Quick Reference Guide

414, 518, & 518HVCentrifuges – Electric

Rev --: 29-Jul-2011

Table of Contents

1. QHSE & Golden Rules

2. Overview

3. Moving and Transporting

4. Rig-up

5. Daily Operations

6. Preventative Maintenance

7. Troubleshooting Guide

Quick Reference Guide

414, 518, & 518 HVCentrifuges – Electric

Scope of Document - This Quick Reference Guide (QRG) is intended to provide operations

personnel the basic information required to install, operate, service and troubleshoot this

equipment while used in the field. It is not a substitute for proper equipment training, nor

does it provide detailed information for major repairs or shop maintenance. This document

should be kept with the equipment for reference and to refresh the operators’ working

knowledge of the equipment.

1.1 QHSE – Safety Precautions

1. All personnel performing installation, operations and

maintenance procedures on this equipment should be

trained on rig safety, operations and maintenance of this

equipment.

2. Wear all required PPE – safety glasses, gloves, steel toe

boots, and all location specific safety equipment.

3. All guards and covers must be securely fastened while the

equipment is energized or spinning.

4. Lock out/Tag out power to unit before beginning any service

work on the equipment.

1

QHSE & Golden Rules

1.2 Golden Rules of Operation

1. Review all safety requirements, start-up, shutdown and isolation procedures

2. Remove shipping brackets before start-up

3. Ensure the correct feed tube is used

4. Ensure unit is properly lubricated prior to start-up

5. Check rotation when starting

6. Build and maintain wall cake during operation

7. High differential for high feed rate or heavy mud

8. Monitor vibration and bearing temperatures

9. Run empty for at least 10 minutes prior to shutdown

10. Keep up with maintenance schedules and general cleaning

11. Install shipping brackets before transit or storage

1

QHSE & Golden Rules

2.1 Overview

1

Title

2

Overview

Back Drive

Motor

Main Drive

Motor

Vessel Cover

Control

Panel

Gearbox

Housing

Back Drive

Belt Guard

Main Drive

Belt Guard

Hour MeterIsolation

Switch

Motor

Support

Bracket

(typical)

2.2 Overview

1

Title

2

Overview

Bowl

Feed

Tube

Hydraulic

Coupling

Back Drive

Sheave

w/ GS Coupling

& Microswitch

Gearbox

Solids

Discharge

Bushings

Solids

Discharge

Wear plate Liquid

Discharge Ports

(Weirs, Dams)

3.1 Moving and Transporting - Shipping Blocks for Main Bearings

To prevent bearing damage from shock and vibration during transportation and long

shutdown periods (> 1 month), the main bearings should be unloaded using shipping

blocks placed under the ROTATING ASSEMBLY (RTA/RA) base at each bearing (feed tube

and gearbox ends) as shown in yellow.

1

Title

2

Moving and Transporting

3

Moving and Transporting

Main Bearing Feed Tube End

With Shipping Block

Main Bearing Gearbox End

With Shipping Block

3.2 Moving and Transporting - Lifting

! CAUTION: Always used trained personnel for lifting operations.

1

Title

2

Moving and Transporting

3

Moving and Transporting

! CAUTION: Always use a four point lift with tag line

!

!

Lifting Points

Dry Weights

414 4936 lb2239 kg

518 5875 lb2665 kg

518HV 6169 lb2798 kg

! CAUTION: An M-I SWACO representative

must be present during lifting

Lifting beam

!

4.1 Rig-Up - Power Requirements

1

Title

3

Rig-Up

4

Rig-Up

! Always use lock out/tag out procedures to isolate the rig power

! The electrical installation should be made by a qualified electrician

!

NEMA – UL, CSA IEC - ATEX

41

4

Power Requirements 460 V, 60 Hz, 3 Phase 380 V – 460 V, 50 Hz - 60 Hz, 3 Phase

Motor 25 hp (18.65 kW), Full Load – 31 A 25 hp (18.65 kW), Full Load – 39 A

Back Drive Motor 7.5 hp (5.6 kW), Full Load –10 A 7.5 hp (5.6 kW), Full Load –12 A

Recommended Main Breaker Size 75 A 75 A

Recommended Power Cable Size 6 AWG – 4 Conductor EP Armored 6 AWG – 4 Conductor EP Armored

Power Cable Gland 1-1/4 in NPT EP 0.93-1.31 in dia. 1-1/4 in NPT EP 0.93-1.31 in dia.

