instruction manual cono profundo

8/10/2019 Instruction Manual Cono Profundo

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Rev. 2

08-2010INTRODUCTION

6017M

1

For confidential use only. Not for circulation, distribution, or reproduction without prior

permission, in writing, by FLSmidth. All Rights Reserved.

FOREWORD

To ensure complete warranty coverage of the equipment, carefully read through and become

familiar with the instructions in this manual.

1. It is FLSmidth’ sincere desire that this equipment will provide dependable, efficient, and

economical operation throughout the entire period of service. To achieve this kind of

performance and ensure full warranty coverage, thoroughly read trough and understandthe contents of this manual before installing, adjusting, or operating the equipment.

2. The equipment, including the accessory equipment furnished but not built by FLSmidth,

must be stored, installed, operated, and maintained according to the instructions in this

manual to ensure the warranty coverage.

3. The instructions in this manual are based on the information that was available at the time

of issue of this manual. FLSmidth reserves the right to make subsequent changes to the

instructions without obligation to replace existing copies.

4. Documents, drawings, technical manuals, and all other information contained in this

manual, which has been provided in conjunction with the purchase of FLSmidth

products and services, are the property of FLSmidth, are confidential, and may not be

made public or copied.

a. FLSmidth will not furnish editable electronic copies of any data and/or drawingsat any time.

b. FLSmidth accepts no liability whatsoever for unauthorized changes and/or

alterations to the data that has been provided.

5. English is the governing language. When manuals are provided in both English and any

language other than English, THE NON-ENGLISH TRANSLATION IS PROVIDED

ONLY AS A CONVENIENCE. FLSmidth shall not be liable for damages caused

by errors in translation.

a. In case of minor discrepancies: The English translation will govern.

b. In the event of major discrepancies: Notify your FLSmidth representative

immediately. Refer to the “Offices” page in this manual for applicable addresses

and telephone numbers (see Table of Contents).

Copyright ©©©© 2009 by FLSmidth



Rev. 2

08-2010PRE-ERECTION ASSISTANCE

6017M

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Before You Erect It Your Way

Let Us Show You Our Way-

Read the Instructions

These instructions are based on years of field experience. The best procedures have been

selected from that experience and have been assembled in this manual in order to provide the

best-suggested methods of erection. Consider them. These instructions will save time and

money during the erection process.

But -

- If you believe you have a better way, call us first anyway.

- If you want assistance or a pre-erection conference before you start, call us.

- If problems should occur, call us at once.

Contact your FLSmidth representative. Refer to the “Offices” pages (see Table of Contents) for

contact information.



Rev. 2

08-2010

SPECIAL INSTRUCTION TO

EQUIPMENT ERECTORS

6017M

3



FLSmidth does not anticipate problems with the erection of this equipment; however, due to thenature of fabricated steel equipment, the erector may require a certain amount of field fit-up and

adapting work. This fit-up and adapting work is considered a normal part of erection, as well as

the use of such tools as come-a-longs, welding and cutting torches, and drift pins.

In case of problems, the following procedures will apply:

A. AISC “CODE OF STANDARD PRACTICE”

The AISC “Code of Standard Practice,” latest edition, specifically states under“Correction of Errors” that cutting, reaming, and the use of drift pins are a part of

standard erection practice:

“Normal erection operations include the correction of minor misfits by moderate

amounts of reaming, chipping, welding or cutting, and the drawing of elements into

line through the use of drift pins. Errors that cannot be corrected by the foregoing

means or that require major changes in member configuration are reported

immediately to the owner and fabricator by the erector. This is done in order toenable whoever is responsible either to correct the error or to approve the most

efficient and economic method of correction to be used by others.”

B. FABRICATION OR ENGINEERING PROBLEMS

1. Should a problem develop because of fabrication or engineering errors,

FLSmidth will not accept back charges; unless, they are authorized in

advance and in writing by your FLSmidth Project Manager.

2. Before corrective work is started, the erector must obtain an FLSmidth

Field Work Order that must include a cost limitation.

3. Payment may be refused for corrective work that is done without the above

authorization.

