O & M Manual for Water Treatement Plant

7/31/2019 O & M Manual for Water Treatement Plant

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O& M for M/s Sitapuram Power Ltd

OPERATION & MAINTENANCE MANUAL

For

PRE TREATMENT, UF, RO, & DM SYSTEMS

For

M/s Sitapuram Power Ltd.

Client LOI No. # : MBF060/52927 Dated 01/03/06

Triveni Order # : PXD 562

DESIGN, ENGINEERING, SUPPLY, ERECTION, COMMISIONING

Triveni Engineering & Industries Ltd.(Water Business Group)8 th Floor, Express Trade Towers15-16, Sector 16A, Noida 201 301UTTAR PRADESH


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TRIVENI ENGINEERING & INDUSTRIES LTD.

Water Business Group


PREFACE

For ease of handling and reference, the operating and maintenance manual hasbeen divided into two Parts (Part-1& II)

Volume I - Pretreatment

Volume I has been arranged in various sections that altogether deal with theprocedure which must be followed to start-up, operate and maintain the plant.

Volume II - UF, RO and DM system

Volume II has been arranged in various sections that altogether deal with theprocedure which must be followed to start-up, operate and maintain the plant.


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COMPANY PROFILE

At the onset, we take this opportunity to congratulate you for opting for a TRIVENIproduct.

Triveni Group is a well established, dynamic and professionally managed group.

With years of experience and the perfect blend of people, technology and

entrepreneurship; the company has developed core competencies in the areas of

Sugar, Steam Turbines, High Speed Gears and Water & Wastewater treatment.

The group turnover is over INR 13 Billion. The employees strength is about 5000

across the group.

Triveni is one of the top three Sugar producers in India.

Triveni command almost 65% market share of Steam Turbine for sizes

upto 27 MW.

Triveni command almost 60% market share for High Speed Gears.

Our major Strategic Alliances with global leaders include:

Lufkin Industries Inc., USA for High Speed Gears, High Power Gearsand Gear Boxes.

Vericor Power, USA for Gas Turbines

Peter Brotherhood, UK. for Steam Turbines

Memcor, Australia for MF / UF / MBR systems

Sugar Research International, Australia

for Sugar Plant & EquipmentManufacturing


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TRIVENIS WATER BUSINESS GROUP

Triveni Engineering & Industries Limited, the leading water treatment company in

India contributes to a clean environment by offering state-of-the-art products and

technologies for turnkey solutions for the treatment of water and wastewater. This

is for both the sectors - Municipal and Industrial. Started in 1984, we have

complete range of products and services, which covers the entire spectrum of

TOTAL WATER MANAGEMENT.

Our strength in providing solutions for water, wastewater treatment and recycling

systems using various physico-chemical for settling, clarification, filtration,

disinfection, membranes and ion exchange technologies. We also have the bestbiological processes for removal of biodegradable organics from the effluent

including nutrient removal and also offer MBR systems.

We use latest technology and software for design, engineering and project

management. Our strong design and engineering capabilities include process,

electrical and mechanical providing optimum designing at the minimum operating

cost. Our In-house project management capabilities ensure timely execution of

the project. Our project team ensures site management during execution with

focus on quality and on-time completion. Our service network exclusively

maintain after sales service for lifecycle partnership with our clients.

We ensure strict Quality Assurance for long life and trouble free performance for

our products.

We have established working relationship with reputed consultants and inspection

agencies such as Engineers India Limited, TCE, DESEIN, MECON, H&G, Dalal

Mott Macdonald, MN Dastur, RITES, KELLOGG, LLOYDS, BUREAU VERITAS,

SGS, TUV, STUP, PDIL, Montgomery Watson etc.The list of our esteemed clients include reputed names like RELIANCE, BHEL,

NTPC, UP Jal Nigam, Delhi Jal Board, DSIDC, RINL, SAIL, ONGC, IOCL, BPCL,

EPI, JVSL, HZL, LANCO, VISA and various other private sector clients.


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We have extensive experience and expertise in the water and wastewater

treatment technologies which is briefly summarized below ::

Municipal Wastewater Treatment

Triveni offers one of the widest ranges of treatment options for Municipal

Wastewater Treatment. Biological systems offered include Vertical Loop Reactor,

Fine Bubble Membrane Diffusers, Oxidation ditch-type Multiple-pass aeration,

Nutrient removal through nitrification/de-nitrification. Besides this, the thrust is

always on efficiency and minimum operating costs. For sludge digestion, Triveni

offers unique gas mixing systems for anaerobic digesters equipped with fixed or

floating covers in single stage or two stage digestion systems. Our major

installations include sewage treatment plant of 160 MLD (6700 m 3 /hr) for the

city of Delhi.

We offer MBR systems for advanced biological treatment requirements.


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Municipal Water Treatment

Triveni offers equipment & technology for turnkey solutions for water treatment

requirement ranging from process water for industries to municipal water for

drinking purposes. Triveni offers entire range that involves chemical conditioning,

clarification, filtration, disinfection, ion exchange and membrane based systems.

Among its other installations, is a 144 MLD (6000 m 3 /hr) water treatment plant

for the city of Agra set up under the World Bank Financing Scheme.

Process Water Treatment

Triveni offers complete solutions for process water requirement including Boiler

Feed water, cooling water Requirement. We have complete range of productssuch as Clarifiers, Sand Filters, Carbon Filters, Softeners, De-ionization Plants

and reverse osmosis systems including pretreatment which includes micro-

filtration and ultra-filtration, to provide even ultra pure water. We ensure the most

appropriate technically and commercially viable system without being biased to

any specific technology. Triveni has installed one of the largest process Water

Treatment Plant of 6000 M 3 /Hr. capacity at NTPC, Vindhyachal.

Intake Water Works

Triveni offers equipment & technology for turnkey packages for intake water,

water and sewage inflows for various applications such as Intake water works for

industries, Intake water for sewage pumping station and Intake water for power

plants. Systems can be offered with fixed or traversing type Trash Cleaning /

Screening equipment to meet the various requirements. We can offer these

packages with Through Flow and/or Dual Flow Traveling Water Screens, to suit

the specific site requirement.

Sludge Dewatering

Triveni offers solutions for industrial / municipal sludge dewatering. Belt Filter

Press and/or Vacuum Filters can be provided to meet the specific requirement of


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these packages. We have one of the largest installations of 17 nos. Filter

Presses till now with Surat Municipal Corporation till date for their various

Sewage Treatment Plants.

High Purity Systems

TRIVENI offers complete range of High Purity Systems including those required

for Boiler Feed applications. This may include RO / MB configuration or DM / MB

option. We provide pre & post options for colloidal silica removal in such systems

which may include Membrane systems. TRIVENI has completed their largest

installation where the combined RO / MB plant capacity is 200 M 3 /Hr. for

Boiler Feed application in Khatauli Co-gen Power Plant.

Advanced Pre-treatment

In various applications water require extensive pre-treatment so that

downstream units are safe from the impurities which may otherwise

damage the system which is crucial for High Purity systems where main

treatment include either Membrane based solutions or Resin based

technologies. We provide Micro filtration and also Ultra filtration inassociation with Memcor, Australia. We are currently executing a

prestigious job involving 3 x 45 M3/Hr. UF Streams as Pre-treatment to

RO / MB plant at Indorama Petrochemicals Ltd., Nagpur.

Effluent Recycle/Reuse

To provide the total water solutions to our esteemed customers, we havestrengthen ourselves with the complete range of membrane based systems.

Our range of product includes cartridge filters, micro- filtration, ultra-filtration

and reverses osmosis systems. We are currently executing 140 M3/Hr.


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Membrane Filtration systems for effluent recycling for Maruti Udyog

Ltd., Gurgaon.

Industrial Waste Water Treatment Plant

Triveni has the widest range of treatment systems to suit specific

application in industries as diverse as:

Steel

Power

Petrochemical/Oil Refinery

Bio - Pharma

Food Processing

Sugar

Distillery/Brewery

Pulp and Paper

Chemicals Textiles & Dyes...

