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General Information
Hydro-Sludge™ Screen General Information
Overview
The Hydro-Sludge™ Screen is a horizontal in-line coarse material separator, comprising of four principle zones;
inlet, screening, pressing (compacting) and discharge. The feed from the inlet, enters the center of the screening
zone, where the coarse material retained on the inner surface of the perforated screen, is transported to the
pressing zone and onwards to the discharge by an Archimedean screw. Compacted coarse material (screenings)
is discharged into a suitable container, by the action of a regulated retention cone, controlled by a pneumatic
system linked the varying drive load (torque) of the drive motor.
Safety Precautions
The purpose of this Operation & Maintenance Manual is to ensure all personnel working with the plant are aware
of the safe and correct way to carry out any work. The instructions and information given are as explicit as is
reasonably practicable, however, competency and expertise are necessary in the operation and maintenance of
the machine, and to ensure reliable operation it is strongly recommended that such work is undertaken by only
experienced and authorized personnel.
Throughout this manual
Before carrying out any inspection, maintenance, repairs, overhauls or commissioning on the Hydro-Sludge™
Screen; this manual must be read in detail, and always ensure that the machine has been isolated from both its
control panel and the raw material feed, where necessary to ensure that accidental starting of the machine cannot
occur.
In addition to the above, full adherence with current health and safety rules, acts, laws and legislation must be
observed, along with specific site procedures.
The Hydro-Sludge™ Screen must not be operated without operational protection devices and
covers in place.
The Hydro-Sludge™ Screen must not be used if any alterations have been carried out to the
machine which affect its normal operational behaviour, and more importantly any alterations which
affect the safe operation of the machine.
If any of the above are observed, isolate the machine and inform the person or department responsible for the
machine.
On completion of any maintenance, all guards/covers must be properly refitted before power and feed are
reinstated and the machine restarted.
This manual should be read in conjunction with the Electrical and Pneumatic Control Panel Operation &
Maintenance Manual, associated with the Hydro-Sludge™ Screen.
The Hydro-Sludge™ Screen warranty will be invalidated, and Hydro cannot be held responsible for product
failure, if:
The machine is used for work for which it was not designed or intended.
© 2018 Hydro International O&M Manual
will be used to highlight important warning notes.
Hydro-Sludge™ Screen • Page 2.0-1
March 30, 2020

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Summary of Contents for Hydro International Hydro-Sludge Screen

  • Page 1 The Hydro-Sludge™ Screen warranty will be invalidated, and Hydro cannot be held responsible for product failure, if: The machine is used for work for which it was not designed or intended.  © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.0-1 March 30, 2020...
  • Page 2 The electrical devices fitted to the standard Hydro-Sludge™ Screen are not intrinsically safe, i.e. they are not explosion proof, and therefore must not be installed in hazardous locations. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.0-2 March 30, 2020...
  • Page 3 The discharged plug is gradually broken up against the retention cone, by the continual action of the cone opening and closing against the nozzle. These pieces are then normally collected in a skip or enclosed bagging © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.0-3...
  • Page 4 The screened outlet is recommended as an open gravity discharge, however an elevated discharge of up to 3 yards is acceptable. However, the start pressure must be adjusted to overcome the back pressure. Figure 3.b: Typical Hydro-Sludge™ Screen Process © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.0-4 March 30, 2020...
  • Page 5: Environmental Issues

    When dismantling the machine for disposal, take care to identify the materials correctly. Table 3.a provides a guide to the key components materials of a standard machine. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.0-5 March 30, 2020...
  • Page 6 Pneumatic air lines and coils O-Rings and gaskets Gearbox, Cyclo and Helical sections Other grease / lubricants Grease pipes to retention cone and gland packing seal. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.0-6 March 30, 2020...
  • Page 7: Installation

    Following delivery, after careful removal of any packaging materials, the machine should be checked for damage and prior to installation, Hydro International must be notified immediately if any damage is found. To install a machine for the first time or following repair, the following instructions must be followed: Lift the machine into position using appropriate and certified lifting equipment, such as a crane, ensuring •...
  • Page 8 / straps have been correctly tested before use. 30° - 90° Figure 4.c: Lifting Arrangement ALWAYS ENSURE THAT THE HYDRO-SLUDGE™ SCREEN IS BALANCED WHEN LIFTING. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.1-2 March 30, 2020...
  • Page 9 Dry the moisture probe, reset the panel, and start the machine. Check the span of control air to ensure that the control and cylinder pressures are equal at maximum drive • load (default 80%). © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.2-1 March 30, 2020...
  • Page 10: Data Collection