4. Authorized charges will be paid only based on standard direct field laborhours, material, and variable overhead. Other charges will not be allowed.

C. DRAWINGS AND ERECTION/INSTALLATION INSTRUCTIONS

1. Drawings and erection or installation instructions must be followed.

2. Minor Discrepancies

The drawings will govern in case of minor discrepancies.



Rev. 2

08-2010

SPECIAL INSTRUCTION TO

EQUIPMENT ERECTORS

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3. Major Discrepancies

a. In the event of major discrepancies, notify your FLSmidth representative

immediately.

b. Refer to the “Offices” page for contact information (see Table ofContents).

D. PROTECTIVE COATINGS

1. If a protective coating (paint, rubber, etc) is to be applied to the mechanism, it

may need to be applied to some parts before they are installed.

2. Parts that must be coated before installation are those that would be inaccessible

after installation.

3. Hold back paint 3" (76.2 mm) from all field welds.

4. Study the Erection Drawings carefully and determine field welded areas in

question before painting.

WARNING:

The fumes given off during welding and cutting can be injurious to theoperator’s health.

Some fumes, such as those produced when working with Zinc, Cadmium, and

painted surfaces, can be toxic



Rev. 2

08-2010RECEIVING AND INSPECTION

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A. RECEIVING AND INSPECTION

1. Although all possible precautions are taken to protect the equipment against

damage or losses during shipment, before accepting the shipment, CHECK all

items against the packing list for shortages, and inspect items for evidence of

physical damage.

2. If there are shortages or physical damages, notify the carrier immediately or

immediately note on the delivery ticket “Accepted, subject to full inspection after

unpacking.”

3. Notify FLSmidth within seven days (maximum) in case of shortages or

discrepancies in the amounts received according to the packing list. If notnotified, FLSmidth will not be responsible for replacing those items.

4. Keep a record of all claims and correspondence. Photographs are recommended.

B. PACKING BOXES AND COVERS

1. Do not remove protective covers unless there are indications of damage.

2. Boxes opened for inspection and inventory should be carefully repacked to

ensure protection of the contents, or the parts should be packaged and stored in a

safe place.

3. Examine all packing boxes, wrappings, and covers for items that may be attached

to them, especially if they are to be discarded.

4. Refer to the “Storage and Precautions” instruction (see Table of Contents).

C. SHIPPING BRACES AND BARS

1. All braces, bars, etc, which are required for shipment, but are not a part of themechanism, should not be removed until necessary for either installation or

removal from the carrier.

2. Shipping braces are marked “SHIPPING BRACE ONLY” with white painted

letters, or the braces are painted purple.

D. STORAGE

1. If the equipment is not to be installed immediately, refer to the “Storage and

Precautions” instruction (see Table of Contents).



Rev. 2

08-2010RECEIVING AND INSPECTION

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2. The information in this instruction is important to ensure warranty protection.

E. ERECTION BOLTS

1. CHECK the types and quantities against the packing lists to avoid shortages later

during assembly.



Rev. 2

08-2010STORAGE PRECAUTIONS

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For confidential use only. Not for circulation, distribution or reproduction without prior


A. CORROSION AND DAMAGE

Equipment that is stored or that is out of use more than thirty days must be protected

against corrosion and damage.

B. ACCESSORY EQUIPMENT

For storage and maintenance of the equipment that is furnished but is not built by

FLSmidth, refer to the manufacturer’s instructions (see Table of Contents).

C. EIMCO®®®® Drive Equipment

Failure to comply with these storage instructions will void the FLSmidth warranty.

1. Drive Shipped from the Factory

a. An EIMCO® drive that is received in shipment can be stored as long as

24 months; these 24 months include the time in transit. No special

precautions are required other than those listed below.

b. All drive unit machined surfaces are coated with LPS #3 (or an equivalent

product), which is a rust inhibitive agent good for approximately 24 of

months storage.

c. No storage oil is required, and in fact, must not be used, since LPS #3

will dissolve in oil or most other petroleum based products.

d. Do not add oil, etc to the drive unit until it will be operated.

e. If the drive storage time is to exceed 24 months, contact FLSmidth SAC

Minerals for long-term storage information.