We have successfully commissioned numerous installations in the above

industries including one of the largest wastewater treatment plants in

the Indian steel sector treating about 184 MLD (7700 m3/hr)

wastewater from the steel plant at Vizag (East Coast of India).

Trivenis Product Range At a Glance

Process Water Systems

High Purity System


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Municipal Water Systems

Municipal Wastewater Systems

Industrial Wastewater Treatment Systems

Recycle / Reuse Systems

Micro-filtration / Ultra Filtration (Submerged & Pressurised) Systems

Membrane Bio-Reactor Systems

Reverse Osmosis / Nanofiltration Systems

Ion Exchange Processes

Side Stream Filtration

Water Softening Systems

Intake Screening System (Travelling water screen / Trash cleaning machines) Mechanical Screening Systems (Fine/ Medium / Coarse)

Sedimentation System (Circular/ Rectangular)

Media Filtration System

Biological Treatment - Aerobic Systems (Suspended Growth & Attached

Growth)

Anaerobic Treatment Systems (Digester / Gas Holders)

Sludge Treatment Units (Thickener/ Vacuum Filters / Belt Filter Press)

Oil water Separation Units (Skimmers / API / DAF)

Chemical Treatment Units


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General introduction

The plant is designed to treat the raw water supplied by client at a flow rate of 235

m3/hour to produce clarified water out of which only 26 m3/hour shall be taken for

further treatment by means of ultra filtration followed by reverse osmosis and

demineralisation consisting of strong acid cation, strong base anion and mixed

bed unit to produce finally demineralised water at flow of 14.75 m3/hour. Final

demineralised water shall be stored in two DM water tanks for use by client in

their plant. The system includes bulk acid and alkali tanks along with sulfuric acid

tank which are utilized in the plant for regeneration and cooling water treatment.

The neutralization system is also provided to treat all plant effluent to neutralize

before its discharge from the plant.

Plant is completely manual but all essential controls are included for safe and

smooth operation of the plant, however due to regular nature of running and

backwashing for ultra filtration membranes automatic operation is included.


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VOLUME 1

PRETREATMENT


8 th, Floor, Express Trade Towers, 15-16, Sector 16-A, Noida- 201301 (UP) IndiaTelephone: +91-120-4308100 Fax: 91-120-4311010

E-mail: [email protected] Website: www.trivenigroup.com/water


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INDEX

SECTION I INTRODUCTION

SECTION II PROCESS DESCRIPTION

SECTION III INSTALLATION

SECTION IV OPERATION

SECTION V MAINTENANCE

SECTION VI OVERHAUL / SPARE PARTS


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SECTION I

INTRODUCTION

General Feed Water Contents

Water Available in nature is drawn for use from mainly two sources:

(1) Surface Rivers, lakes, surface wells, Canals

(2) Underground Tube Wells

Natural water before reaching source traverses a long path through various

geological minerals and other substances. As such it contains various impurities

which can be categorized into

(1) Suspended from

(2) Colloidal form

(3) Dissolved form

As the name implies the first two categories contain impurities due to particles in

suspension form of macro and micro sizes. These are settle able/suspended

solids & contribute turbidity to raw water. The balance are dissolved impurities i.e.

alkaline salts and neutral salts, The alkaline salts mainly comprises of Sulphates,

chlorides, nitrates etc. of calcium, manganese, dissolved carbon dioxide and

organic matter.

Treatment of Water


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With the rise in the level of technology, the demand on the quality of water has

also improved accordingly. The stringency in quality of water required is varied

with its usage. For example, for high pressure boilers, dairy and laundry

applications, prevention of scale formation is main important factor, whereas for

pharmaceutical, laboratory, electronics, dyes etc., presence of any dissolved

impurity is undesirable, since the same may contaminate the product. To satisfy

the demand the natural water is treated to desired quality. Suspended impurities

and to some extent colloidal impurities are removed by deaeration, sedimentation,

clarification and filtration. Organic matter, if present, is treated by injecting

chlorine. The above process is termed as pre-treatment. The treated water thus

obtained is clear and colorless, containing mainly the impurities of dissolved saltsand traces of residual chlorine.

Dissolved salts are removed to desired residual level by ion exchange process

in demineralising or Deionizing plant or by reverse osmosis process.

Demineralising plant consists of ion-exchange columns housing ion exchange

resins which systematically remove the ions in water. Reverse osmosis system

consists of semi permeable membrane acting on high pressure for removal of

dissolved solids depending on total dissolved solids of water.


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SECTION II

PROCESS DESCRIPTION

Triveni Reactor Clarifiers are Upflow Solids Contact Type units and are generally

applied in water treatment applications for softening and elimination of turbidity

and color. In the softening process, the hardness caused by divalent

metallications is removed with the introduction of lime and soda ash.

In case of turbidity and color removal, aluminum sulphate and ferric sulphate or

chloride may be applied. When turbidity and color removal are required along

with softening, the processes may be combined in one tank or separate tanks

may be utilized depending on the degree of treatment desired.

Reactor clarifier can be full bridge or half bridge type. Full bridge type is used in

tank upto about 24 M diameter and is usually provided with side feed entry. Half

bridge types are used in tanks ranging from 15 M diameter to 60 M diameter and

are usually with bottom feed entry.

In case of side feed entry, the influent pipe joins the draft tube while in case of

bottom feed entry, the inlet pipe extends into the center column. The raw influent

is brought into immediate contact with a large circulating volume of relatively

dense, previously formed floc and precipitate (and treatment chemicals). The

mixture of raw influent liquid and recirculated slurry is sent upward into the

reaction cone by the action of turbine agitator with 75 to 90 percent being returned

to recirculation with the incoming raw water. The remaining 10 to 25 percent pass

under the cone and into the clarification zone. Once in the clarification zone, the

solids settle to the tank floor with the clarified liquid moving into the effluent

launder and existing the tank.


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The agitator acts somewhat like centrifugal pump; it draws water into the center of

turbine and discharges it by propelling it outward. This action establishes mixing

action in draft tube / center column and flocculating action in the secondary zone.

The flocculation or reaction cone provides several functions. With gentle agitation

from the turbine, floc particles form. The increasing cone cross-sectional area

allows decreasing turbulence, which makes the floc particles agglomerate and

become larger. As the particles become larger they settle to the bottom of the

cone where they are either recirculated or become part of the sludge inventory.

The cone also provides an upward increasing cross-section in the clarification to

aid in the solid-liquid separation.

REACTOR CLARIFIER START-UP

To begin operation of the reactor clarifier by starting the flow, make sure the flow

is within the hydraulic flow design limits. Once the flow is started, start the

chemical feed to the reactor clarifier at predetermined chemical dosage rates

(depending on influent flow turbidity etc.) using the appropriate feed point for eachchemical. Waiting for the reactor clarifier to fill before starting the chemicals will

delay attainment of steady state operation and desired effluent quality. Start the

rakes and turbine on a medium setting. In order to operate the reactor clarifier

properly, it is necessary to develop and then maintain a relatively constant sludge

inventory. Until a sludge inventory is achieved, the blowdown should be off

except for an occasional short manual blow-down to keep the lines open and free

of grit.

Allow the solids concentration to increase in the reactor clarifier until sludge

appears at the bottom tap but not in the middle tap. This will usually take from 2

to 5 days depending on the solids production and influent flow rates. Once the

desired sludge level and reaction zone concentration are achieved, begin sludge


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blow-down at a frequency and flow rate to be determined based on solids

production and on the volume of the sludge thickening cone.

Once the reactor clarifier is operating with sludge blow-down, the sludge level,

influent and effluent turbidity, chemical feed rates, pH, flow rates and mechanical

operation should be monitored routinely. Sludge underflow concentrations should

be checked about twice a day.