51

8

Power Requirements 460 V, 60 Hz, 3 Phase 380 V – 460 V, 50 Hz – 60 Hz, 3 Phase

Motor 25 hp (18.65 kW), Full Load – 31 A 25 hp (18.65 kW), Full Load – 39 A

Back Drive Motor 7.5 hp (5.6 kW), Full Load – 10 A 7.5 hp (5.6 kW), Full Load – 12 A

Recommended Main Breaker Size 75 A 75 ARecommended Power Cable Size 6 AWG – 4 Conductor EP Armored 6 AWG – 4 Conductor EP Armored

Power Cable Gland 1-1/4 in NPT EP 0.93-1.31 in dia. 1-1/4 in NPT EP 0.93-1.31 in dia.

51

8H

V

Power Requirements 460 V, 60 Hz, 3 Phase 380 V – 460 V, 50 Hz – 60 Hz, 3 Phase

Motor 50 hp (37.3 kW), Full Load – 57 A 50 hp (37.3 kW), Full Load – 67 A

Back Drive Motor 15 hp (11.2 kW), Full Load – 17 A 15 hp (11.2 kW), Full Load – 22 A

Recommended Main Breaker Size 100 A 125 ARecommended Power Cable Size 3 AWG – 4 Conductor EP Armored 2 AWG – 4 Conductor EP Armored

Power Cable Gland 2 in NPT EP 1.14-1.69 in dia. 2 in NPT EP 1.14- 1.69 in dia.

!

4.2 Rig-Up - Installation

518 & 518HV: 3023 mm (119 inch)414: 2424 mm (96 inch)

• The centrifuge must be mounted

level on a suitable structure and

safely secured during operations

1

Title

3

Rig-Up

4

Rig-Up

1353 mm(54 inch)

1778 mm(70 inch)

4.3 Rig-Up - Installation

Liquid

Discharge

(Outlet)

Solids

Discharge

(Outlet)

Feed Tube

(Inlet)

Liquid Discharge Solids Discharge Feed Tube

414 & 518

518HV

8 in ANSI 150 flange with

6 in Victaulic adapter

8 in ANSI 150 flange with

8 in Victaulic adapter

21 in x 13-7/8 in

rectangular flange

(1-1/4 in flange width)

2 in NPT Male

1

Title

3

Rig-Up

4

Rig-Up

! CAUTION: Flexible connector necessary for hard pipe

connections to inlet or outlets

!

Feed Tubes• 414/518 uses P/N 9610429 (standard – side discharge) and P/N 9610427 (increased volume – side discharge) • 518HV uses P/N 9610832 (standard - open end)

4.4 Rig-Up - Installation

• Centrifuge stand must– Be rated to support the weight of the centrifuge(s) while loaded and operating

– Set the centrifuge level and at least 3 feet (~1 meter) higher than the mud tanks

– Positioned to minimize vibrations from other rig equipment

– Be located near solids collection site / waste pit

– Allow a max solids discharge chute angle of 40 degrees from vertical

– Allow for an auger if the max chute angle is exceeded

• Liquid discharge piping must– Match the liquid discharge connection on the centrifuge (see liquid discharge

dimensions)

– Not be restricted, reduced in size, or have sharp and/or numerous bends

– Have a 10% or greater downhill slope

• Feed tube inlet hose must– Be sized to minimize head loss due to line friction (2 inch for < 100 gpm, 3 inch for ≥

100 gpm)

– Be supported so its weight is not loaded on the feed tube

– Be attached to the feed tube with a flexible coupling

– Have an auxiliary line fitting to flush out the feed tube and bowl during cleaning

• Feed pump must– Be wired into centrifuge control box to allow for automatic shutoff

– Provide adequate flow and pressure to transport mud up to the feed tube

– Allow for variable feed rates, either by controlling pump speed or allowing bypass

