The Screening

Screening, Dewatering
and Drying
y g Experts
p
Centrifuge and Belt
elt Press
Maintenance
   Previous Slide
 Introduction
Brian Lent
Western Regional Aftermarket Sales Manager
Experience
1976 – 1981 BIRD MACHINE – Walpole MA
Based out of Boston MA
1981 – 1998 Humboldt Decanter -Norcross GA
Based out of San Ramon CA
1998 – 2006 BAKER PROCESS – Walpole MA (Formerly BIRD)
Based out of San Ramon CA
2006 to Present Andritz Separation Inc – Arlington TX
Based out of San Ramon CA

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 Long Term Maintenance of Dewatering Equipment

Belt Press

Centrifuge
g

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

Dewatering Equipment like and other processing devices have there limits

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

Belt Press units have a basic rule of thumb

100 gpm per meter of belt width
1000 #/hr per meter of belt width

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 Long Term Maintenance of Dewatering Equipment

Centrifuges

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

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

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

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

The newer designs are pushing that curve to it’s limits

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

Known: Flow Rate

Feed Solids
Specific Gravity of Feed Slurry (use 1.0 if unknown)

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

S

or simplified

T = 5 x FR x FS x SGSL

T --- Throughput in lbs/hr Dry Solids

FR --- Flow Rate in Gallons per Minute
FS --- Feed Solids in % Dry Solids
SGSL --- Specific Gravity of sludge or slurry (use 1.0 for municipal sludge)

Example: Flow Rate = 100 GPM

Feed Solids = 2.5 % DS
SG Sludge = 1.0

Throughput = 1,250
1 250 lbs/h DS

Andritz Separation Inc.

Slide No. 6
 SLUDGE FROM TYPICAL WASTEWATER TREATMENT

Andritz Separation Inc.

Slide No. 7
 Long Term Maintenance of Dewatering Equipment
From the simple sketch you can see that sludge is made up of waste and
that waste has the “kitchen sink” in it. The wastewater treatment plants
try to remove the heavy particulate and screen most of the plastic and
grit but a large amount still manages to get to the solids handling end
of the plant where it is dewatered.
Contrary to popular thought not all Poop is the same – each sludge has its
own characteristics, chemical make up, grit levels, ash content, settling
rates
t and d any other
th individual
i di id l componentt one can thi
think
k of.
f
With that thought how do we protect our equipment
Most Belt Press units have
• Protected and coated frames
• Protected bearings and sealed housings
• Protected rollers
• Stainless steel fasteners and fittings
• Plastic and protective housings and covers
Buenos Aires
• Gear boxes and drives
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 Long Term Maintenance of Dewatering Equipment
Having said this – EVERYTHING REQUIRES SOME DEGREE OF
MAINTENANCE
The normal wear items for a Belt Press are
• The Belts – normal wear is 2000 to 3000 hours but this depends on the grit
and pressure applied to the rollers
•The Rollers – the rollers have an normal life expectancy of 10 years – again
d
depending
di on ththe grit
it and
d pressures applied
li d
•Tracking and tensioning systems (either pneumatic or hydraulic) have a life
cycle also – there life is dependent on the pressure, operating cycles and
generall h
housekeeping
k i off th
the unit
it
•Drives / gear boxes – there life cycle depends on lubrication changes,
alignment and general housekeeping
•Bearings and seals – these are the only items that require constant attention
as far a grease and housekeeping
•The frame and ancillaryy equipment
q p requires
q attention when it fails or is
damaged Buenos Aires

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 Long Term Maintenance of Dewatering Equipment

Belt press lubrication

5.3.1 Lubricant Specification

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

5.3.2 Lubrication Schedule

Frequency Lubricant
1. Grease bearings monthly A
2. Grease tracking device 1 month A
3. Grease thrust rods on tensioning device 6 months A
4. Check oil level in drive gearbox 80 hours B
5
5. Ch
Change oilil iin d
drive
i gearbox
b 10 000 hours
10,000 h (2 years)) B
6. Repack bearings in drive gearbox 20,000 hours (4 years) C
7. Grease bull gear & drive pinion gear 1 month A

5.3.3 Lubrication Location

*Graphics
Graphics may differ from actual machine*
machine

All equipment should have a simple grease chart that can be followed
g these lubrication events
It is up to the customer to log
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 Long Term Maintenance of Dewatering Equipment
C t if
Centrifuges h
have similar
i il wear and
d maintenance
i t points
i t

Most centrifuges
g in the market these days
y are outfitted with the following
g
standards
•Bowls, bowl heads, conveyors and hard components are 316 SS or made
from a casting type duplex Stainless Steel
•The feed compartments, feed ports, cake ports and conveyor tips are
protected or made from a Tungsten Carbide or similar material
•Most have SS liners or covers protecting the solids and liquids discharge
points
•Most have bearings are designed for L10 ratings and the seals are Buna or
better – depending on service
•Most bases are carbons steel with powder coating or epoxy coatings