The sludge slurry level should be maintained between the bottom and middle taps

using sludge blow-down. During high flow periods the sludge level may rise

above the middle tap of short periods of time. For alum, due to their dilute

suspension qualities, it is often difficult to maintain the sludge level below the

middle tap. If this is the case, maintain the sludge level between the middle tapand top tap attempting to maintain the level near the middle tap. If the sludge level

drops below the bottom tap, too much sludge has been removed and the sludge

blow-down should be discontinued until the solids build-up in the reactor-clarifier.

Since reactor clarifier is designed to handle variable flows, the chemical feed rate

should be paced with the flow in order to maintain a constant dosage.


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TROUBLE-SHOOTING

Occasionally the steady state operation of the reactor clarifier will be upset. Upset

conditions generally result in poor effluent quality. These upsets are usually

caused from one or more of the following conditions:

1. Loss of or inadequate dosage.

2. Excessive sludge withdrawal

3. Excessive built-up of sludge inventory

4. Excessive hydraulic flows5. Loss of solids in the reaction zone

6. Mechanical failure.

Table-1 is a tabulation of typical upset condition symptoms, probable causes, and

corrective actions.


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SHORT-TERM SHUTDOWN

If the reactor-clarifier must be by-passed for more than a few days, the followingprocedure should be followed:

1. Shut-off flow

2. Shut-off chemical(s)

3. Turn-off turbine

4. Blow-down all sludge

5. Turn off the rakes

6. If desired, drain the RC

7. Operate turbine and rakes about once per week for 5 minutes to lubricate

all running surfaces.

LONG TERM SHUTDOWN

Mechanical

The following precautions cover non-operation or shut-down periods that exceed

two months. They apply mainly to the Triveni or accessory mechanical drive

equipment. First, completely drain the reactor clarifier. Two plans can be used

depending on the availability of power.

Plan-1: Power Available

When power is available, all equipment should be lubricated and operated for

about five minutes, or run through a complete cycle, once each week. Driveshould have accumulated water removed monthly.

Plan-2 : No Power Available

Fill housing and gear cases with clean oil to maximum level. A rust inhibitive

agent is recommended for adding to the oil. On certain type Triveni drives, make


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sure the primary, as well as the secondary drives, are lubricated. Check that all

greased bearings are well lubricated. Cover seals, screws, chains and guides

with heavy grease and cover breather caps with tape. Cover with tarpaulins, but

allow ventilation.

Once each month open drain plugs to remove accumulated water and return oil to

maximum level. Check all greased items monthly for adequate covering.


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TABLE-I

TROUBLE-SHOOTING

Symptom Probable Cause Corrective ActionLoss of or inadequatechemical feed due to Increase chemical flowInsufficient chemical flow Repair and / or unplug the

chemical feed systemFeed system failureLine Plugging

High Effluent Turbidity,Suspended solids and poor settling sludge

Exhaustion of chemicals

Pace chemical flow withwastewater flow

Excess sludge withdrawal Turns sludge withdrawal off until solids rebuild.

No solids in the reactionzone or at the bottom tap.Poor Effluent quality Insufficient chemical

dosageRepair or adjust chemicalfeed system

Inadequate blow-down dueto;Inadequate frequencyBlowdown system failurePlugged Blow-down

Reduce turbine speed

Excessive hydraulic flows Increase blow-downfrequency (unplug pumpsand lines

Sludge level above the toptap or overflowing thelaunders

Excessive turbine and rakespeed

Return RC to normaloperation when upsetconditions passDecreased turbine speedNo solids in the reaction

zone, thickening cone or blow-down, but heavysolids in clarification zone.Rake show high torque

Excessive turbine speedBlow-down excess sludge

Plugged turbine or drafttube

Clean draft tube and turbineby running at full speed 10minutes twice a week

Turbine speed too slow. Increase turbine speed

No solids in the reactionzone, but solids at bottomtap and in blow-down

Mechanical failure of turbine and / or rakes

Repair turbine and / or rakes


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SECTION III

INSTALLATION

CONTENTS

1. SAFETY PRECAUTIONS

2. STANDARD ERECTING PRACTICES

3. SPECIAL ERECTING PRECAUTIONS

4. SAFETY FEATURES

5. SUGGESTED SEQUENCE AND METHOD OF ERECTION

6. ADJUSTING TORQUE OVERLOAD MICRO SWITCHES

7. USE OF SHEAR PIN DRIVEN SPROCKETS

8. ESTABLISHING TRUE PLANE ROTATION

9. ADJUSTMENT & PRE-OPERATIVE CHECK-OUT


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1. SAFETY PRECAUTIONS

During any erection, primary consideration must be given to the safety of the

workmen. Because the use of welding equipment and cutting torches is almost

mandatory in the erection of this equipment, the possibility of a fire is an ever

present hazard. Cover any wooden or cardboard crates or, better still, move them

away from areas in which welding or cutting is being done.

Because metallic equipment is frequently coated with inflammable substances

and non-metallic substances are now used in many components of present day

machinery and instruments, a fire can quickly grow to a major conflagration,

sometimes emitting toxic gases, imperiling lives as well as destroying expensive

machinery. Fire extinguishers and plant water must be available in the tank as

well as on the surface. Workman must be able to leave the tank quickly from

number locations.

The sequence and method of erection of this unit can be completed in several

ways. The following pages outline a sequence and method we recommend.

Local site conditions, equipment and personnel available may dictate that another sequence be followed.

During the erection of this equipment, the instructions should be used with the

General Arrangement drawings, the Bolted connection drawing and the various

assembly drawings found in the manual as well as the pocket. These drawings

are to be considered a major part of this manual. As much they should be

referred to continually while installing the equipment and retained as a detailed

reference for replacement parts and spare parts. If there is any discrepancy

between the drawings and the manual, the drawings should always prevail.

Most motor reducers are shipped filled to capacity, however, some reducer

manufactures ship dry, others use partial fillings of rust preventives such as


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vaporizing oils. In all cases, lacking specific tag instructions to the contrary, drain

the reducer when received to eliminate any accumulation of condensation.

Unless the unit is to be stored, flush and refill to operating level with the seasonal

lubricant specified in the manufacturers bulletin we provide or proceed according

to the name plate instructions.

After fitting up chain guards, remove them until the equipment has been dry run

and sprocket alignment, chain tension and electrical wiring has been double

checked and all grouting has been done.

Be sure that all shaft bearings, reducers and motors are properly protectedagainst arcing across the bearing before any field welding is done.

2. STANDARD ERECTING PRACTICES

Fabricated steel equipment as manufactured by TRIVENI should pose no out-of-

the-ordinary erecting problems. However, due to the nature of such equipment

and the condition of the containing structure (over which we have no control) a

reasonable amount of fit-up and adaptation must be considered standard erection

practice. The use of tools such as come-alongs welding and cutting torches,

drift pins and reamers is considered standard erection practice.

When new units are tied into existing units, it can be expected that a major

amount of fit-up is required. The accumulated tolerances are already built into the

existing equipment, making the job of tie-in and alignment a matter of detail fit-up.

3. SPECIAL ERECTING PRECAUTIONS

Erecting Multiple Section Bridges


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a) Field Welding Procedure

Refer to the General Arrangement drawing(s) in the manual pocket. When field

welds are specified on these drawings, the welds must be completed before

removing crane slings or cribbing. Fit-up bolts are to be used only to position the

bridge for field welding. The bridge will not support itself field welding is

completed.

During the erection of this equipment these instructions should be used with the

GENERAL ARRANGEMENT drawing and other drawings referred to in the

following pages. These drawings are considered part of the manual and shouldbe filed with the manual for future reference. If there is any discrepancy between

the drawings and the manual the drawings should always prevail.

TRIVENI Reactor Clarifier is furnished with a slip connection on one end of the

bridge where it lays on the tank wall. The bolts connecting the bridge to the wall

are to be fully tightened, however. The location of this joint is indicated on the

General Arrangement drawing. The fastenings are itemized on that drawing also.