    % dry solids of the sludge. (This will have to be laboratory measured from samples taken.) • • % dry solids of the screenings. (This will have to be laboratory measured from samples taken.) © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.2-2 March 30, 2020...
  • Page 11: Maintenance Schedule

    Clean & inspect screening zone (see section 6.2.5, p5). ● Check gearbox oil levels (see section 6.1.6, p2). ● Carry out metal work checks (see section 6.2.7, p5). © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-1 March 30, 2020...
  • Page 12 For further information and details on the recommended types of oil, see Table 6.c, and for full details, including oil viscosity class chart, refer to the Sumitomo Buddybox information in the appendix, section 11.3.1. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-2...
  • Page 13 Table 6.d: Recommended Types of Oil for the Gearbox Manufacture Type of Grease Shell Omala Energol GR-XP Castrol Alpha MW Esso Spartan EP Total Carter EP Mobil Mobilgear © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-3 March 30, 2020...
  • Page 14: Inspections And Checks

    Operate the cone reversal system on the panel. • Open the discharge cover, item 256 and check that the retention cone, item 22, is fully back. • © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-4 March 30, 2020...
  • Page 15 All platform steelwork is hot dipped galvanized to BS EN ISO 1461 and needs to be examined every 6 months for corrosion. Any areas found to be affected, should be wire brushed and cold galvanized. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-5 March 30, 2020...
  • Page 16 Note - A spare screening zone screw & screen should be ordered once Lp = 40 mm (1.6 in.), as maximum adjustment is approximately 50mm (2.0 in.) and delivery time can be up to 8 weeks. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-6...
  • Page 17 Remove the screw covers items 240 and 256 and unscrew the outermost lock nut, item 15 on the pressing zone screw, using the adjusting bars, items 216. • Loosen grub screw, item 204 in the gearbox collar, item 358. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-7 March 30, 2020...
  • Page 18 As the pressing zone is located on casters, it can now be disconnected and moved aside, providing access • to both the screening and pressing zones. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-8 March 30, 2020...
  • Page 19 Carefully withdraw the screening zone screw from the body of the machine, taking care as the diameter • varying shaft sections pass through the stuffing box. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-9 March 30, 2020...
  • Page 20 Check the condition of the O-rings, items 39, in the intermediate flange, item 21, and replace if necessary. • Refit the intermediate flange and secure using two M8 countersunk fixings, items 139. • © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-10 March 30, 2020...
  • Page 21 Via the hole exposed when the ½” plug, item 150, was removed; ensure that the flange of the screen is fully • home up against the inlet casting. Re-fit the plug. Re-assembly of the Split Machine. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-11 March 30, 2020...
  • Page 22 Electrically disconnect the cable from the motor terminal box, noting terminal positions and numbers. Remove the 4 bolts from the motor flange that connect it to the X-adaptor on the gearbox. • © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-12 March 30, 2020...
  • Page 23 Working through the openings in the inlet casting from the removal of the access covers, refit the 6 no. M16 fixings, item 243. • If a new geared motor has been fitted, ensure that the unit is correctly filled with oil. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-13 March 30, 2020...
  • Page 24 In addition, the Hydro-Sludge™ Screen should be drained before shutdown, to ensure there is no sludge within the body of the machine and all lubrication points are well greased (see section 6.1). © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-14...
  • Page 25: Preventative Maintenance

    Grease content too high, not enough Sludge break-through solid or coarse matter to promote a Check sludge composition. plug. Throughput too high. Reduce feed flow rate. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-15 March 30, 2020...
  • Page 26 Adjust start pressure to above static pressure. back pressure. Failure to stop in Auto Check operation of transducer and Failed inlet pressure transducer. diaphragm for damage. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-16 March 30, 2020...
  • Page 27: Panel Faults

    Data is for a standard Hydro-Sludge™ Screen, however machines specifications can vary, therefore refer to the Build Log for the specific information. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.3-17 March 30, 2020...
  • Page 28: Parts List

    Screening Zone Screw (std - MS & 304 st/st) Screening Zone Screen Pressing Zone Screw Pressing Zone Screen NOTE: This relates to the required quantities for the standard Hydro-Sludge™ Screen machine. © 2018 Hydro International O&M Manual Hydro-Sludge™ Screen • Page 2.4-1 March 30, 2020...

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