– Have an isolation valve at the tank for the pump suction line

– Have a flush line connection with valve at the inlet

1

Title

3

Rig-Up

4

Rig-Up

4.5 Rig-Up - Rotation

Back drive motor

typically rotates

towards operator

Main drive motor

ALWAYS rotates away

from operator

5

Daily Operations

4

Rig-Up

For maximum differential, the back drive

motor must turn opposite of the main

drive motor

5.1 Daily Operations - Start-up & Shutdown Procedures

Start-up Procedure

1. Start the back drive motor – check rotation

2. Wait 10 seconds and start the main drive

motor – check rotation

3. Give the centrifuge up to 2 minutes to achieve

set speed

4. Open the suction valve on mud tank

5. Start pump at the minimum feed rate

6. Bring the feed rate up slowly to desired

processing rate

Shutdown Procedure

1. Bring the feed rate down to minimum

slowly, and then shut off the feed pump

2. Close the suction valve on mud tank and

open flush valve on the feed pump

3. Turn on feed pump and flush for 30

seconds, then shut the pump off

4. Flush at feed tube until diluted mud is

discharged from the centrifuge; stop flush

5. Run centrifuge empty for at least 10

minutes

6. Shut off the main drive motor, back drive

should still be running

7. Back drive motor will shut off automatically,

motor is on a time delay switch – should be

adjusted to 6 minutes minimum

5

Daily Operations

4

Daily Operations

Note: For a more thorough cleanout after

shutting down, leave the centrifuge off for 20

minutes, and then run it empty for another 30

minutes before shutting it down again.

5.2 Daily Operations - Changing Settings

Setting Increase Decrease

Bowl speed • G-force increases

• More solids recovered

• More fine solids (LGS) recovered

• Drier solids

• G-force decreases

• Less solids recovered

• Less fine solids (LGS) recovered

• Wetter solids

Feed rate • Less fluid retention time

• More solids recovered

• Lower cut point

• Wetter solids

• More fluid retention time

• Less solids recovered

• Increased cut point

• Drier solids

Differential speed • Less solids retention time

• Wetter solids

• Less torque on gearbox

• More solids retention time

• Drier solids

• More torque on gearbox

Feed tube position in bowl* Feed tube in

• Drier solids

• More torque on gearbox

Feed tube out (8 in or 200 mm

max)

• Wetter solids

• Less torque on gearbox

Pool depth • More torque on gearbox

• Longer retention time

• Increase cut point

• Lower processing rate

• Wetter solids

• Less torque on gearbox

• Less retention time

• Lower cut point

• Higher processing rate

• Dryer solids

* Feed tube position changing only for 414 and 518, not 518HV

5

Daily Operations

5.3 Daily Operations - Bowl Speed

5

Daily Operations

4

Daily Operations

Pulley Diameters – Inches (mm)

414 518 518 HV

50 Hz - 1450 RPM 60 Hz - 1750 RPM 50 Hz - 1450 RPM 60 Hz - 1750 RPM 50 Hz - 1450 RPM 60 Hz - 1750 RPM

Speed(rpm) G's Motor Bowl Belt Size Motor Bowl Belt Size Motor Bowl Belt Size Motor Bowl Belt Size Motor Bowl Belt Size Motor Bowl Belt Size

1900 7059.6

(244)7.4

(188)3V-850

P/N 05061168.0

(203)7.4

(188)3V-850

P/N 05061169.6

(244)7.4

(188)3V-850

P/N 05061168.0

(203)7.4

(188)3V-850

P/N 050611610.0(254)

7.7(196)

3-5V-900P/N 0506227

8.3(211)

7.7(196)

3-5V-850P/N 0506223

2500 122112.3(312)

7.4(188)

3V-900P/N 0506120

10.6(269)

7.4(188)

3V-900P/N 0506120

12.3(312)

7.4(188)

3V-900P/N 0506120

10.6(269)

7.4(188)

3V-900P/N 0506120

12.8(325)

7.7(196)

3-5V-950P/N 0506231

11.0(279)

7.7(196)

3-5V-900P/N 0506227

3200 2000 -- -- -- -- -- --12.3(312)

5.6(142)

3V-850P/N 0506116

10.6(269)

5.6(142)

3V-850P/N 0506116

12.8(325)

5.8(147)

3-5V-900P/N 0506227

11.0(279)

5.8(147)

3-5V-850P/N 0506223

To adjust bowl speed, change belt position and pulley alignment so that the appropriate pulley sizes listed below are used. Re-tension belt after changing bowl speed.