This slip joint provides for movement of the bridge due to expansion or contraction

without transferring force to the tank walls.

b) Repairing Painted Surfaces Damaged in Storage

Stored materials may have been neglected, even though they had been properly

prepared for storage. Paint or special protective surface coatings may have been

disturbed or destroyed. Paint and other surfacing can be replaced or renewed just prior to start-up.

c) Preparing Gear Reducers for Installation


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Before installing any gear reducers, check wiring for correct rotation.

Gear reducers with oil sumps should be drained of lubricant and the draining

checked for condensed water even if oil was added for storage. If water is

present, flush with hot motor oil, drain thoroughly and refill with manufacturers

recommended seasonal lubricant.

d) Preparing Circular Drive for Installation

Remember that TRIVENI, final, circular drives are shipped dry and should be

drained of all condensate, then filled with operating lubricant according to

seasonal requirement.

e) Torque Overload Device Furnished (if applicable)

NF-18, NF-30, H-40, H-60 & H-80 Drives for the lower rotating elements are

provided with torque overload micro switch devices. Although these switches are

pre-set at the factory, they must be re-set in the field.


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4. SAFETY FEATURES

TRIVENI Reactor Clarifier Bridge is provided with a well braced handrailextending to and around the drive unit. This bridge must be properly maintained

as well as all other parts of the reactor. Keep the chequered floor plates clean of

oil or grease.

Chain guards and vari-speed drive guards are provided as required. These are to

be replaced before starting up a unit shut-down for maintenance or repair.

Shear pin torque overload devices are provided to protect the gear reducer and

some final TRIVENI circular drives. Other TRIVENI final drives are protected by

micro switches. At no time should the drives be powered without these safety

devices being operable. Make no substitution for the correct shear pin. Do not

wire around the micro switches.

5.I SUGGESTED SEQUENCE AND METHOD OF ERECTION

(SIDE FEED DESIGN)

The erection sequence employed may deviate from that suggested due to

manpower or shortage or lack of erecting machinery. The following sequence is

one, which will work for most of the times.

a) Assembling the Cone

This is mot conveniently done out of the tank on a level ground surface or onsubstantial timber blocking within the tank. Refer to the general arrangement.

Bolted connection drawings to assemble the component parts. Use the fit-up

bolts provided, then field weld the segments together. Tack weld braces across

the top, narrow end of the cone to stabilize it when being moved.


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b) Assembling the Scraper Arms

While the cone is being assembled outside the tank, the scraper arms can be

assembled in the tank. Do not assemble the squeegees to the plow blades until

the finished grouting of the tank is accomplished at a later point in the erection.

c) Connecting the Scraper Arms to Lower Torque Tube / Torque Cage

Prop the lower torque tubes / torque cage in a vertical position and assemble all

tie rods, struts and spares between torque tube / torque cage and scraper arms.

The scraper arms can be blocked up a few inches off the unfinished floor. This

blocking must not interfere with the blocking which will be required for the cone

and draft tube.

d) Erecting the Cone

Refer to the general arrangement drawing and note the elevations for the top and

bottom of the cone. Place supporting members in the tanks so as to support the

cone at the elevation indicated. This blocking must bridge the scraper arms and

still allow access to the interior of the cone. Lift the cone using 3 or more cables

with spreaders and lower it slowly on to its supports. Center the cone in the tank

as best you can. Do not remove the cables at this time, but let the cones weight

transfer to the blocking. Assemble all cone support tie rods and horizontal /

inclined stabilizer tie rods.

Connect all tie rods and adjust lengths so as to raise cone to its designed

elevation and to locate it concentrically within the tank. With the cone completely

suspended from its tie rods remove all cone blocking, leaving the props holding

the lower torque tube / torque cage vertical.


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e) Erecting the Draft Tube

First remove any temporary braces tack welded across the top of the cone. Pick

up the draft tube and lower it to its designed elevation. Fit-up and bolt all draft

tube supports in place. Assemble all horizontal stabilizer tie rods between draft

tube and cone. Check for concentricity with cone at upper and lower ends of draft

tube. Do not field weld the draft tube supports in place at this time.

Assembling the Upper Torque Tube to the Lower Torque Tube

Bring the upper torque tube into position over the lower torque tube. Refer to

bolted connection drawing for flange fastenings. Check blocking of lower torque

tube before removing crane sling. Grease the bearing collars on the torque tube.

f) Erecting the Bridge

Assemble the chequered plate to the bridge. Note that one end of the bridge has

a slip mounting or expansion joint while the other end of the bridge is held fixed to

the tank wall. Secure the bridge to the tank, checking the area of drive assembly

for level. Adjust till level. Note that upper flange of torque tube extends above

bridge floor.

g) Sub-assembly of Agitator / Scraper Drives and Agitator Shaft

Raise the drive assembly and its drive base into a position where the agitator

shaft can be bolted to the underside of the lower drives ring gear. Raise the sub-

assembly over the bridge and lower it carefully over the torque already in the tank.

Thread the torque tube up through both steady bearing until the drive base is

within 6 inches of the bridge.

CAUTION!!

If the sweep arms were blocked up too high off the tank floor, you will find the

torque tube bearing against the underside of the top drive ring gear. This must be

avoided, so before lowering the drive base onto the bridge, remove the blocking

from beneath the scraper arms and also remove any props from the torque tube.


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Lower the drive assembly on to the bridge secures the drive base to the bridge.

Pull torque tube / scraper arms sub-assembly up until torque tube flange can be

bolted to ring gear of upper drive. At this point entire lower rotating arms should

be suspended from the drive ring gear. If any part of the scraper arms touch the

unfinished tank floor, check the slope of the scraper arms against the dimensions

on the general arrangement drawings. Remember that the squeegees have not

yet been assembled to the underside of the plow blades! If the slope of the arms

is found to be correct and contact with floor remains check drive for level on

bridge and check torque tube for plumb.

Assembling Agitator Disc and Blades

Lower the agitator discs segments into the tank and assembles to agitator shaft.

Attach agitator blades to disc.

Assembling Radial and Effluent Launder

Erect the radial and effluent launders by welding one end to the collecting launder

around the cone and anchored the other end by bolting to the inserts provided in

the tank walls as shown in the general arrangement drawing.

h) Preparing the Final Drive for Operation

Before any final adjustment to the cone or draft tube which would alter their

elevation or concentricity with the drive, the drive must be prepared for operation

and the sweep arms adjusted to rotate in a true plane.


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5.2 SUGGESTED SEQUENCE AND METHOD OF ERECTION

(BOTTOM FEED DESIGN)

The erection sequence employed may deviate from that suggested due to

manpower or shortage or lack of erecting machinery. The following sequence is

one, which will work for most of the times.

a) Center Pier Erecting Sequence

The erecting sequence of a reactor clarifier is essentially the same. The following

instructions will hold for both except where noted.

Refer to general arrangement drawings for location of anchor bolts for the center

pier.

b) Setting of Anchor Bolts

When constructing the tank, it will be necessary to locate and set the combination

anchor bolt template and grout shield exactly in the center of the tank. The

template locates the anchor bolts for the center pier. Be sure to allow sufficient

thread to plumb and grout center pier at a later time.

c) Center Pier Installation

Assuming concrete around anchor bolts as above. Adjust level to design

elevation of center pier bottom flange, level to within 0.010 in two feet.

Although the anchor bolts are now ready to receive the center pier, some

comparative measurement will have to be made to determine which components

must enter tank first, the center pier or the center cage assembly.


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Proceed as follows:

Measure outside diameter of center pier top flange (part on which drive unit

will rest).

Measure opening of center cage assembly.

If center pier top flange is larger, place center cage assembly in the center

of the tank first. Block the center cage off the floor so workmen have

access to center pier previously leveling. Thread center pier into tank

through its leveled anchor bolts, washers and nuts. Temporarily secure

center pier with another washer and full hex nut.

