HMWS & SB

BELT FILTER PRESS MECHANISM

PURPOSE: The belt filter press mechanism consist of 5 Nos (4 Nos working + 1 No standby) of 20
cum/Hr. sludge handling capacity each. The belt filter press is designed to provide a dewatered
cake that can be readily disposed. Sludge is first conditioned “in–line” with polymer and pumped to
a distribution ramp which is mounted on the gravity drainage section of the belt press frame. The
resultant agglomerated solids, “flock” release large amounts of free water as they are distributed
onto the gravity drainage section of the press. This free water is removed by gravity through
openings in the belt and through a nonmetallic grating to a drain pan.
Dispersion devices (plow blades) move sludge over the belt and open additional drainage channels
for removal of bonded water which has formed on the sludge surface. Movement of the belt over
the supporting non-metallic grit assists in removal of capillary water.
After sludge has been concentrated by means of gravity, the agglomerated solids are gently
distributed onto a lower belt. The upper and lower belts than come together to a form a moving
wedge section. The sludge is sandwiched between two belts. Gradually increased pressure is
applied as the sandwiched sludge passes around rollers of decreasing diameter. The final roller
from a “s” – shaped configuration which generates a shear force and release additional water.

Dewatered sludge is discharged from the press for ultimate disposal. To aid the removal of
dewatered sludge, doctor blades are utilized for each belt. After the cake has been discharged, the
belts are continuously washed with high pressure spray water. Belt presses are equipped with an
optional screws type discharge conveyor to remove thickened sludge from the gravity drainage
deck as desired. This thickened sludge is then automatically loaded on the parked truck.

No of Units - 5 NoS.
Capacity - 20 cum / Hr.
Make - TRIVENI
Supplied by - M/s. Triveni Engineering & Industries Ltd.
Water business group,
A-44, Hosiery complex, Phase-II Extn,
Noida – 201305, Uttar Pradesh.

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MAJOR EQUIPMENTS
Doctor blades
Roller (sensing and tracking)
Seals – sludge fence and wash trough
Filter elements (hydraulic return – line on power pack)
Bearing for each size
Set of seals “O” rings
Seal and bearing kit for each size motor
Belt skew limit switch
Roto valve
Spray nozzles
Emergency pull cord limit switch
SAFETY PRECAUTIONS
Following are the steps of a typical lock – out procedure that to used by maintenance and repair
crews:
Alert the operator and supervisor.
1. Indentify all sources of residual energy.
2. Before starting work, place padlocks on the switch, lever or valve, locking it in the “OFF”
position, installing tags at such locations to indicate maintenance in progress.
3. Insure that all power sources are off and “Bleed Off” hydraulic or pneumatic pressure of
“bleed off” any electrical current (capacitance) as required, so machine components will not
accidentally move.
4. After maintenance is completed, all machine safeguards that were removed should be
replaced, secured and checked to be sure they are functioning properly.
5. Only after ascertaining that the machine is ready to perform safely should padlocks be
removed and the machine cleared for operation.
Maintenance work can be hazardous if not done in a careful manner. When attempting any
maintenance of repairs be sure of the following:
1. Lock out all electrical controls.
2. Hydraulic pressures should be relieved.

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3. Use the proper non – flammable cleaning solvents. Follow the solvent manufacturer’s
instructions for use.
4. Be sure all connections are retightened. Do not over torque.
5. When searching for hydraulic leaks with the system under pressure, DO NOT USE HAND.
Fluid escaping from a small hole can be almost invisible. Pressurized fluid can penetrate the
skin and cause serious injury. Use a place of cardboard or wood.

FREQUENTLY MAINTENANCE
To fully utilize the long life and excellent service designed and build into this machine, it is
necessary to perform the preventive maintenance services outlined below. Conditions which
impose greater wear, loads or staring on the machine may dictate reduced check intervals.
A complete visual inspection should be made each day prior to start – up. Examine the belt press
for damage, missing accessories and check for hydraulic leaks.

