Vaughan ROTAMIX SYSTEM Installation, Operation & Maintenance Instructions Manual

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ROTAMIX

SYSTEMS

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

VAUGHAN CO., INC.

364 Monte Elma Road, Montesano, WA 98563

Phone: 1-360-249-4042 / Fax: 1-360-249-6155

Toll Free Phone (US only): 1-888-249-CHOP (2467)

Web Site: www.chopperpumps.com

Company E-mail: info@chopperpumps.com

Form V372, Rev. 12

12/18, ECN4334

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Page 1 ™ ROTAMIX SYSTEMS INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS VAUGHAN CO., INC. 364 Monte Elma Road, Montesano, WA 98563 Phone: 1-360-249-4042 / Fax: 1-360-249-6155 Toll Free Phone (US only): 1-888-249-CHOP (2467) Web Site: www.chopperpumps.com Company E-mail: info@chopperpumps.com Form V372, Rev. 12...
Page 2 This manual is for all Vaughan Rotamix Systems. NOTE: The pump for your Rotamix System will require an additional IO&M manual. Form V372, Rev. 12 10/18, ECN4334...
Page 3: Table Of Contents
TABLE OF CONTENTS INSTALLATION, OPERATION, & MAINTENANCE INSTRUCTIONS IMPORTANT SAFETY INFORMATION ............Page 1 DESCRIPTION OF VAUGHAN ROTAMIX SYSTEM ........Page 3 INSTALLATION INSTRUCTIONS …………………………………………..Page 3 A. Receipt Inspection B. Storage Considerations C. Installation Vaughan Foambuster Roof-Mounted Nozzles III.
Page 4: Important Safety Information
This equipment is intended for installation by technically qualified personnel. Failure to install it in compliance with national and local electrical codes, building codes and within Vaughan Co. recommendations may result in electrical shock, personal injury or death, fire hazard, unsatisfactory performance, and equipment failure.
Page 5 Pressure may build up in the standard mechanical seals used in Vaughan pumps. Whenever checking or maintaining the oil in the Vaughan Cartridge Seal, or the welded metal bellows seal with seal oil chamber, make sure the pump and seal are cool to the touch. Use care when removing the oil chamber plugs and pressure relief valve, in case any residual pressure exists.
Page 6: Description Of Vaughan Rotamix System
C. INSTALLATION The Vaughan chopper pump is to be installed as described in the pump IO&M Manual. Note however, that the Rotamix system reason for being is to achieve improved efficiency over your previous mixing systems.
Page 7: Vaughan Foambuster
So gas buildup in the system may keep your pump and Rotamix system from working properly. This can be particularly troublesome if your system operates intermittently. Gas binding is also much more common if your pump has other than a top discharge on the pump casing.
Page 8: Nozzle Aiming Instructions
E. NOZZLE AIMING To perform this procedure, you will need the Vaughan nozzle aiming kit, Part# V108-205. This kit includes the aiming protractor, mounting bungee, and the plumb bob. You will also need two 15/16”, and two 1-1/8” wrenches or sockets and a ladder tall enough to reach the top nozzles.
Page 9 STEP 2 Tie a string to the protractor at the zero point hole, and attach the other end of this string to the center of the tank in some manner. This will align the protractor so that the nozzles can be properly aimed relative to the center of the tank.
Page 10: Startup Instructions
Rotamix tank drawing marked up with nozzle locations, nozzle angles, nozzle elevations, and confirmation of all bolt torques, to be sent to Vaughan Engineering. If the job-specific tank drawing is not available please contact Vaughan Engineering prior to performing Start-Up to have the correct drawing supplied.
Page 11 Vaughan Co. requires the Startup & Certification Checklist pages, with the job specific Vaughan Rotamix tank drawing marked up with nozzle locations, nozzle angles, nozzle elevations, and confirmation of all bolt torques, to be sent to Vaughan Engineering. All verified dimensions should be indicated by a circle or check mark on that dimension.
Page 12 COMMENTS: _______________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ Form V372, Rev. 12 - 9 - 12/18, ECN4334...
Page 13: Normal Operation
100% duty cycle. Many times this system may be operated on a timer, on a duty cycle less than 100%. As a general rule, a Rotamix system requires 30- 60 minutes to reach steady state mixing, and it may require several days of mixing after that to achieve a homogeneous slurry in the tank.
Page 14: Shutdown Instructions
Installation, Operation and Maintenance Manual for your Rotamix system. Venting systems may require yearly inspections to make sure they are working properly and staying clear of debris. Vaughan always supplies the flushing option with the air release valves we supply. B. CORRECTIVE MAINTENANCE Replacement of any Rotamix™...
Page 15: Troubleshooting
Anything that could cause trouble for a pump in any other system could cause similar problems for a pump in a Rotamix system. To head off future problems, a careful pump startup is important. Verify correct pump rotation and take and record suction and discharge pressure readings and motor amperage readings to compare against future readings.
Page 16 Sometimes modifying the mixing pump to add finer chopper capability may also be an option. B. Nozzles need to be placed correctly in the tank as described by Vaughan Co. Rotamix nozzle plan drawings for the project. The nozzles also must be aimed correctly in accordance with Vaughan drawings.
Page 17 Troubleshooting foaming or RVE problems can be difficult because the causes of these problems are complex. b. Many of the causes of foaming and RVE are out of Vaughan Co.’s control, such as: i. Feeding a digester in slugs rather than continuously. The best way to avoid foaming is to spread out the feeding of new sludge over as much time as possible.
Page 18 The best approach is to install the Foambuster with the Rotamix system so that there is a way to control foaming right from the start. If foaming occurs after startup of the mixing system and a Foambuster has not been installed with the system, the recovery costs for installing a Foambuster are much higher.
Page 19: Warranty
Vaughan Co. to be free from defects in workmanship or material for a period of ten (10) years from date of shipment from Vaughan Co. If during said warranty period, any components of the mixing assembly wear or corrode through the walls of any of the nozzles or fittings under normal use in biological sludge mixing service, Vaughan Co.