If the center pier top flange is smaller than the hole in the center cageassembly, lower center pier on to its previously leveled anchored bolts,

washers and nuts. Temporarily secure with another set of washers and full

hex nuts.

d) Plumbing the centre pier

After checking to be sure studs and outside of pier top flange are concentric with

centerline of pier, drop 4 plumb lines 90 apart from the top flange of the center

pier. Let plumb bobs hang in a can of water or oil. Measure in from each plumb

line to outer surface of center pier. Adjust leveling nuts under pier until the four

measurements are the same within 1/16. Tighten down the hold-down nuts.

A non-shrinking grout can now be used under these components, allow to dry for

at least 24 hours.

e) Assembling Agitator MIL Propeller and Shaft

Lower the agitator MIL propeller and shaft into the tank and assemble the agitator

shaft to propeller. Lower the assembled shaft and propeller into the center pier

before erecting drive head base frame and drive head.


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f) Drive Head Mounting Base Frame

After lowering the shaft with coupling half and propeller into the center pier, hold

the upper end of the shaft nearly vertical at the center and then bolt the drive

head mounting base frame to the top flange of the center pier.

Assembling the Cone and Collecting Launder

This is mot conveniently done out of the tank on a level ground surface or on

substantial timber blocking within the tank. Refer to the general arrangement,

bolted connecting drawing to assemble the component parts. Use the fit-up bolts

provided, then field weld the segments together. Tack weld braces across the top,

narrow end of the cone to stabilize it when being moved.

g) Assembling the Scraper Arms

While the cone is being assembled outside the tank, the scraper arms can be

assembled in the tank. Do not assemble the squeegees to the plow blades until

the finished grouting of the tank is accomplished at a later point in the erection.

h) Connecting the Scraper Arms to Center Cage

Prop the center cage in a vertical position and assemble all tie rods, struts andspares between center cage and scraper arms. The scraper arms can be blocked

up a few inches off the unfinished floor. This blocking must not interfere with the

blocking which will be required for the cone.

Setting Drive Head with Drive Head Mounting Base Frame

Orient the drive unit with respect to bridge anchor bolts in the tank wall and lower

the drive unit on to the drive mounting base frame. Run a washer and full hex nut

down each bolt and tighten nuts.

i) Erecting the Cone and Collecting Launders

Refer to the General Arrangement Drawing and note the elevations for the top

and bottom of the cone. Place supporting members in the tank so as to support

the cone at the elevation indicated. This blocking must bridge the scraper arms


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and still allow access to the interior of the cone. Lift the cone using 3 or more

cables with spreaders and lower it slowly on to its supports. Center the cone in

the tank as best you can. Do not remove the cables at this time, but let the cones

weight transfer to the blocking. Assemble all cone support tie rods and horizontal

/ inclined stabilizer tie rods.

Connect all tie rods and adjust lengths so as to raise cone to its designed

elevation and to locate it concentrically within the tank. With the cone completely

suspended from its tie rods, remove all cone blocking.

j) Erecting the Bridge

Using care not to knock center pier out of plumb, set the bridge over its anchor

bolts in tank wall and over final drive housing.

Note: The Bridge is rigidly secure to the drive housing, but has a sliding

expansion joint at tank wall. There must be adequate room to allow for

expansion and contraction. If, due to misalignment of the anchor bolts,

sufficient room does not exist then the slotted holes will have to be

enlarged.

Assembling the Center Cage to Drive

Assuming that power is not available and drive chain has been removed; revolve

internal gear until attaching holes line up with holes in the center cage. Lift center

cage up and secure to final drive. Hand-tighten the nuts at this time.

CAUTION!!

At this point entire lower rotating arms should be suspended from the drive head

through center cage. If any part of the scraper arms touch the unfinished tank

floor, check the slope of the scraper arms against the dimensions on the general

arrangement drawings. Remember that the squeegees have not yet been

assembled to the underside of the plow blades! If the slope of the arms is found to


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be correct and contact with floor remains, check drive for level on drive mounting

base frame and center case for plumb.

Assembly of Agitator Drive and Agitator ShaftRaise and bolt the drive assembly (e.g. gear box and vari-speed drive unit) on its

drive base frame so that the agitator shaft can be bolted to the underside of the

reducer output shaft coupling half. Raise the agitator shaft already in the center

pier and fix with reducer output shaft coupling half.

Assembling Radial & Effluent Launder

Erect the radial and effluent launders by welding one end to the collecting launder

around the cone and anchored the other end by bolting to the inserts provided in

the tank walls as shown in the general arrangement drawing.

Prepare the Final Drive for Operation

Before any final adjustment to the cone or center cage which would alter their

elevation or concentricity with the drive, the drive must be prepared for operation

and the sweep arms adjusted to rotate in a true plane.

6. ADJUSTING TORQUE OVERLOAD MICRO SWITCHES

All electrical wiring should be completed and the torque overload device field

adjusted to protect the equipment during its dry tank run-in and subsequent daily

usage.

Note: Although the device is carefully set at the factory, rough handling during

shipment or at the site can alter the shop settings.

The device is located in a separate housing opposite the driven end of the worm

shaft.


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A signal light and / or sound system can be connected to the device which

consists of two (2) micro switches mechanically actuated through movement of

the worm shaft as the torque load is transmitted to it.

One micro switch should be connected so as to activate an alarm when a certain

torque loading is reached. The other switch normally closed will open and

shut off the motor if the torque loading continues to increase. The torque loadings

have been pre-determined for your equipment and the related feeler gauge

settings for both micro switches are indicated in Table Refer to that table and the

other drive assembly drawings found in the manual pocket while preparing your

drive to run.

A dial indicator is usually attached to the outside of the micro switch housing.

This indicator does not read in lbs/ft. of torque. It does, however, have

approximate warning and shutdown decals attached to its face glass. These

decals are attached at the factory and relate directly to the warning and shutdown

micro switch settings.

Note: The torque overload device is operational only when the equipment is

rotating in its designed direction.


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To set or check the micro switch you will need:

1. Test light to establish when switch is activated.

2. Feeler gauges.

Refer to the sectional views on torque overload device drawing for component

part names.

Set the micro-switches as follows:

1. Because the pre-travel in micro-switches varies considerably, realizebeforehand that when either switch is properly adjusted, no air gap may

exist after the feeler gauges are withdrawn. It is because of this pre-travel

variation that a test light is an absolute necessity. It is not always possible

to hear the micro-switch click as it is activated.

2. Refer now to the feeler gauge or air gap setting for the alarm setting

indicated for your particular drive. Obtain feeler gauge for that dimension.

For example, your drive might call for 0.017 air gap setting.

3. Connect the test light to the alarm micro-switch.

4. Loosen the setscrews in the top of the bar; loosen the jam nut on the

adjustable contact capscrew and run the capscrew in until the feeler gauge

will slide easily between the adjustable contact and the micro-switch

plunger. Then run the adjustable contact out until the test light shows the

switch has been actuated. Holding the capscrew head, run the setscrew in

until it seats. Then run the jam nut up to the bar. To check the setting,

remove 0.003 from the feeler gauge and insert between adjustable contactand micro-switch plunger. Test light should not light. Return to the proper

feeler gauge and insert. Test light should light.

5. Repeat the above for the motor shut-off micro-switch.


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6. Note whether the drain plug in the bottom of the housing is in place. This

plug should be removed every 30 days (more frequently in humid weather)

to drain out condensation or oil. It is not good practice to leave this hole

open continually.

Zeroing the Dial Indicator

Reset the dial indicator to zero if it has moved at all during the checking of micro-

switches.

The drive can now be used to rotate the equipment to establish true plane rotation

and, if practicable, to assist in leveling the finish grout on the tank floor.

After the unit has been used for that purpose, you will find that the dial indicator

will not return to its former zero. This is normal. One more zeroing may be

necessary, that being shortly after the equipment has been rotating in a full tank.