2. Store Drive

a. Store the drive set up in normal operating position.

b. If possible, store the drive indoors in a dry, well-ventilated place with a

relatively constant temperature.

c. Do not add oil. See section “C.1.Drive Shipped from Factory” in thisinstruction.



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3. If the Drive Must Be Stored Outdoors

When the drive equipment is not installed, but must be stored outdoors:

a. Use wooden blocks that are arranged for even and firm support to elevate

the drive equipment above ground.

1) Shipping crates or skids will often do.

2) CHECK to make sure that the storage area is not located wherewater can collect.

b. If the drive equipment’s protective covers have been removed ordamaged, cover the equipment with canvas or protective tarpaulin.

1) Allow adequate ventilation.

2) Do not use space heaters.

c. Whenever possible, store the drive equipment in a shaded area protected

against the sun and wind. This area should be located away from moving

equipment.

D. DRIVE INSTALLED: LONG TERM STORAGE INSTRUCTIONS

1. Non-Operation or Shutdown Period PRECAUTIONS

The following precautions cover non-operation or shutdown periods that exceed

two months. They apply to the EIMCO® drive or the accessory mechanicaldrive equipment that has been installed and operated.

a. Keep records and schedules to ensure compliance with these instructions.

b. Failure to comply with these storage instructions will void the

FLSmidth warranty.

c. Because LPS #3 will dissolve in oil and is compatible with oil, it is notnecessary to remove the LPS #3 with solvents before adding oil.



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2. Plan #1: Power Available

a. When power is available, lubricate and operate the equipment about five

minutes each day, or run the equipment through a complete cycle once

each week.

b. Remove accumulated water from the drive, each month, at the drain plugs.

c. Refer to the accessory equipment manufacturer’s instructions foradditional information.

WARNING:

In climates where snow and ice might accumulate in the tank, do not operatethe drive. Follow the instructions in the “D.3.Plan #2: No Power Available”section of this instruction.

3. Plan #2: No Power Available

a. Fill the main drive housing and upper bearing housing assemblies with

clean oil to the maximum level.

Note: A rust inhibitive agent is recommended for adding to the oil.

b. CHECK that all greased bearings are well lubricated.

c. Cover seals, screws, chains, and guides with heavy grease and cover

breather caps with tape.

d. Cover the main drive housing and upper bearing housing assemblies with

tarpaulins, but make sure to allow adequate ventilation.

e. Space heaters or dehumidifiers should operate continuously.

f. Once each month, open drain plugs to remove accumulated water and

return oil to maximum level.

g. Monthly, CHECK all greased items for adequate covering.



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h. When the storage period extends into seasonable warm or cold weather,

1) Drain the main drive housing and upper bearing housing

assemblies and flush them with oil to remove residual water after

the storage period.

2) Do not flush them with solvents.

3) Refill them with oil up to their normal operating level.

WARNING:

Before the drive equipment is put into operation after storage,(1) Drain all oil and lubricate according to instructions.

(2) Re-lubricate all greased bearings and pump out old grease.

(3) CHECK motor windings.

(4) Refer to accessory equipment manufacturer’s instructions.

E. STORAGE PRECAUTIONS: STRUCTURAL

1. Inspect painted surfaces for deterioration of paint and apply finish coats as soon

as possible. When this is not possible, remove rust or corrosion and paint, asnecessary.

2. Shop Primed Steel Equipment

Shop Primer Paint Durability PRECAUTIONS

a. Shop primer paints are intended to serve only as a bonding coat between

metal surfaces and protective finish or seal coats and to act as a minimal protective finish.

b. FLSmidth will not be responsible for the condition of primed or finish

painted surfaces after the equipment leaves its shops.

c. Purchasers are invited to inspect the painting in shops for proper

preparation and application prior to shipment.

d. FLSmidth assumes no responsibility for field surface preparation or touch

up of shipping damage to paint.

e. Painting of fasteners and other touch-ups to painted surfaces will be bythe Purchaser’s painting contractor after mechanism erection.



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3. Identification tags that are removed for painting prior to assembly must be

reattached to the original components for correct identification.