5.4 Daily Operations - Torque Limiter

• GS Coupling

– Provides over-torque protection for the gearbox by

utilizing a spring loaded coupling

– If torque exceeds limit, coupling will disengage, trip a

limit switch and shut down centrifuge

• Checking GS Coupling Torque Setting

– Measure the torque of the assembled GS coupling, both

the right and left side values.

– Note: The sunwheel will need to be secured in order to

measure the torque value. Torque values should be

between 50 and 60 ft/lbs (68 and 81 Nm).

– Use GS Coupling calibrator (p/n 9601033) with a torque

wrench

• Resetting GS Coupling

1. Remove center screw, washer and driver

2. Apply light grease to balls on coupling teeth

3. Line up grooves on coupling to teeth on sheave

assembly

4. Line up teeth on driver to teeth on coupling

5. Line up pin on sun wheel shaft to inside groove on

driver

6. Re-install washer and center screw

7. Reset limit switch and check for proper movement

and position

5

Daily Operations

G4

Daily Operations

Coupling

Driver

6.1 Preventative Maintenance - 360° Rig Maintenance & Inspection STEM

5

Daily Operations

6

Preventative Maintenance

4

Daily Operations

12

3 3

4

5

3

6

6.2 Preventative Maintenance - Field Maintenance Checklist - STEM

5

Daily Operations

6

Preventative Maintenance

4

Daily Operations

Follow STEM Field Maintenance Check Lists (STEM 1 – 6)

for all scheduled maintenance

6.3 Preventative Maintenance - Bearings

5

Daily Operations

6

Preventative Maintenance

4

Daily Operations

DO NOT USE CALCIUM BASE GREASE

Calcium base grease is not compatible with recommended

greases and will cause bearing failure.

!

Pillow block bearings – 10 shots greaseDaily (STEM 1)

Internal / conveyor bearings – Pump grease until clean grease is returned - Weekly (STEM 2)

“Mystik JT-6 Synthetic Blend” (blue) and

“NILS LITHOPLEX” are the only approved

bearing greases.

Nave bearings – 5 shots greaseWeekly (STEM 2)

Typical both endsBack Drive

Sheave

Gearbox

NOTE: Remove plug before greasing, replace after

6.4 Preventative Maintenance - Gearbox

The centrifuge is equipped with planetary gearbox, daily check is not necessary

• Check oil level every week (STEM 2)

• Change oil after:

– If new gearbox: 1 week (STEM 2)

– Every 4 months (STEM 4)

• Oil Suggested: SAE 80W90

1

Title

6

Preventative Maintenance

Metallic Inspection & Oil Level Procedure1. Rotate gearbox until 1st magnetic fill plug is at 12 o’clock, remove

plug and inspect for metallic wear particles - a large accumulation of particles should be investigated

2. Repeat with 2nd plug 3. With 2nd plug removed, rotate gearbox to 2 or 10 o’clock and check

oil level, add oil if necessary4. Reinstall plug, check for oil leaks

Oil Change Procedure1. Place one fill plug at 12 o’clock and remove it for ventilation, place a

bin under the opposite plug2. Remove the lower plug and drain the oil 3. Re-insert the lower plug with a new seal4. Add oil into the upper plug port using a clean funnel, fill to 2 or 10

o’clock level, re-insert upper plug with a new seal

Magnetic Fill Plugs

2 o’clock

Magnetic Fill Plug with Debris

6.5 Preventative Maintenance – Hydraulic Coupling

• Hydraulic coupling allows the centrifuge to gradually accelerate to full speed from a dead stop when line power is applied to the electric main motor.