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Resetting if Torque Overload Stoppage Occurs

If a torque overload develops which is severe enough to activate the shut-down

micro-switch, it is possible that the spring plate may have been permanentlydeformed. It will be necessary to replace the spring plate before attempting to

reset the micro-switches or re-zero the dial indicator.

Disassembly and Inspection

Remove the flange bolts. The housing can then be withdrawn, bringing with it the

spring plate, spring plate retainer, lock nut, bar with adjustable setscrews and

adjustable plunger with nut which locks the bar to the plate retainer. To further

disassemble the unit, remove the dial indicator from the housing. Next, loosen the

nut on the adjustable plunger and then screw the plunger out of the spring plate

retainer. The spring plate lock nut and plate-retainer can then be withdrawn and

disassembled. Check the spring plate for flatness. If it has been deformed,

replace it with a new plate.

Re-assembly

Reverse the above procedure to re-assemble. One test must be made, however,

before re-setting the micro-switches. This test is to be made with the drive at rest,

under no load. When all but the dial needle when assembling the indicator to the

housing. The needle should move at least a quarter revolution as the indicator is

being secured. If the needle does not move off the peg, loosen the nut on the

adjustable plunger and screw the plunger back out of the plate retainer until it

contacts the dial indicator plunger sufficiently to move the needle at least a

quarter revolution. Hold the plunger while re-tightening the locking nut against the

bar. To zero the indicator, simply rotate the dial.

Once the above conditions have been met, refer to the instructions in the

beginning and reset the air gaps with a test light.


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GAP SETTING FOR MICRO SWITCHESUSED FOR DRIVE HEAD

For Alarm For Motor Shut-off

NF-18 0.041 0.048

NF-30 0.021 0.025

H-60 0.014 0.018

H-80 0.025 0.031

7. USE OF SHEAR PING DRIVEN SPROCKETS

Shear pin driven sprocket is provided at the worm shaft of the drive head. Nosubstitute for the proper shear pin is to be allowed at any time. Grease the

sprocket bore and shear pin faces before operating the drive under full load.

Clean and re-grease semi-annually.

8. ESTABLISHING TRUE PLANE ROTATION

Readjusting the Rotating Members for Slope

The scraper arms must be re-checked for correct slope and tip elevation. When

the sweep arms were first blocked into position and then assembled to the torque

tube, these assemblies were at their designed slope. Any adjustments made to

level the drive mechanism will have altered the tip elevations and designed slopes

off the members. If those changes were in excess of the various tie bars, etc.

should now be re-adjusted to bring all scraper arms back to designed slope and

floor clearances. All adjustments to be made with the tie bars and struts do not

alter the drive mechanism level again.

Pre-operative Check

After a complete check out of the units torque overload device, if power is

available, we suggest operating the unit in a dry tank for at least two complete

revolutions. A better check would be to run for a period of two hours and then


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check to see if the scraper arm is still operating in the same plane. Even if

running under temporary power do not bypass the overload device of the unit.

During the dry tank run-in, check the unit for:

Smooth operation no stopping or jerking movement.

Overhauling be sure proper heaters are used in the starting controls.

Oil leaks through reducer seals or drain plugs.

Oil leaks through main drive unit drain or level plugs

Loose bolts.

9. ADJUSTMENTS AND PRE-OPERATIVE CHECK-OUT

With the scraper arms rotating in a true plane, check reactor cone for concentricity

with torque tube and check the elevation of its upper edge. Adjust all tie rods to

bring cone into position. Add cone supports, shimming between underside of

bridge and support until field weld can be made at lower end of support where it

must contact the cone. Do not pull cone out of position to make these joints. Use

shims or use longer angles.

Now check concentricity of draft tube with torque tube. Move draft tube on its

supports and adjust horizontal tie rods to obtain concentricity.

Complete all electrical wiring. Erect all miscellaneous steel such as handrails,

weirs, baffle plates, etc. Fit up any chain guards, and then remove until run-in

period is finished.

Remove all debris from tank floor and bridge.Double check the gear reducers and both final circular drives for oil. Grease all

final drive grease fittings.

Double check the electrical connections between micro switches and scraper

drive motor.


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Start the scraper drive and let it run for an hour.

Observe gear reducers for oil leaks through seals.

Observe final circular drives for oil leaks.

Power the agitator drive. Run speed control through its entire speed range. Allow

it to run along with scraper drive. Change speed frequently so as to polish pulley

if unit has been stored.

If unit checks out after an hour run in, it is ready to assist in screeding the finished

grout.


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SECTION IV

O P E R A T I O N

SAFETY PRECUATIONS FOR OPERATING PERSONNEL

1. Do not operate any drive unit without its chain guard being in place.

2. Do not operate any drive unit if its torque overload device is not functioning

properly.

3. Do not stand outside the handrail surrounding the bridge.

4. Do not attempt any maintenance to the main drive unit other than

lubrication.

5. Do not allow excess slack to build up in a drive chain nor tighten it to the

point that the links can not flex.

6. Do not neglect to thoroughly hose down the submerged equipment and

fully drain the tank when a prolonged shut-down is necessary. The

possibility of scum coatings turning septic is always present. Also,

excessive build-up affects the balance.

7. Provide forced ventilation and exhaust facilities when workmen are in a

drained tank.

8. Wipe up all oil and grease spills after any maintenance.

9. Be alert to changes in the sound of the operating drives. Unusual noises

should be investigated.

10. Electric motors run hotter than they did years ago, and, for that reasonhand contact is no longer a reasonable method of detecting an overheated

motor. Provide for overload protection in the starter.


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SECTION VMAINTENANCE

CONTENTS

1. SAFETY PRECAUTIONS FOR MAINTENANCE PERSONNEL

2 .GENERAL MAINTENANCE

3. MAINTENANCE SCHEDULE


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SAFETY PRECAUTIONS FOR MAINTENANCE PERSONNEL

Before any maintenance is performed:

01 Disconnect the drive, preferably at the motor and lock out electrically.

02 Have adequate room to work in. Remove any guard or housing so that you

are able to reach the part to be removed with ease. Do not work outside

the handrail surroundings the bridge.

03 Illuminate the area properly.

04 Ventilate the area properly if you intend to use volatile solvents to clean or loosen parts.

05 Wipe up any oil spills, scum, etc. in the area where you need good footing

or hand holds for leverage.

06 Have a fire extinguisher handy if any torch work is anticipated or flammable

solvents may be used.

07 Have snubbing timbers and / or cable available for ting off heavy parts and

chain.

08 Use an overhead crane or portable hoist to support the heavier parts

removed.

09 Use a proper tool always.

Before Start-up

01 Refer to the drawings and / or manual when re-assembling. Operating

elevations should be restored. If weight has been added or subtracted

from rotating machinery, check the static balance of the rotating machinery

See Service Manual instructions.

02 Realign all sprockets moved or replaced before start-up.

03 Replace all housings and guards.


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04 Re tension chain before start-up.

05 Check electrically any torque overload devices before start-up.


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GENERAL MAINTENANCE

No special tools are required to maintain or repair the TRIVENI Reactor Clarifier.

Check the oil level of the reducer at 30 days intervals. Also check for water

condensation in the oil. If water is present, drain completely flush out and fill to

the correct level with new oil.

When reducers are idle for an extended period of time, they should be completely

filled with oil to prevent internal condensation. Drain down to proper level before

re-starting.

MAINTENANCE

We suggest that the flow is diverted and the tank drained once every six months.

After the tank is drained:

1. Clean the tank hose down walls, floor and all the submerged parts of the

unit.

2. Check adjustable brace between scraper arms and torque tube / torque

cage.

3. Check scraper arms for

Missing, broken or badly bent squeegees.

Clearance between floor and bottom of squeegees if this

clearance is not uniform around the tank, it is possible that themachinery is no longer rotating in a true plane. Before making any

mechanical adjustments, use a high pressure hose on all the

rotating machinery normally submerged so as to remove any build-

up of heavy bodied sludge, slime or lime.


