Vulcan-Hart FT48 CI Operation And Maintenance Training

Beaver channel pump station and related modifications and contract c- new wwtp

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Table of Contents

Cover – Title Sheet

Instructor Resume

Coarse Objectives

Training Outline

Operation and Maintenance Training for Vulcan Industries "Mensch" Bar Screen

Section 1 - Safety

Section 2 – Operations

Section 3 – Electrical Sequence of Operation

Section 4 – Maintenance

All training will consist of both Classroom and hands-on training.

Twelve (12) sets of this outline will be provided for training purposes

No additional audio/visual training aids are required for this training.

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Summary of Contents for Vulcan-Hart FT48 CI

Page 1 Table of Contents Cover – Title Sheet Instructor Resume Coarse Objectives Training Outline Operation and Maintenance Training for Vulcan Industries “Mensch” Bar Screen Section 1 - Safety Section 2 – Operations Section 3 – Electrical Sequence of Operation Section 4 – Maintenance All training will consist of both Classroom and hands-on training.
Page 2: Training Manual
Modifications and Contract C- New WWTP Project Location: Clinton, IA Equipment: 2 - Mensch Crawler Screen Model No. FT48 CI “Severe Duty” Contract Specification Section: 11092 Equipment Tag Numbers: 10INF-CSCN02 & 10INF-CSCN01 Related Equipment: 1 – Screening Washing Press Model EWP 250-1200...
Page 3 VULCAN INDUSTRIES, INC. Submittal Documents for: Clinton WWTP Clinton, IA Vulcan Ind. Job No.: 10010 Contractor: Gridor Construction 11092 Specification Section References: SERVICE TECHNICIAN RESUMES Vulcan Industries, Inc. 212 S. Kirlin St., Missouri Valley, IA. 51555 Email: www.Vulcanindustries.com Phone 712.642.2755 • Fax 712.642.4256...
Page 4 VULCAN INDUSTRIES, INC. WATER / WASTEWATER TREATMENT EQUIPMENT 212 S. KIRLIN ST. MISSOURI VALLEY, IA. 51555 (712) 642-2755 or fax (712) 642-4256 Email www.vulcanindustries.com SERVICE REPRESENTATIVE QUALIFICATIONS Carlton Griffin Mr. Griffin has been employed full time by Vulcan Industries for fifteen years as a service representative.
Page 5 Kenny assisted other service representatives on several service and training operations before becoming a full time serviceman. Prior to being employed by Vulcan, Kenny worked for many years as a technician in the HVAC and electrical industry. He has extensive knowledge in the areas of electrical, electronics, mechanical and pneumatic equipment.
Page 6 Coarse Objectives Mechanical Bar Screen Identify, describe and/or perform the following: 1. Safety Hazards 2. Functional Description of Equipment 3. Technical Description and Component Identification 4. Equipment Operation 5. Troubleshooting 6. Maintenance and Lubrication 7. Maintenance Demonstration The intent of this training is to provide all plant personnel (Operations, Maintenance and Electrical) with the general knowledge to operate and maintain the equipment.
Page 7 c. Electrical equipment device functions 4. Maintenance a. Lubrication schedule b. Daily maintenance schedule c. Weekly maintenance schedule d. Monthly maintenance schedule e. Half-yearly maintenance schedule f. Maintenance and repair of individual components...
Page 8: Section 1 General Safety Instructions
Section 1 General Safety Instructions General Safety Instructions Operator’s Responsibilities This machine was designed and built to operate within all applicable safety guidelines. In practice, however, this safety can only be achieved if all the necessary measures are taken. It is the responsibility of the owner and/or operator to ensure that these measures are taken and to monitor their performance.
Page 9 Section 1 General Safety Instructions C. Before Turning the Machine on Familiarize yourself with:  The operating and control elements of the machine.  Machine equipment.  The mode of operation of the machine.  The immediate surroundings of the machine. ...
Page 10 Section 1 General Safety Instructions  Ensure that all tools, materials and other equipment used have been removed from the work area.  Clean the work area and remove liquids that might have spilled.  Ensure that all safety devices of the machine are functioning properly. F.
Page 11 Section 1 General Safety Instructions These personnel must be familiar with the operating instructions. In addition, the following qualifications are needed for the following activities:  Only electricians may perform work on electrical equipment.  Only trained personnel may perform maintenance, upkeep and repair work. Other Dangers A.
Page 12 Section 1 General Safety Instructions Safety Symbols The following are pictures and an explanation of all the safety stickers that are used on Vulcan equipment. Some of these may or may not pertain to your particular machine. A spreader bar must be used when lifting this machine.
Page 13 Section 1 General Safety Instructions Grease point for maintenance reference. Grease point for maintenance reference. Watch for an open pit. Equipment in Automatic mode may start if sensors are triggered. Make sure the machine is properly locked-...