Note: Assistance from FLSmidth will be charged at the normal service rate.

4. Plates, Signs, Nameplates, Etc

a. Lubrication plates, WARNING and CAUTION signs, and the FLSmidth

nameplate must be masked off prior to field painting.

b. Do not remove these signs/plates from the drive.

c. After field painting is completed, CHECK to make sure that theLubrication plates, WARNING and CAUTION signs, and the FLSmidth

nameplate are clearly visible and readable.

DRIVE UNIT VENT CAUTION:

Vent holes in vented pipe plugs and sight glass vent openings must be kept

clear of dirt, paint, and other foreign material.



Rev. 2

08-2010DRIVE PRECAUTIONS AND WARNINGS

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Failure to heed these WARNINGS will void the drive and hydraulic power unit

warranties!

LUBRICATION WARNING:

The drive unit is shipped from the factory without operating lubricant.

HYDRAULIC POWER UNIT AND SYSTEM:

The hydraulic oil system and power unit require special care during installation

and start up. Refer to the “Install the Hydraulic Power Unit” installationinstructions (see Table of Contents).

SANDBLASTING WARNING:

The EIMCO® main drive unit, each of the drive’s input drive (reducer and

hydraulic motor) and upper bearing housing assemblies, and hydraulic power unit

must be fully covered and sealed off to protect against sand and dust when

sandblasting in the vicinity.

All external openings, vents, breathers and areas between the rotating parts must be covered with air tight covers and taped closed, especially the hydraulic power

unit, its accessories and the hydraulic motors.

After sandblasting and before start-up, drain a portion of oil from the main drivehousing, each upper bearing housing assembly, each input drive reducer, and the

hydraulic power unit to be sure that dust has not penetrated any of the drive

system components. Remove all protective covers.

Sand dust or other foreign material must not enter into the main drive mechanism

or hydraulic power unit.

WELDING WARNING:

The fumes given off during welding and cutting can be injurious to the operator’s

health.

Some fumes, such as those produced when working with Zinc, Cadmium, and

painted surfaces, can be toxic.

Use the piece being welded as the ground to prevent drive unit damage due to

electrical circuit contact.



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DRIVE DIRECTION OF ROTATION:The drive and its input drive assemblies must rotate in the direction specified onthe General Arrangement Plan drawing.

TORQUE CONTROL WARNING:

Before the drives are operated, the primary drive torque control must be properlyinstalled and checked for operation, as specified in the General Drive

Maintenance instructions.

Electrical wiring (not by FLSmidth) must be installed, as specified on the wiring

diagram drawings and in the individual components manufacturer’s instructions.All interconnecting wiring must meet Local and National Electrical Codes.

The Hydraulic Power Units pump motor must be wired so that an automatic

restarting of the pump motor cannot occur after a shutdown, following a torque

overload.

A. SAFETY SIGNS

1. Area Safety Signs

a. Safety signs should be installed to alert anyone entering dangerous areas.

b. Several safety signs may be required. These signs should be located so

that they can be seen from any direction the equipment might be

approached.

2. Suggested text for these signs in the appropriate language(s) would be:

WARNING:

EXPOSED MOVING PARTS – KEEP AWAY



Rev. 2


6017M

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WARNING:

LOCK OUT POWER

BEFORE

PERFORMING MAINTENANCE

3. If personnel working with this equipment cannot readily read or understandEnglish, the WARNING signs on the equipment and the procedures that are set

forth in this manual must be translated and must be provided for their benefit in a

language that they can understand.

Note: Multilingual signs may be needed.

4. Sign Location

Location of signs will depend upon the specific design and placement of the

equipment.

a. Signs may be located above catwalks, affixed to walls adjacent to the

equipment, or on the equipment itself.

b. CHECK to make sure that the WARNING signs are visible to theoperator during operation and visible to persons who may be approaching

the area of the machine.