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If, after taking the above actions, the scraping arms are found to be

rotating in other than a horizontal plane, and adjust the drive on the

bridge accordingly.

Check chain and cable assemblies for undue wear.

4. Check torque overload switches.

5. Check drive chain and sprockets for wear and alignment.

Refill tank and begin normal operation.


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EQUIPMENT MAINTENANCE SCHEDULE

PRIMARY GEAR REDUCERObserve in passing for lubricant leakage through shaft seals.Listen for unusual noises.

Daily

Observe for looseness on drive support base.Weekly Check housing temperature hand contact. If main housing

is more than warm, check for too little or too much lubricant.Check oil sump lubricant level(s). Grease bearings.Check for condensation and / or metal particles in lubricant.If contaminated, drain, flush, drain and refill with seasonallubricant recommended in manufacturers bulletin.

Monthly

Clean out vent.Quarterly Check manufacturers bulletin for appropriate seasonal

lubricant.Semi-annually When tank is drained for semi-annual inspection use this

down time interval to replace leaking seals or gaskets.PRIMARY GEAR REDUCERDaily Observe for looseness on reducer.

Annually If equipment is in constant use, bearings can be regreased(SPARINGLY). Remove grease relief plug if furnished. Uselow pressure, high volume type gun.

H-DRIVESWorm Gear Section of Drive HeadMonthly Check oil level at sight gauge on worm gear housing.

Clean air vent.Grease worm gear bearings with a Servogem-2 grease.Fittings are on top of worm gear housing. Clean fittings, addapproximately two pumps from grease gun each fittings.Check condition of oil for condensation etc. If contaminantsare found, drain, flush and refill with fresh oil, drain byremoving plug in street elbow. Filter plug is located at top of drive.

Final Turn Table Section of Main DriveMonthly Check oil level at sight gauge under floor plate. Oil drain

plug is in tee below gauge. Filter plug is in elbow of pipebelow worm gear section of main drive.Check condition of oil-use same procedure as listed for wormgear section of main drive.Change oil, use same procedure and oil as listed for wormgear section of main drive.


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When reducers are idle for an extended period of time,completely fill with oil.

Torque Overload SwitchQuarterly Check gap setting. Dial indicator to read zero when

equipment not operating, adjust dial as necessary.


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NF-18 DRIVE HEADLubrication Oil Capacity 6 Quarts

Oil Specification Servocyl C-460 (IOC Eqv.)

Oil & Drain Plug Located in street elbow on outside of worm housingOil Filler Plug Located on top cover (vent plug)Oil Slight Gauge Located on outside of worm gear housingGrease Fittings-3 Two on top of worm housing, one on pipe line to steady

bearing)Monthly Check oil level sight gauge on side of worm gear housing.

Add oil by removing vent plug in top cover. Clean out air vent. Wipe up all spills.Remove plug in bottom of torque overload micro switchhousing and drain off any condensation or oil seepage.Grease worm bearings and steady bearing. Use lowpressure high volume gun. Two pumps for each wormbearing. Three pumps for steady bearing. Use Servogem-2grease. Wipe off any grease that passes worm shaft sealadjacent to driven sprocket.Remove cap plug in chain guard to draw off water. Greasechain.Check capscrews holding collector drive housing to agitator drive housing.

Quarterly Check sample of oil for condensation, metal particles and or sludge. Drain, flush, drain and refill per precedinginstructions.Check air gap of torque overload micro switches. See testprocedure described earlier.

Semi-annually When tank is drained for semi-annual inspection of rotatingmachinery, use this down time to replace or retension thedrive chain.Retighten any loose bolts.Change oil to proper seasonal viscosity.If drive is with shear pin driven sprocket, remove shear pin,rotate sprocket to expose shear faces. Clean up faces andwipe with same grease used elsewhere.

DRIVE CHAINMonthly When checking oil level of circular drives, check drive chain

for slack. Move gear reducer on its base to remove excessslack. If reducer movement has been used up, return gear reducer to its original position and remove link(s) in chain,then retension drive.

Semi-annually Examine chain and sprocket for wear. Flop chain for additional wear. If sprocket teeth have hooked appearance,install new sprockets and new chain.


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BRIDGESemi-annually Check all fastenings

Examine fastenings at expansion joint at tank wall. Retorqueif loose.

BOTTOM SCRAPER ARMSSemi-annually When tank is drained for semi-annual inspection, hose off

with pressure hose to remove all sludge and lime deposits.Examine all joints for loose or missing bolts (and shims).Rotate machinery and test for true plane rotation.Examine scraper blades. Replace those badly bent or missing.

MAIN DRIVE AND AGITATOR DRIVE(for lubricant capacities & specificationDrive Housing Approx. Oil capacity

(Quarts) Final ReductionOil Specification (IOC Eqv.)

NF-7 2.5 Servocyl C-460NF-18 & NF-24 6 Servocyl C-460NF-30 4 Servocyl C-460

Agitator HousingR-7 4 Servocyl C-460R-18 4 Servocyl C-460Note 1 Qts. = 0.946 LitersELECTRIC MOTOR (for variable speed drive)

Annually If drive is in constant use, bearings can be re-greased(sparingly). Remove grease relief plug if furnished. Use lowpressure, high volume gun. One-fourth (1/4) ounce of greasewill take 2 pumps

R-7 & R-18 WORM GEAR DRIVESOil Capacity 4 Qts.Oil Specification Servocyl C-460 (IOC Eqv.)Oil Drain Plug Located in outside of worm housingOil Fill Plug Located on top cover (vent plug)Oil Sight Gauge Located on outside of worm gear housing.Grease Fittings 3 Two on top of worm housing, one on pipe line to steady

bearing.Monthly Check oil level sight gauge on side of worm gear housing.

Add oil by removing vent plug in top cover. Clean out air vent. Wipe up all spills.Grease worms bearings and steady bearings. Use lowpressure high volume gun. Two pumps for worm bearing.Three pumps for steady bearing. Use Servogem-2 grease.Wipe off any grease that passes worm shaft seal.


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Quarterly Check sample of oil for condensation, metal particles and / or sludge. Drain, flush, drain and refill per precedinginstructions.

Semi-Annually Re-tighten any loose bolts.

Change oil to proper seasonal viscosityRemove vari-speed belt drive guard. Check drive V-belt for slack. Move motor slide base by hand wheel for proper tension of varispeed belt. Grease adjustable hand wheelscrew.

AGITATOR BLADESSemi-annually When tank is drawn down for semi-annual inspection,

examine all fastenings.


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SECTION VIOVERHAUL / SPARE PARTS RECOMMENDED

CONTENTS

1. LIST OF SUGGESTED SPARE PARTS

2. SUGGESTIONS REGARDING OVERHAUL

3. OVERHAULING AGITATOR DRIVE

4. OVERHAULING SCRAPER DRIVE

5. OVERHAUL SUGGESTIONS FOR EQUIPMENT

6. ERECTOR AND PLANT OPERATOR NOTE


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LIST OF SPARE PARTS

Name of Part One to ThreeDuplicate UnitsMore than ThreeDuplicate Units

NF DRIVESWorm W/Key - 01Worm Gear W/Key - 01Set of Vent Plugs - 01 SetMotor W/Pair of Spare Bearings - 01Micro Switches on Bracket for TorqueOverload Device

- One Assy

Squeegees for Scraper Arm - One Complete set for

Pair of ArmsReduction Gear Reducer with Pair of SpareBearings and Oil seals

- 01

H-DRIVES One to three Units More than Three UnitsDrive Chain 01 02Drive Sprocket (W/Key & Setscrews) 01 02Driven Sprocket (W/Key & Setscrews) 01 01Worm (W/Key) - 01Worm Gear (W/Key) - 01Vent Plug for Drives - 01 SetShaft Seals for Drives - 01 SetSqueegees W/Fasteners (if originallyfurnished)

- 01 Set

Motor W/Set of Spare Bearings - 01 each for varioushorsepower used.

