The Screening

Screening, Dewatering
and Drying
y g Experts
p
Centrifuge and Belt
elt Press
Maintenance

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Introduction
Brian Lent
Western Regional Aftermarket Sales Manager
Experience
1976 1981

BIRD MACHINE Walpole MA

Based out of Boston MA

1981 1998

Humboldt Decanter -Norcross GA

Based out of San Ramon CA

1998 2006

BAKER PROCESS Walpole MA (Formerly BIRD)

Based out of San Ramon CA

2006 to Present

Andritz Separation Inc Arlington TX

Based out of San Ramon CA

Buenos Aires

Long Term Maintenance of Dewatering Equipment

Belt Press

Centrifuge
g

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Long Term Maintenance of Dewatering Equipment

Dewatering Equipment like and other processing devices have there limits

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

Belt Press units have a basic rule of thumb

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

Buenos Aires

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Long Term Maintenance of Dewatering Equipment

Centrifuges
Centrifuges are sized by the Optimal capacity of the bowl configuration and volume
that can be put through it at that optimum loading
The solids loading is dependent on the feed solids THE HIGHER THE FEED
SOLIDS THE LOWER THE FLOW to maintain the optimal performance
The liquid loading is also dependent on the feed solids THE THINNER THE
FEED THE HIGHER THE FLOW RATE to maintain the optimal performance
This is why in the market most companies have sizes that have similar sizes and
geometry
The newer designs are pushing that curve to its limits
When these loadings are exceeded the optimal performance of these machines
suffers drastically loss of % cake solids and flow through put
Buenos Aires

How to calculate Throughput

Known: Flow Rate

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

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

S
or simplified

T = 5 x FR x FS x SGSL
T
FR
FS
SGSL

---------

Example: Flow Rate

Feed Solids
SG Sludge

Throughput in lbs/hr Dry Solids

Flow Rate in Gallons per Minute
Feed Solids in % Dry Solids
Specific Gravity of sludge or slurry (use 1.0 for municipal sludge)
= 100 GPM
= 2.5 % DS
= 1.0

Throughput = 1,250
1 250 lbs/h DS
Andritz Separation Inc.
Slide No. 6

SLUDGE FROM TYPICAL WASTEWATER TREATMENT

Andritz Separation Inc.

Slide No. 7

Long Term Maintenance of Dewatering Equipment

From the simple sketch you can see that sludge is made up of waste and
that waste has the kitchen sink in it. The wastewater treatment plants
try to remove the heavy particulate and screen most of the plastic and
grit but a large amount still manages to get to the solids handling end
of the plant where it is dewatered.
Contrary to popular thought not all Poop is the same each sludge has its
own characteristics, chemical make up, grit levels, ash content, settling
rates
t and
d any other
th individual
i di id l componentt one can thi
think
k of.
f
With that thought how do we protect our equipment
Most Belt Press units have

Protected and coated frames

Protected bearings and sealed housings

Protected rollers

Stainless steel fasteners and fittings

Plastic and protective housings and covers

Gear boxes and drives

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Buenos Aires

Long Term Maintenance of Dewatering Equipment

Having said this EVERYTHING REQUIRES SOME DEGREE OF
MAINTENANCE
The normal wear items for a Belt Press are
The Belts normal wear is 2000 to 3000 hours but this depends on the grit
and pressure applied to the rollers
The Rollers the rollers have an normal life expectancy of 10 years again
d
depending
di on th
the grit
it and
d pressures applied
li d
Tracking and tensioning systems (either pneumatic or hydraulic) have a life
cycle also there life is dependent on the pressure, operating cycles and
generall h
housekeeping
k
i off th
the unit
it
Drives / gear boxes there life cycle depends on lubrication changes,
alignment and general housekeeping
Bearings and seals these are the only items that require constant attention
as far a grease and housekeeping
The frame and ancillaryy equipment
q p
requires
q
attention when it fails or is
damaged
Buenos Aires
9

Long Term Maintenance of Dewatering Equipment

Belt press lubrication
5.3.1

Lubricant Specification

REFERENCE SYMBOLMOBILSHELLTEXACO
A - GreaseMobilith SHC 460- - - -- - - B - OilMobilgear 630Shell Omala Oil 220Meropa 220C - GreaseMobilux EP2Shell Alvania Grease R3Multifak EP2
5.3.2

Lubrication Schedule
Frequency Lubricant
1.
2.
3.
4.
5
5.
6.
7.