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 Centrifuge Maintenance Requirements

5.3.1 Lubricant Specification

LUBRICANT LIST
LUBE TYPE SKF Mobil Shell BP
Centrifuge A. Grease SKF LGMT2 Mobilux EP2 Alvania EP2 Energrease LS EP2
Technology B. Grease SKF LGMT3

C. Grease EXCLUSIVELY
Quality Energrease PR EP 00
D. Oil Mobil SHC X100 30 BP Super visco static
627 20w50
Innovative
5.3.2 Lubrication Schedule
Frequency Lubricant Quantity
Reliability 1. Grease bearing - feed end 200 hours A 20 Gr
2. Grease bearing - drive end 200 hours A 15 Gr
High Performance 3. Grease thrust bearing - feed end 4000 hours B 100 Gr
4. Change grease in drive speed inducer 4000 hours C 3000 Gr
5. & 6. Grease electric motor bearings 3000 hours A see Vendor info

5.3.3 Lubrication Location

 Long Term Maintenance of Dewatering Equipment

Maintenance Service Intervals

Most suppliers have a standard chart that is used as a guide for the
customers to logically project the maintenance of a particular size
centrifuge (the parts cost and labor vary by size) but they all have a
specific repair interval.
These type of charts can be used as guides for projected maintenance
costs.
The frequency of the intervals is dependent on the operating hours per
day, week and year.
The first few years of a 4000 operating hour centrifuge is obviously less
than a unit that is in service 24/7/365 unit

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 Andritz Centrifuge Features
12 Centrifuge Maintenance Requirements
12.
DESCRIPTION 200 3000 4000 6000 8000 9000 12000 15000 18000 24000
HRS HRS HRS HRS HRS HRS HRS HRS HRS HRS

1. * Lubricate both support bearings EVERY 200 hrs X

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

*…EExceptt it
item 1
1, th
the iintervals
t l above
b are ffrom b
beginning
i i operation.
ti
When 24000 hrs is reached, revert back to beginning of chart.

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 Long Term Maintenance of Dewatering Equipment

Simple rules of thumb for operating any piece of equipment

The Harder you run it the more it will cost you to maintain it
The Faster you operate and unit (above its performance optimum speed)
the more wear you will have
The more solids you put through a unit (above it’s optimum performance
range) the more wear you will have in the unit
The more grit or non biological particulate you have in the sludge the more
wear and plugging that will occur
The lless h
Th housekeeping
k i you performf on a piece
i off equipment
i t tto ffaster
t ththe
surfaces and housing will deteriorate
The less Electrical upkeep that is performed on the controls and electrical
components of a ssystem
stem the faster they
the will
ill fail

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 Long Term Maintenance of Dewatering Equipment

YES - I SAID CONTROLS

How many times have you heard – “It’s a Mechanical problem” – when the
motor won’t start or the panel does not function
function.
Electrical components have a shelf life and in today’s market they have a
Factory support life as well
Most PLC units are good for 10 years
OIT or HMI units are about the same or a little less
Instrumentation seems to have a better cycle if taken care of
VFD drives are supported by the factory for 10 years but some parts can be
recycled to extend the life by a few years

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Andritz Centrifuge Features
11 Centrifuge Control System
11.

NEMA 4X Stainless Steel

316L Control Panel with
Color Touch Screen

   Previous Slide
 Long Term Maintenance of Dewatering Equipment

CONTROL PANELS
This is the heart of the operation – if the controls are poor then the
machine operation
p and pperformance are p poor
If the Control Panels are left open and allowed to have a poor quality air
into the panel the wiring, instruments and controls can prematurely fail.
If the conduits into the panels are not sealed off then what ever can get
into the conduits is inside the panels
If the air conditioners (and most do have them if they have VFD’s) filters
and inlets are not serviced and the efficiency of the conditioned air is
affected the heat generated inside the panel can reach 150 deg F and the
function of the PCL and HMI (along with other controls) can fault.
If the controls on the machines are SO cord with plastic grommet fittings
they are in direct contact with the operating atmosphere, possible damage
and the big feet of most Maintenance people (OPS) – these need to be
inspected at timely intervals for damage and wear.
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 Long Term Maintenance of Dewatering Equipment

GENERAL NOTES
General Housekeeping is never a bad thing
All lubes and oils should be changed at least twice a year – regardless of
operating hours
Filters are always changed with the oils - these include air, oil, water and
screens.
Never operate a unit that one does not feel comfortable operating – if a guard
is missing or left off after a service – report it and correct it
If something
thi iis showing
h i signs
i off wear, erosion
i or corrosion
i replace
l it d
do nott
operate it
Motors need love too – they have lubrication intervals or life cycles (sealed
bearings) and the loads on the shafts req
require
ire alignment and thethey sho
should
ld be
checked during required service
Belts – the forgotten band – belts do not last until the break – they should be
checked for cracks and replaced ar specified intervals
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 Long Term Maintenance of Dewatering Equipment

QUESTIONS:
There are NO dumb questions –

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