Page 14 Section 1 General Safety Instructions Do not operate the machine with covers removed. Take care in not getting caught in the exposed screw or other moving parts.
Page 15: Section 2 Operation
Section 2 Operation Equipment Type: Mensch Bar Screen Function: The Bar Screen is designed to remove solid debris from the influent channel flow. This is accomplished by placing a trash rack in the sewer channel. Debris accumulates on the bars of the rack. A traveling rake assembly cleans the accumulated debris.
Page 16 Section 2 Operation...
Page 17: Operating Procedure
Section 2 Operation OPERATING PROCEDURE Start-Up (Initial start-up or after long term shutdown) Prior to initial start-up and following long periods of maintenance shutdown, the following must be checked and verified. a) Visual inspection of all moving parts to insure that all tools, rags and other loose items have been removed.
Page 18 Section 2 Operation i) Operate the rake upward through the bars and deadplate stopping prior to reaching the wiper. Jog the rake forward until the rake shelf contacts the wiper blade. Make necessary wiper adjustments as needed to ensure the wiper does not jam on the rake shelf.
Page 19 Section 2 Operation Protective Devices: 1. High Torque Protection: A Current Sensing Relay is used to monitor single-phase line amps. When the motor is overloaded, the CSR senses the amp draw and de-energizes the motor starter, stopping the motor. The CSR is calibrated in the field at start-up and should be tested periodically.
Page 20: Section 3 Electrical Functions
Section 3 Electrical Functions Bar Screen Sequence 1. After the Mensch Screen has been properly installed/adjusted, motor rotation checked and all control panel devices (timer(s), overload(s), current sensing relay, etc.) have been set, automatic operation may proceed. Go to the local control station and make sure the Emergency Stop button is pulled out, the Hand-Off-Auto selector switch is in the "Auto"...
Page 21 Section 3 Electrical Functions 5. The rake is protected from overrotation by the action of the rake arm activating the overrotate limit switch (LS-2) in line 14. When (LS-2) closes, CR5 is energized and the overrotate pilot light is illuminated. The CR5 contact in line 15 forms the holding circuit.
Page 22 Section 3 Electrical Functions Screw Conveyor Sequence 1. After the Screw Conveyor has been properly installed/adjusted, motor rotation checked and all control panel devices (timer(s), overload(s), current sensing relay, etc.) have been set, automatic operation may proceed. Make sure all personnel are clear of the equipment.
Page 23: Section 3 Electrical
Section 3 Electrical Functions Bar Screen Components Disconnect The disconnect removes high voltage from the circuit breakers and transformer. Voltage is still present at the top of the disconnect. When the disconnect switch is in the "Off" position, the control panel will not function. This will not remove voltage supplied from other external sources.
Page 24 Section 3 Electrical Functions Current Sensing Relay This relay monitors the current draw of the drive motor. When the current exceeds the preset of this relay the machine will stop. The cause of the increased current draw must be corrected before automatic operation may continue. Press the Reset push button to reset.
Page 25 Section 3 Electrical Functions machine after the machine has started. The rake will park at this switch after one cycle unless a run signal is present. Overrotate Limit Switch This switch is mounted to the rake carriage. If the rake would encounter an object to large to pass over, the articulation of the rake will close this switch and stop the Mensch Screen.
Page 26 Section 3 Electrical Functions Push Buttons Conveyor Reset This push button resets the Washing Press current sensing relay after an overtorque condition. The Hand-Off-Auto selector switch should be placed in the “Off” position before pressing the Reset push button. Pilot Lights Control Power This pilot light will be lit when control power is available at the control panel.
Page 27 Section 3 Electrical Functions Off Delay Timer The set point of this time delay determines how long the Conveyor will run after the bar screen has stopped. Differential Level Detector If a high upstream level condition is detected, the equipment will run continuously until the high level condition is no longer present.
Page 28: Section 4 Maintenance
Section 4 Maintenance GENERAL SAFETY PRECAUTIONS Only fully trained and authorized personnel should be permitted to enter owner defined boundaries around, within, or on, any equipment or component that presents a potential for injury through a lack of knowledge concerning proper safety precautions.
Page 29: List Of Required Tools