• Coupling consist of symmetrical impellers that oppose each other within a sealed main housing. Torque is transmitted from the input impeller to the output via the fluid.

1

Title

6

Preventative Maintenance

•Low fluid level will weaken the couplings capacity to

transfer power.

•High fluid level will increase the temperature of the fluid

•The fluid coupling is protected from high operating

temperatures by having a fusible plug that melts at

285°F. (140°C). The plug protects the motor by releasing

the fluid and thereby disengaging it from the centrifuge.

• Check oil level every month (STEM 3)

• Change oil after:• If new coupling 1 month (STEM 3)• Every 4 months (STEM 4)

• Oil Suggested:

• ISO HM 32 or SAE 10W

• ISO FD 10 or SAE 5W (low temp applications)

Fusible Plugs:

•Turbostart: 3170536 Plug fusible 140°C Turbostart

•Transfluid: 3170700 Plug fusible 140°C Transfluid

•Rotomech: Contact manufacturing

Max Fill

Position 45°

6.6 Preventative Maintenance - Belt tensioning

1

Title

6

Preventative Maintenance

• Move the motor by adjusting the motor support bracket to remove belt – never force it over the side

of the pulley

• Tighten belt to a light tension by moving motor – use straight edge to check alignment

• Rotate drive parts by hand to check for binding

• Increase pulley center-to-center distance until belt is properly tensioned

• Check belt tension by striking with a clenched fist – slack belt will feel dead, well tensioned belt will

vibrate

• New belts will stretch – adjust every two hours on first day of use

• For belt part numbers, see Daily Operations – Bowl Speeds section of this document

6.7 Preventative Maintenance - Scroll Wear

1

Title

6

Preventative Maintenance

Scroll Wear Maintenance – depth

• Remove scroll wear inspection screw from the bowl

• Clean the wall cake plugging the hole inside the bowl

• Rotate the conveyor to where the flight top edge is visible

inside the hole

• Using calipers, measure the depth from the bottom of the

inspection screw hole to the top of the flight

• If the value exceeds 5mm more than the original depth,

the scroll needs to be reworked or replaced

• Record scroll wear Monthly (STEM 3)

7.1 Troubleshooting

5

Daily Operations

6

Preventative Maintenance

7

Troubleshooting

Problem Cause Corrective Action

Motors do not start 1. No power to unit2. Emergency stop engaged3. Lid switch open4. Overload breaker tripped5. Vibration switch not reset6. Limit switch on GS coupling tripped

1. Restore power2. Reset ES button3. Make sure all coffin are properly closed4. Reset overload breaker / check amps5. Reset or repair vibration switch6. Reset limit switch

Pump shuts off 1. Amp limiter has detected current in the back drive motor that exceeds limit

2. Overload tripped in the pump starter

1. Pump can be restarted after back drive current drops below limit2. Reset overload / Check pump for malfunction

Start-up and shutdown vibration 1. Moderate vibration at critical rpm during start-up and shutdown 1. None required

Machine vibrates 1. Bowl may be out of balance due to poor cleaning, bowl partsinterchanged with another bowl or uneven wear on conveyor or bowl

2. Vibration damping mounts have lost elasticity3. Uneven wall cake

1. Determine if vibration is due to causes described2. Replace rubber mounts3. Slow feed rate and flush unit

Fluid coupling plug melts 1. Feed pump rate to high2. Wrong type oil3. Solids discharge plugged4. Not enough fluid in coupling

1. Reduce feed rate2. Check oil in coupling / Replace oil if in doubt3. Clean solids discharge area and coffin / check installation4. Add fluid

Noise from gearbox 1. Oil volume low or type wrong2. Worn gears3. Worn bearings

1. Check oil level and oil type, replace if in doubt2. Replace gearbox3. Replace gearbox

GS coupling disengages 1. Large accumulation of solids in bowl2. Excessive amount of solids in feed mud

1. Flush bowl2. Reduce feed rate

Solids discharge too wet 1. Feed rate too high2. Conveyor differential too high3. Feed tube adjustment wrong

1. Decrease feed rate2. Change back drive motor direction and/or sheave to reduce

differential3. Adjust feed tube