Torque Overload Spring Plate - 01Micro switches and Bracket Assembly - 01


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SUGGESTIONS REGARDING OVERHAULING

Suggestions regarding overhauling equipment furnished by Triveni, but of other

manufacturers:

1. When a manufacturers separate operation & maintenance manual is

provided, have the maintenance personnel become thoroughly familiar with

its components. No brief summary of lubricating requirements can ever be

considered as adequate. Name plate instructions are no substitute for

having read the manual.2. Observe all safety precautions consistent with the type of machine and the

extent of overhaul.

Provide a crane or block and tackle for lifting and moving.

Provide adequate ventilation if volatile or toxic solvents or adhesives

are to be used.

Provide uncluttered work space and a dry clean surface for parts

layout. Provide adequate light.

Have fire extinguisher handy if burning, brazing or welding is

necessary.

Provide adequate grounding before any electric arc welding is done

on machines whose bearings could be damaged by internal arcing.

Use proper tools while disassembling and re-assembling.


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OVERHAULING THE AGITATOR DRIVE

It is unlikely that the Agitator drive will require overhaul for many years if proper

maintenance procedures are carefully monitored. Refer to the drive assembly

drawing in the manual pocket. Proceed as follows after locking out the drive at

the panel:

1. Drain lubricant from collector drive.

2. Block up scraper arms in the tank bottom, to take the weight off the drive

gear.

3. Remove top cover and remove the capscrews holding the torque tube to

the drive gear.

4. Remove the bolts holding the collector drive to the agitator drive. Remove

the collector drive.

5. Remove chain cover and chain from drive. Tie off agitator shaft to bridge.

Remove capscrews holding shaft to work gear.

6. Remove thrust bearing retainer from worm housing.

7. Drift the worm shaft towards the torque overload housing end of the shaft.

8. Remove worm and key and spacer. If worm teeth are chipped or pitted,

replace. Remove, clean and inspect bearings.

9. Lift out worm gear, being careful not to lose ball bearings on which it rests.

If balls are pitted, replace. Surface corrosion (without pitting) can be

removed with crocus cloth. If gear teeth are worn thin, replace.

10. Wipe out ball races. If pitted, replace.11. Before reassembling, purges all grease fittings to remove any grit. Wipe all

surfaces thoroughly. Solvent clean all bearings in the worm housing dry

without spinning and repack with grease.

12. Reassemble in reverse order, taking care not to lose any bearing balls.

13. Secure agitator shaft to worm gear.


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14. Refill drive with seasonally appropriate lubricant. Reconnect chains and

replace cover. Grease at all fittings.

15. Lower collector drive onto agitator drive, taking care to feed collector torque

tube through collector drive steady bearing without damaging either.Secure

torque tube to collector worm gear.

16. Refill collector drive with seasonally appropriate lubricant. Grease all

fittings.

17. Remove blocking from beneath scraper arms in tank bottom.

Note: The above overhauling procedure is generally applicable for all

agitator drives and especially for R-drive reducer. For standard gear reducers,refer to vendor information section of the bulletin.


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OVERHAULING REACTOR MAIN DRIVE(FOR NF-DRIVES)

It is unlikely that the final drive will require overhaul for many years if proper

maintenance procedures are carefully monitored. Refer to the drive assembly

drawing in the manual pocket.

Proceed as follows:

1. Drain lubricant from final drive.

2. Block up the rotating members in the tank, scraper arms, headers etc.

3. Removes final drive cover plate and gradually loosen the capscrews

holding the torque tube to the worm gear.

4. Remove chain guards and drive chain.

5. Remove driven sprocket.

6. Remove torque overload housing from drive housing.

7. Drift the worm shaft towards the torque overload housing end of the shaft.

8. Remove worm and key and spacer. If worm teeth are chipped or pitted,

replace. Remove, clean and inspect bearings.9. Lift out worm gear, being careful not to lose ball bearings on which it rests.

If balls are pitted, replace. Surface corrosion (without pitting) can be

removed with crocus cloth. If gear teeth are worn thin, replace.

10. Wipe out ball races. If pitted, replace.

11. Before re-assembling, purge all grease fittings to remove any grit. Wipe all

surfaces thoroughly. Solvent clean all bearings in the worm housing dry

without spinning and repack with grease.

12. Reassemble in reverse order, taking care not to lose any bearing balls.

13. Reassemble torque overload device and zero the indicator. Reset the

micro switches with a test lamp.

14. Refill drive with seasonally appropriate lubricant.


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15. Assemble torque tube to worm gear. Draw up the joining capscrews

gradually. Replace top cover.

16. Assemble driven sprocket, drive chain and guard.

17. Remove blocking from beneath rotating members.


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OVERHAULING REACTOR MAIN DRIVE

(FOR H-DRIVES)

1. Disconnect and lockout the drive electrically.

2. Drain the final drive. We also recommend that the primary and secondary

worm gear drives be drained, flushed and relubricated.

3. Remove the dust shield segments, this will expose the stop blocks.Remove stop block capscrews and stop blocks. (Stop blocks can be held

from turning with channel lock or vise grip pliers).

4. Remove capscrews and taper pin joining the internal gear segments, lift

and remove segments. The internal gear segments on larger units are

heavy, they will require a block and tackle or small crane to lift them out.

(Lifting hooks at all four flanges will keep the segment in balance when

removing it from housing).

5. Remove the ball bearings and races from the housing. Thoroughly clean

housing, gear segments, bearing races, etc. with a good commercial

solvent or kerosene.

6. Examine the ball bearings and races for galling, pitting or any other

roughness, if none is evident, the parts can be reused. Check the

condition of the interior of the housing for rust and loose paint. If needed,

scrape out the repaint non-machined surfaces.

7. If the ball races have to be replaced on the gear segment, it will be

necessary to stake them in place. When installing the ball bearings in the

housing set them in gobs of grease to hold them in position until the gear

segments are reinstalled. Lightly cement a new felt strip in the housing V

groove. The gear segments can now be reinstalled in the housing. Use


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care when setting segments in position so as not to upset ball bearings or

newly installed felt seal. Drive the taper pins into the flanges of grade 5

bolts. Reinstall stop blocks and dust seal segments.

8. Replace any drain plugs that were removed and fill with proper lubricant to

operating level.

ROTATING EQUIPMENT SEGMENT

After overhauling the final drive, the rotating equipment which was blocked in

place and then reconnected to the drive, will have to be realigned in the same

manner as when it was installed.


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SUGGESTIONS REGARDING OVERHAULING EQUIPMENT

MANUFACTURED BY TRIVENI

1. Drain the tank, hose down the equipment and the tank so that noxious

fumes are at a minimum and surfaces afford good footing.

2. Have a small crane or portable hoist available. Many components are

heavy and some procedures require lifting before timber supports are

placed.

3. Use cable in first class condition when chain strands are to be tied off or

parts lifted.

4. Provide a dry area for storing parts prior to re-assembly.5. Have the Triveni Service Manual available to you. Refer to the General

Arrangement and assembly drawings for locating dimensions when

questions arise.

6. TRIVENI equipment other than motor reducers and electrical components

do not require special tools for disassembly. Care must be taken, however,

when removing cast iron or semi-steel sprockets and bearings or set

collars. Clean up shafts before attempting to slide sprockets, bearings or

set collars off the shafts. Use rust solvents to loosen set screws.

7. Take care when burning off nuts or bolts heads that adjacent

accumulations of oil, grease or paint do not start to burn.

8. If it is necessary to use a torch to help remove a sprocket, do not attempt to

burn completely through the hub. Burn a groove into the hub and use

chisels to split the hub.

9. Be sure to use a proper ground when doing any welding so that arcing

across any bearing in adjacent machinery is avoided. Be especially carefulwhen welding near motors and reducers.

10. Grind all welds smooth in areas where some other part has to cross the

weld.


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ERECTOR & PLANT OPERATOR NOTE

We recommend incorporating the entire Triveni Service Manual into your overall

Documents

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