MAINTENANCE
Operator should also be aware of the following ‘DONTS’
1. Don’t allow foreign objective to remain in the fluid reservoir. Remove immediately.
2. Don’t use kerosene or other light oils to flush the system; use hydraulic fluid.
3. Don’t allow water to get into the hydraulic fluid. A quick test to determine if water is
present is to heat the underside of a piece of sheet metal with a torch. Place a drop of fluid
on the heated surface. If the fluid sizzles and dances around, this indicates that water is
present and the system should be flushed and the reservoir refilled.
4. Don’t run the press if foreign objects, i.e wrenches, nuts, bolts, etc. are on the belt.

RECOMMENDED HYDRAULIC FLUIDS

Recommended greases for roller bearings:
Manufacturer - Lubricant
Indian oil - Servogem # 2
Any equivalent reputed make.
Bearing lubrication procedure

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Grease nipple is provided on top of all plummer blocks housing bearings for ease of lubrication. Re
– grease the bearing by means of grease gun. It is absolutely essential to ensure that the plummer
blocks are filled with grease to its maximum to prevent any rusting of the bearings likely in his
environment.
EQUIPMENT MAINTENANCE SCHEDULE

Item Description Interval

BELT Recondition / replace hydraulic fluid if necessary as Annually
PRESS the analysis recommends.
Change gear reducer lubricant Annually
Lubricate bearings Extended shutdown
Revolve all rollers 1 1/3 turns, once a week (except Extended shutdown
the drive roll)
To prevent rust from forming inside the hydraulic Extended shutdown
reservoir fill it to the top with hydraulic fluid. Lower
the fluid to the proper level before restarting the
press

HYDRAULIC SYSTEM OF BELT FILTER PRESS

Purpose: the hydraulic power pack comprises of an MS reservoir of 200 liters capacity. Mounted on
the top plate of the tank is an electrical motor coupled to a variable displacement pump, through a
geared coupling. A pressure switch, a level switch, returns line filter are fitted on the reservoir. A
level indicator & oil filter are also part of the assembly.
MAJOR COMPONENTS
Hydraulic power pack - 1 No.
Tensioning cylinders - 4 Nos
Tracking cylinders - 2 Nos
Manifold Block - 1 No
MAINTENANCE
Daily / at start up

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Prior to start up check oil level in the oil level gauge provided at the top left hand side of the oil
reservoir. In case the oil is not visible in the sight glass top up till the oil level is well above the
minimum level marked. Care must be taken to ensure that the oil used to top the tank is of the
same make and grade as the one in the tank. Care must also be taken to ensure that the oil level
does not exceed the maximum level. Please note that the minimum level switch provided may not
allow the equipment to start and / or may give indication on the electrical control panel.
Check the suction & return line filter clogging indicators. If filters are clogged wash suction with a
commercial solvent, return line filters must be replaced.
After start up check for unusual noise, vibration, and clockwise rotation of motor shaft.
Check for correct actuator / control sequence.
Weekly
 Cycle oil through portable filtration cum pumping unit to remove dirt or contaminants till
the oil is circulated approximately 20 times for every 40 hours of system operation. i.e. for a
hydraulic system with a reservoir of 100 liters the time for which the oil should be passed
through a portable filtration unit can be calculated as under.
 Time (in minutes) = 100x20 / pump capacity of available filtration unit in liters per minutes.
 Check and maintain record of condition of return line filter on gauge panel.
 Check for clogging of high pressure filter. This must be done when the oil is flowing through
the filters i.e. when the actuators are moving in / out. If the red indicator provided on the
clogging indicator is VISIBLE switch to stand by filter by opening shut – off valves provide
before and after the stand – by filter. To replace filter element by unscrewing the top plate
of the filter. Both the above operations can be carried out while the equipment is operation.
Monthly
 Check and maintain record oil condition for water by visual inspection of oil.
 Check and maintain record of full operation of the system.
Yearly
 Send sample of oil for analysis to a reputed laboratory. Replace if condition is not found
satisfactory. The sample should be taken when the machine has been operating for some
time i.e. at operating temperature.
 Check all piping, fittings and hoses for dents, aberrations and general condition. Maintain
record.

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