personnel who are trained and qualified to perform advanced mechanical procedures. WARNING! THESE PROCEDURES ARE TO BE PERFORMED ONLY BY TRAINED, QUALIFIED PERSONNEL.
Document No. DER05104 Page 2 of 4 ADJUSTMENTS Effective Date 25 May 07 MOTOR SHEAVE REPLACEMENT (CONT’D) 12. Insert feed tube into feed tube support until shoulder fully contacts support, and tighten screws to specification listed in DER05018. Figure 5104-1 Drive Belt Tensioning Adjustment Overload Release Clutch Torque Frequent overload tripping that cannot be corrected by feed rate and/or pond depth adjustments may be due to an incorrect torque setting of the overload release assembly.
Section No. DER05104 ADJUSTMENTS Effective Date 25 May 07 Page 3 of 4 c. Check that clutch has reset by attempting to rotate the cam/hub assembly. If rotation is possible, repeat steps a and b, above. CAUTION! In the following step, T-Handle Reset Screw Must Be Backed Out Fully To Its Original Position Before Returning Centrifuge To Service. d. After confirming that the clutch is reset, return the T-handle set screw to its original position by turning counterclockwise (outward). e.
Document No. DER05104 Page 4 of 4 ADJUSTMENTS Effective Date 25 May 07 Overload Release Clutch Torque (Cont’d) Figure 5014-3 Setting Overload Release Torque The content of this document is subject to change at any time. Information provided does not cover all details or variations possible with DERRICK equipment, nor does it cover every contingency that may be met in conjunction with installation, operation, maintenance, or troubleshooting of the equipment.
Document No. DER11000 bvacu-Flos Effective Date Page 16 May 08 1 of 1 REFERENCE DRAWINGS DE-1000 GBD CENTRIFUGE This section contains Derrick engineering drawings FOR REFERENCE ONLY. For assistance in troubleshooting, repair, and parts ordering, please refer to your Derrick manual.
PE-S-014-09 rev. 01/15/08 RECOMMENDED THERMAL UNIT SELECTION TABLE FOR DERRICK® SUPPLIED MANUAL STARTERS DERRICK VIBRATING MACHINES F, FX, K, KX, L, LX, T, TX MOTORS E, EX, M, MX, SG, SGX MOTORS R, RX MOTORS A, C, N MOTORS 575V.A.C. 460V.A.C. 230V.A.C. 215V.A.C. 440V.A.C. 380V.A.C. 220V.A.C. 60Hz 60Hz 60Hz 60Hz 50Hz 50Hz 50Hz 1.5HP 1.5HP 1.5HP 1.5HP 1.5HP 1.5HP 1.5HP = = = = = = = 575V.A.C. 460V.A.C. 230V.A.C. 215V.A.C. 440V.A.C. 380V.A.C. 220V.A.C. 60Hz 60Hz 60Hz 60Hz 50Hz 50Hz 50Hz 2.5HP 2.
bvacu-Flos Document No. DER12016 Effective Date 25 May 07 Page No. 1 of 1 SUPPLIER DATA DE-1000 CENTRIFUGE - GEARBOX DRIVE GENERAL This section contains manufacturers’ manuals, bulletins, instructions, and other technical data for components installed on the centrifuge. Refer to Section 11 - Reference Drawings for the Derrick assembly drawings, parts lists, and electrical diagrams.
Performance Data: M7064T-I Nameplate Data General Characterstics at 460 V, 60 Hz Rated Output 50 HP Full Load Torque 149 LB-FT Volts 230/460 Start Configuration DOL Full Load Amps 120/60 Break Down Torque 440 LB-FT Speed 1775 Pull-Up Torque 191 LB-FT Hertz 60 Locked-Roter Torque 240 LB-FT Phase 3 Starting Current 398 Amps NEMA Design Code A No-Load Current 20 Amps LR KVA Code H Line-line Resistance @ 25° C 0.119 Ohms NEMA Nom. Eff.
Specifications: M7064T-I Catalog Number: M7064T-I Specification Number: 12S077X139H1 Horsepower: 50//40 Voltage: 230/460//190/380 Hertz: 60//50 Phase: 3 Full Load Amps: 120/60//114/57 Usable at 208 Volts: 126 RPM: 1775//1475 Frame Size: 326T Service Factor: 1.
Boston Gear® ORC Series Trig-O-Matic™ Overload Release Clutches Installation and Maintenance Instructions Doc. No. ORC Series Model S www.bostongear.