B. EQUIPMENT SAFETY SIGNS (by FLSmidth Minerals)

1. Safety and WARNING signs are shop mounted to the equipment.

2. These signs must be kept clean and must not be covered up.

3. If these signs become damaged or if they deteriorate, replace them.



Rev. 2

08-2010

LIFTING PRECAUTIONS

-STRUCTURAL-

AND SHIPPING BRACES

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WARNING: Do not pull, drag, push, or dump the structural components off the carrier.

– All structural components should be lifted and handled as covered in this instruction.

– Proper handling is necessary to protect special coatings or coverings and to ensure ease of

assembly during equipment installation.

– FLSmidth will not accept charges for repair or replacement of equipment or materials

damaged due to improper handling.

A. LIFTING RECOMMENDATIONS AND CAUTIONS

Observe these PRECAUTIONS when lifting or handling structural components that are

furnished by FLSmidth:

WARNING: Stand clear as the equipment is lifted.

1. CHECK to make sure that the equipment being lifted and the lifting equipmentcannot come into contact with overhead electrical cables, etc.

2. CHECK to make sure that the rigging and hoist equipment are of adequate liftingcapacity.

Note: Weights for major components are listed in the parts list.

3. Experienced personnel should do all rigging and lifting.

4. Before removing the equipment from the carrier, CHECK to make sure that the

blocking, bracing, and banding that are securing it to the carrier have beenremoved, and CHECK to make sure that the equipment is ready to be moved.

5. Use multiple-point lifting whenever possible.

6. When lifting structural members of this equipment, such as the rake arms,

superstructure sections, etc, avoid twisting or bending the members.

Note: Use spreader beams, as necessary, to fully support the pieces as they arelifted.



Rev. 2

08-2010

LIFTING PRECAUTIONS

-STRUCTURAL-

AND SHIPPING BRACES

6017M

16



7. CHECK to make sure that the shop provided camber is maintained when lifting

the superstructure sections.

8. Lift the equipment an inch (mm) or two off the carrier to make sure that it is free

to be moved and that it is balanced correctly. Adjust, as necessary.

9. Do not move the equipment suddenly or in jerks. Do not allow the equipment to

strike the ground, tank, or other equipment.

10. When lifting components, use rubber belting, burlap, or other padding betweenthe lifting cables and the equipment to prevent damage to the protective

coverings.

Figure 1

B. SHIPPING BRACES

1. Shipping braces may be used to protect the segmented superstructure and the rakearms from damage during shipping. This bracing must be removed.

Note: Shipping braces are marked “Shipping Brace Only” in white or purple

painted letters.

2. Burn the braces from the chords, angle braces, or structural members, as

required.

3. Do not attempt to scarf braces, as this may cause weakening of the structural

members.



Rev. 2

08-2010TANK ERECTION

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A. TANK ERECTION

It is the tank erector’s responsibility to construct the tank in accordance with the API 650

Code. Dimensional tolerances of erection shall meet the API 650 Code. It is also thetank erector’s responsibility to inspect and test the welds in accordance with API 650

Code. Refer to the drawings in the “Certified Drawings” section (see Table of Contents)

and to the tank manufacturer’s instructions and drawings.

1. FLSmidth is not responsible for difficulties caused by negligence, inadequate

skill, or inexperience of the erection crew. Refer to the “Special Instructions toEquipment Erectors” instruction (see Table of Contents).

2. Knock Down “KD” tank shell plates will be shipped direct from the fabricator.

a. Refer to the tank erection drawings and plate match-mark numbers

furnished by the fabricator to identify the respective tank sections.

b. CHECK for orientation of superstructure support brackets, launder

sections, etc.

Note: This orientation of the tank is important and must be followed

carefully during tank erection.

3. The tank plates and structural components will be fabricated as large as shippingrestrictions will allow.

a. Tank plates will be rolled for horizontal courses. Vertical courses are not

allowed.

b. Field erection clips will be furnished, as necessary.

4. Erect the Tank

Refer to the tank manufacturer’s instructions and drawings.

Note: Tank erection is not by FLSmidth.

5. Tank Shell Erection

a. In erecting the tank shell, the tank plates of the courses must bestaggered.

b. Vertical welded seams between successive courses should be offset from

each other a minimum of 1'-0" (305 mm).