Section 4 Maintenance Vulcan Industries will not be responsible for any harm or injury that may result from the improper operation of this equipment. Furthermore, Vulcan Industries will not guarantee this equipment if improperly operated or operated without designed safety features. LIST OF REQUIRED TOOLS HAND TOOLS: Standard Maintenance Tools:...
Page 30: Safety Devices
Section 4 Maintenance SAFETY DEVICES: Lock-Out Tag-Out as required by Local Policy Hazardous Gas Detector Appropriate Work Attire and Gloves...
Page 31: Maintenance And Lubrication Schedule
Section 4 Maintenance MECHANICAL BAR SCREEN MAINTENANCE and LUBRICATION SCHEDULE Semi- Weekly Bi-Weekly Monthly annually "May be extended if rollers permit, important thing is to prevent PIN RACK ROLLERS (Carbon Steel Type) seizing of rollers." DRIVE SHAFT ROLLER BEARINGS PILLOW BLOCK BEARINGS IDLER SHAFT ROLLER BEARINGS IDLER ROLLER GUIDE TRACK WIPER PIVOTS...
Page 32 Section 4 Maintenance Lubrication is considered very important to the operation of the equipment. Proper lubrication will extend the life of the equipment and all wearable parts Mensch Screen Lubrication Schedule Weekly: Grease Points: Drive Shaft Rollers, equipped with grease zerks Wiper Pivot Points, equipped with grease zerks Monthly: Grease Points:...
Page 33: Daily Preventative Maintenance
Section 4 Maintenance DAILY PREVENTATIVE MAINTENANCE: NO SPECIAL TOOLS REQUIRED Visual observation: (Look, Listen, Feel) Corrective measures for the check list shown below will be detailed in the corrective maintenance section of the manual.
Page 34 Section 4 Maintenance  Look for misalignment, Listen for unusual noises and Feel for unusual vibrations.  Rake Teeth aligned to the bars properly, smooth transition out of bar rack.  Wiper engaging rake shelf properly (wiper is in full contact, side to side, with the rake shelf, wiper removes all screenings from rake shelf).
Page 35 Section 4 Maintenance  Test Rake Overload/Over-rotate switch.  Verify Timer Settings  Check Differential Control Settings  Test Float Switch(s)
Page 36: Monthly Preventative Maintenance
Section 4 Maintenance MONTHLY PREVENTATIVE MAINTENANCE:  Grease Cup Replacement  Conduct Bearing Inspection  Rake Teeth Straight  Bar Rack Bars Straight, Open Space between Bars free of obstacles.  Rake Tooth to Deadplate properly adjusted  Rake Tooth to Bar Rack Penetration adequate. ...
Page 37: Corrective Maintenance
Section 4 Maintenance o Drive Shaft Collars and Pillow Block Bearing Eccentric Collars Tight CORRECTIVE MAINTENANCE LOOK (MISALIGMENT) “SAME SIDE” RAKE SHELF RUBBING PIN RACK BOTH DIRECTIONS: REFER TO RAKE ADJUSTMENT DRAWING, SECTION 5  Confirm the “A” distance is equal on both rake arms. Adjusting one side will cause the rake shelf to pull towards one side or the other.
Page 38 Section 4 Maintenance REFER TO RAKE ADJUSTMENT DRAWING, SECTION 5  Verify rake pivot points are properly positioned. If pivots are binding or sticking, thoroughly grease the pivot points.  Verify rake adjustment nut (Adjustment 5, Rake Adjustment Drawing, Section 5) is tight, jam nut is tight. (Loosening these nuts allows the rake teeth to pull away from the bars.
Page 39 Section 4 Maintenance  Wiper adjustment is discussed on the wiper assembly drawing. Follow adjustment steps to realign the wiper assembly.
Page 40 Section 4 Maintenance LISTEN (Abnormal or Grinding Noise) Motor starts and noise emitted from motor or brake. BRAKE GRINDING:  If rake will run, position rake at maintenance level and remove brake cover. With cover off, jog motor to determine if brake noise exists. ...
Page 41 Section 4 Maintenance  Lubricate all guide tracks as indicated on the maintenance schedule. Inspect guide track for damage/wear while lubricating.  Confirm proper rake adjustment to prevent rake from riding to one side causing face of roller wear on inside of guide tracks. 6.
Page 42 Section 4 Maintenance Motor Grinding:  Brake adjustment needed.  Brake repairs needed.  Motor-to-gear coupler failure  Motor bearings bad Rake Drive and Idler Rollers: Drive rollers and Idler rollers should roll smoothly throughout the cycle. (Some floating may be present especially when the rake shelf is unloaded) If rollers are loose, wobbling or seized inspection is necessary.
Page 43 Section 4 Maintenance Common causes of failure are:  Failure to replace after lubrication change.  Puncture  Corrosion  Normal Deterioration (replace canister every two years) Component Disassembly and Repair: A. Rake Mechanism/Drive Assembly: 1. To remove rake assembly from unit, bring rake assembly to the area directly across from the access plates provided at the front of the framework.
Page 44 Section 4 Maintenance Drawing, Section 5). Once the assembly is removed from the screen, the mounting plate and shaft can be slid out of the pivot arm by removing the snap rings and washers. The wiper blade assembly will detach from the pivot arm by removing four (4) bolts from wiper head pivot plate.
Page 45 Section 4 Maintenance Always use a high quality, nickel based, anti-seize lubricant on bolt threads to prevent galling and false torque readings. Bolt Torque: 3/8” 15 Ft. Lb. 1/2" 35 Ft. Lb. 7/16” 45 Ft. Lb. 5/8” 50 Ft. Lb. 3/4"...