ORC SERIES, MODEL S CLUTCHES ORC SERIES TRIG-O-MATIC™ OVERLOAD RELEASE CLUTCHES – STANDARD MODEL S INSTALLATION AND MAINTENANCE INSTRUCTIONS Reset Spring Housing I. INTRODUCTION A. Operating Principle The ORC Series, Model S Overload Release Clutch consists of two basic components: the rotor and the housing assembly. The clutch rotor is keyed and secured to a shaft with a setscrew. The housing assembly includes a drive pawl and a reset pawl which are pivoted within the clutch housing.
ORC SERIES, MODEL S CLUTCHES When an overload occurs, the rotor rotates from its normal position within the housing. At this instant, the combined compression of the drive and reset springs is overcome. For a manual reset clutch, the drive pawl is forced out of its engaged position from the rotor and as it pivots up, the reset pawl lifts and locks the drive pawl out of contact with the rotor as shown in Figure 2. The clutch is then free to rotate until it is reset.
ORC SERIES, MODEL S CLUTCHES LIMIT SWITCH ACTUATING MECHANISM (LSAM) If the torque output of the clutch is altered, it may be necessary to adjust the actuating mechanism. This is accomplished by first disengaging the clutch, then removing access plug #5 and inserting an allen wrench into the actuating adjusting screw #29. (Refer to Table 5 for wrench sizes).
ORC SERIES, MODEL S CLUTCHES 6 Tapped Holes at 60º 4 Tapped Holes at 90º 3 Tapped Holes at 120º 60º Typ. 0 Typ. 20 Typ.
ORC SERIES, MODEL S CLUTCHES III. LOCATING AND MOUNTING CLUTCH AND COUPLINGS TO SHAFT Flexible Coupling A. Location The clutch should always be located as close as possible to the source of an overload condition. Figures 9 through 12 indicate both preferred and not preferred locations for mounting an ORC Series, Model S Overload Release Clutch. Note: Clutch mounted sprockets, etc. and couplings should be positioned as close to a supporting bearing as possible to minimize overhung loads.
ORC SERIES, MODEL S CLUTCHES TABLE 5 - WRENCH SIZE CHART Clutch Size 1 2 3 4 5 6 Drive Spring Screw Hex Wrench 3/16 1/4 5/16 5/16 3/8 3/4 Reset Spring Screw Square Wrench 3/8 3/8 1/2 1/2 1/2 3/4 Manual Reset Screw Hex Wrench 3/16 1/4 5/16 3/8 1/2 1/2 5. Select the correct hex wrench from Table 5 and insert it through the hole stamped 22 in the housing. Tighten the rotor setscrew securing the clutch to the shaft.
ORC SERIES, MODEL S CLUTCHES c. If a correction is required to satisfy angular alignment requirements, then recheck the parallel alignment. TABLE 8 - TYPE “C” MISALIGNMENT Maximum Allowable Misalignment 5. Secure the coupling to the drive shaft by tightening the two setscrews located in the hub of the flange. Refer to Table 7 for recommended setscrew seating torques. 6. Parallel Alignment Parallel Angular a. Place a straightedge across the clutch housing and coupling flange as shown in Figure 13. 1 .
ORC SERIES, MODEL S CLUTCHES The actuating plate must be reset by manually pushing it back into position. The clutch must be engaged when resetting the plate or the plate will not reset when the clutch is disengaged. IV. LIMIT SWITCHES The ORC Series, Model S Overload Release Clutch is available with two types of limit switch actuators, a limit switch pin (LSAP) and a limit switch actuating mechanism (LSAM). A.
ORC SERIES, MODEL S CLUTCHES 11. Remove the housing (1) from the mounting surface and press out the rotor (12). VI. REPAIR INSTRUCTIONS A. General Disassembly 1. All item numbers in parenthesis will refer to the key numbers shown in the clutch exploded view drawing and parts identification tables. 2. Place the clutch preferably in a three-jaw chuck with the actuating plate or cover facing up. 12. If clutch is manual reset, remove the reset screw (24) by turning clockwise into the housing. 13.
ORC SERIES, MODEL S CLUTCHES 4. Remove the drive pawl (10). The drive pawl and the drive spring (18) will have to be installed simultaneously. If a drastic change in torque is desired, use this step to change the drive spring. Place one end of the drive spring over the drive spring thrust washer (22). Insert the knob of the drive pawl into the other end of the drive spring.
ORC SERIES, MODEL S CLUTCHES D. Limit Switch Actuating Mechanism (LSAM) Assembly 1. Apply a graphite lubricant to the release ring groove of the cover (8). 2. Insert the actuating stud (40) through the appropriate hole in the release ring (35). To identify this hole place the release ring in the groove of the cover. When the trip pin holes line up with the through holes of the cover, the actuating stud hole will line up with the counterbored hole in the groove of the cover. 3.