Grease bearings
monthly
Grease tracking device
1 month
Grease thrust rods on tensioning device
Check oil level in drive gearbox
Ch
Change
oilil iin d
drive
i gearbox
b
Repack bearings in drive gearbox
Grease bull gear & drive pinion gear

A
A
6 months
A
80 hours
B
10 000 hours
10,000
h
(2 years))
20,000 hours (4 years)
1 month
A

B
C

5.3.3
Lubrication Location
*Graphics
Graphics may differ from actual machine*
machine

All equipment should have a simple grease chart that can be followed
g these lubrication events
It is up to the customer to log
Buenos Aires

10

Long Term Maintenance of Dewatering Equipment

C t if
Centrifuges
h
have similar
i il wear and
d maintenance
i t
points
i t

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

Buenos Aires

11

Centrifuge Maintenance Requirements

5.3.1 Lubricant Specification

Centrifuge
Technology

LUBE TYPE
A. Grease
B. Grease

SKF
SKF LGMT2
SKF LGMT3

LUBRICANT LIST
Mobil
Shell
Mobilux EP2
Alvania EP2

BP
Energrease LS EP2

Mobil SHC
627

X100 30

EXCLUSIVELY
Energrease PR EP 00
BP Super visco static
20w50

Frequency
200 hours
200 hours
4000 hours
4000 hours
3000 hours

Lubricant
A
A
B
C
A

C. Grease

Quality
D. Oil

Innovative
Reliability
High Performance

5.3.2 Lubrication Schedule

1. Grease bearing - feed end
2. Grease bearing - drive end
3. Grease thrust bearing - feed end
4. Change grease in drive speed inducer
5. & 6.
Grease electric motor bearings
5.3.3 Lubrication Location

Quantity
20 Gr
15 Gr
100 Gr
3000 Gr
see Vendor info

Long Term Maintenance of Dewatering Equipment

Maintenance Service Intervals

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

Buenos Aires

13

Andritz Centrifuge Features

12 Centrifuge Maintenance Requirements
12.
DESCRIPTION

200
HRS

1. * Lubricate both support bearings EVERY 200 hrs

3000
HRS

4000
HRS

6000
HRS

8000
HRS

9000
HRS

12000
HRS

15000
HRS

18000
HRS

24000
HRS

2. Renew grease in cyclo & thrust brg.

3. General inspection

4. Inspect scrapers, deflector rings (D7L only)

5. Inspection of drive belts

6. Mechanical inspect of feed brg. block

7. Inspection of nozzles

X
st

8. Renew grease in REDEX pulley after 1 200 hrs

X
X

9. Inspection of bearings & seals

10. Inspect / dismantle of reducer

11. Inspect / overhaul of torque limiter

12. Inspect deflector

13. Inspect feed & discharge ports ( where applicable)

14. Inspect drive belt tension

X
X

X
X

15. Inspect vibration isolators (shock absorbers)

16. Inspect elastic coupling

17. Inspection of feed tube
18. Replacement of drive belts, support brgs., & seals

X
X

X
X

19. Replacement of deflectors, scrapers (D7L), & nozzles

20. General complete mechanical overhaul & inspection

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

Previous Slide

Long Term Maintenance of Dewatering Equipment

Simple rules of thumb for operating any piece of equipment
The Harder you run it the more it will cost you to maintain it
The Faster you operate and unit (above its performance optimum speed)
the more wear you will have
The more solids you put through a unit (above its optimum performance
range) the more wear you will have in the unit
The more grit or non biological particulate you have in the sludge the more
wear and plugging that will occur
The lless h
Th
housekeeping
k
i you perform
f
on a piece
i
off equipment
i
t tto ffaster
t th
the
surfaces and housing will deteriorate
The less Electrical upkeep that is performed on the controls and electrical
components of a ssystem
stem the faster they
the will
ill fail

Buenos Aires

15

Long Term Maintenance of Dewatering Equipment

YES - I SAID CONTROLS

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

Buenos Aires

16

Andritz Centrifuge Features

11 Centrifuge Control System
11.

NEMA 4X Stainless Steel

316L Control Panel with
Color Touch Screen

Previous Slide

Long Term Maintenance of Dewatering Equipment

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

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Long Term Maintenance of Dewatering Equipment

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

19

Long Term Maintenance of Dewatering Equipment

QUESTIONS:
There are NO dumb questions

Buenos Aires

20

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