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c. CHECK to make sure of the orientation of the fabricated details before

setting the courses.

d. Welded Seams

1) All welded seams in the sidewall should be double butt-welded.

2) The joint between the tank shell and bottom plates should be fillet

welded on both sides.

3) All welds are to be watertight and must conform to API 650*

“Standards on Tank Components.”

4) Hold back paint 3" (75 mm) from all field welded seams.

e. Exercise CAUTION to avoid warping or buckling.

f. As the erection proceeds, CHECK the tank for plumb, roundness, and

concentricity with the center.

g. The top edge or rim angle must be level all around.

h. It is suggested that welded items be tack welded first and then, checked

against the tank erection drawings before final welding.

6. Integral circular launders, as furnished, must be level all around and at specified

elevation.

Note: This also applies to overflow boxes, discharge cones, and any other itemsthat might be integral parts of the tank shell.

7. Mounting Holes, Openings, Nozzles, and Wall Spools

a. Mounting holes or openings may be either drilled or burned, but they

must be reasonably accurate. The edges of burned holes must be groundsmooth.

b. When nozzles or wall spools are installed, use the piece to be welded as a

template to mark the size and shape of the required hole on the tank wall

and then, burn the hole as marked.

c. All items must be carefully oriented and positioned, and the nozzles andwall spools must be level and at their specified elevations.



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8. Superstructure Supports

a. The orientation of the superstructure supports must conform to the

General Arrangement Plan drawing.

b. The supports must be in alignment with the centerline of the tank and at

the required elevation.

9. Items that do not weld to the tank, such as weirs, will be installed later.

10. All other items that weld to the tank can be installed during tank erection.

11. Radiography and Hydro-testing

a. Radiography testing shall be performed, as required, per API 650*

Section 6.

b. Hydro-testing shall be performed, as required, per API 650* Section 5.

c. Radiography and Hydro testing is not by FLSmidth.



Rev. 2

08-2010CHECK THE TANK

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Reference Drawings: General Arrangement Elevation, General Arrangement Plan

A. TANK

The tank must conform to certain specifications in order to accommodate the

mechanism. If the tank fails to meet these specifications and requires any modifications

of the equipment, FLSmidth will not accept charges.

Figure 2

1- Superstructure mounting surfaces(superstructure support columns)

5- Wall diameter 14- Tank centerline

2- Tank bottom center 8- Launder 15- Top of rim angle

3- Bottom of discharge cylinder 9- Tank bottom specified slope: 30° 16- Top of radial beam

4- Tank true center 11- ELEVATION VIEW

Reference drawing: General Arrangement Elevation

1 1

2 3

5 5

8 8

911

14

1515

16



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Figure 3

4- Tank true center 7- Superstructure mounting bolt holes 10- PLAN VIEW

6- Centering of discharge cylinder 8- Launder 12- Tank wall

Reference drawing: General Arrangement Plan 13- Superstructure centerline

CHECK the Tank as Follows (See Figures 2 and 3):

1. CHECK the elevation at the superstructure mounting surfaces (superstructuresupport columns) at (1) only.

77

8

12

13

10

4

6



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2. CHECK the elevation at the tank bottom center at (2) and at the bottom of the

discharge cylinder at (3).

3. CHECK for true center at (4).

4. Use true center at (4) to CHECK for proper diameter of the tank wall at its

circumference (5) and to CHECK for diameter and centering of the discharge

cylinder at (6).

5. CHECK the superstructure mounting bolt holes locations (7) for alignment withtrue center at (4) and for correct orientation.

6. The launder at (8) must be the size specified and must be at the elevationspecified.

7. CHECK the tank bottom for specified slope (9) on top of the radial beams.

CHECK the tank bottom for slope at approximate 90o locations around the tank,

on top of the radial beams.

Note: Do not check the slope of the tank bottom in the scallops. Checking

must be done on top of the radial beams.



Rev. 2

08-2010

HIGH STRENGTH BOLTS

(H.S. BOLTS)

TIGHTENING INSTRUCTION

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A. HIGH STRENGTH (H.S.) BOLTS (ASTM A325)

1. High Strength Bolts (H.S. Bolts) must be used where shown and specified. Refer

to the General Erection and Connection and Fastener List drawings.