27 9 12 11 17 3 5 1 7 24 26 16 25 10 5 25 26 3 4 6 2 18 23 22 21 20 19 15 14 13 8 ORC SERIES, MODEL S CLUTCHES ORC SERIES, MODEL S WITH LIMIT SWITCH PIN (LSAP) TYPES SA & SM BOSTON GEAR ® ORC Series, Model S 12
ORC SERIES, MODEL S CLUTCHES PART IDENTIFICATION - MODEL S WITH LIMIT SWITCH PIN (LSAP) TYPES SA & SM Key No. *1 2 3 4 5 6 7 8 9 3 10 *11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Name T Housing Ass’y., or B Housing Ass’y.,or C Housing Ass’y.
41 40 11 43 18 28 7 5 24 26 25 29 5 1 4 10 25 3 26 2 6 23 22 41 39 20 19 15 14 35 36 12 38 37 3 9 13 33 36 43 27 8 31 34 32 ORC SERIES, MODEL S CLUTCHES ORC SERIES, MODEL S WITH LIMIT SWITCH ACTUATING MECHANISM (LSAM) TYPES SB, SC, SP & SS BOSTON GEAR ® ORC Series, Model S 14
ORC SERIES, MODEL S CLUTCHES PART IDENTIFICATION - MODEL S WITH LIMIT SWITCH ACTUATING MECHANISM (LSAM) TYPES SB, SC, SP & SS Key No. 8 9 3 10 28 29 30 Name Cover Ass’y.
ORC SERIES, MODEL S CLUTCHES COUPLINGS Boston Gear 14 Hayward Street Quincy, MA 02171 Tel 617.328.3300 fax 617.479.6238 www.bostongear.com CLUTCHES Boston Gear 14 Hayward Street Quincy, MA 02171 Tel 617.328.3300 fax 617.479.6238 www.bostongear.com Boston Gear 14 Hayward St. Quincy, MA 02171 tel fax www email BOSTON GEAR ® 617.328.3300 617.479.6238 bostongear.com info@bostongear.
® Document No.: PE-S-069-03-03 CERTIFICATE OF ORIGIN Equipment: Centrifuge Equipment Model: DE-1000 GBD, DE-1000 FHD, DE-1000 VFD Characteristics: 0-600VAC, 50/60Hz, 3PH Derrick Corporation certifies that the above described articles are of the growth, product, or manufacture of the United States of America and the prices true and correct. Material furnished is in accordance with the requirements of order.
® Document No.: PE-S-009-08-00 CERTIFICATE OF QUALITY Equipment: Centrifuge Equipment Model: DE-1000 GBD, DE-1000 FHD, DE-1000 VFD Characteristics: 0-600VAC, 50/60Hz, 3PH Derrick Corporation certifies that the delivered goods for the above referenced order conforms to the requirements of the specified order in that all construction materials and components are new and unused, manufactured for this order, and that the goods are free of any known defects as to their design, material, and workmanship.
® Document No.: PE-S-073-04-00 SHIPPING FINAL INSPECTION AND RUN TEST CERTIFICATE Equipment: Centrifuge Equipment Model: DE-1000 GBD, DE-1000 FHD, DE-1000 VFD Characteristics: 0-600VAC, 50/60Hz, 3PH The equipment listed above was inspected and found to be in conformance with Derrick’s internal coating, run test, and assembly inspection documents that were required for the type of equipment manufactured in accordance with the Derrick Quality System.
® Document No: PE-S-036-02-06 CERTIFICATE OF CONFORMANCE Equipment: Mining & Oilfield equipment manufactured specifically for Hazardous Location Areas including but not limited to: Flo-Line Cleaners, Primers, Agitators, Degassers, Centrifuges, Centrifugal Pumps, Scalpers, etc. Rating and principal characteristics: 0 - 600VAC , 50/60Hz, 3PH Model/Type ref.: Various Additional information: None This product was found to be in conformance with (as a minimum): U.L.
Document No. DER13000 Effective Date 15 Apr 05 Page No. 1 of ___ INSTALLATION AND MAINTENANCE LOG PURPOSE The ruled, blank pages provided will assist the customer in establishing and maintaining historical information accumulated during the installation and operation of the Derrick equipment. The resultant log is valuable for adjusting maintenance intervals and intercepting trends that may indicate the need for changing operating procedures.
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INSTALLATION AND MAINTENANCE LOG Effective Date Notes: 15 Apr 05 Document No.
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