2. Assembly Instructions: Turn-of-Nut Method

a. All joint surfaces shall be free of loose mill scale, burrs, and foreign

material.

b. Enough bolts shall be brought to a “Snug Tight” condition to insure that

the parts of the joint are properly compacted (i.e. brought into full contact

with each other).

1) Snug Tight: The tightness attained by a few impacts of an impact

wrench or the full effort of a man using an ordinary spud wrench

following the initial tightening.

c. Bolts shall be placed any remaining holes in the connection and brought

to snug tightness.

d. All Bolts in the joint shall be tightened additionally by the applicable

amount of nut rotation, specified in the “Turn-Nut-Method” table in this

instruction, with tightening progressing systematically from the most rigid part of the joint to its fee edges.

TURN-OF NUT METHOD

Disposition of Outer Faces of Bolted Parts

Bolt Length

(As measured from the under sideof head to extreme end of point)

Both faces normal to bolt axis One face normal to bolt axis andother face sloped not more than1:20

(bevel washer not used)

Both faces sloped not more than1:20 from normal to bolt axis

(bevel washer not used)

Up to and including 4 diameters 1/3 turn 1/2 turn 2/3 turn

Over 4 diameters but notexceeding 8 diameters

1/2 turn 2/3 turn 5/6 turn

– Nut rotation is rotation relative to the bolt, regardless of the element (nut or bolt) being turned.

– Tolerance on Rotation: 30 over or under

– For other than Turn-of-Nut Method, follow the procedures outlined in the latest edition of the AISC Steel Construction Manual.

– To ensure that proper torque has been achieved, spot checking the bolts with a torque wrench is recommended.

3. Do not torque tighten the High Strength Bolts until all final adjustments are

completed.

4. Do not reuse the High Strength Bolts after they have been torque tightened.



Rev. 2

08-2010

HOLD BACK PAINT

INSTRUCTION

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A. HOLD BACK PAINT FOR FIELDS WELDS

Figure 4

1- Field welds 2- No paint 3- 3" (76.2 mm)

1. It will be necessary to hold back paint for field welding on all steel.

2. Study the erection drawings carefully to determine field weld areas in question.

3. Paint must be held back 3" (76.2 mm) from all field welds. See Figure 4.

2

1

33

3

3



Rev. 2

08-2010

PLACE RAKE SHAFT ASSEMBLY

IN POSITION IN THE TANK

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Reference Drawings: General Erection, Connection and Fastener List

– Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions” (see Table of

Contents) for information on snug tightening and torque tightening the H.S. Bolts.

Figure 5

1- Lower rake shaft 4- Straight edge 7- 1’ – 00” (305 mm)

2- Upper and lower rake shaft connecting flanges 5- Equal thickness blocks 8- High Strength bolts

3- Upper rake shaft 6- Measure these two places at 90° intervals around the lower rake shaft.Run-out must not exceed 1/32” (0.79 mm).

A. ASSEMBLE AND ALIGN THE UPPER AND LOWER RAKE SHAFTS

The upper and lower rake shafts will be assembled and aligned outside of the tank. Once

the rake shaft assembly is aligned, it will be placed in position in the tank.

1. Set up blocking that is arranged at the same height and level.

12

3

45

67

8



Rev. 2

08-2010



6017M

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a. Because the cylinder scraper is part of the lower rake shaft, make sure the

blocking is set to keep the cylinder scraper from contacting the ground.

b. If necessary, set up blocking to support the cylinder scraper portion of thelower rake shaft.

2. Set the upper and lower rake shafts on the blocking.

3. Use the H.S. bolts, nuts and washers specified to connect the upper rake shaft to

the lower rake shaft. See Figure 5.

a. Snug tighten the H.S. bolts only at this time; do not torque tighten them.

b. Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions”

instruction (see Table of Contents).

4. CHECK the lower rake shaft for alignment (run-out). See Figure 5.

a. Use a long straight edge and two blocks of equal thickness.

b. Measure the distance from the straight edge face to the upper rake shaft,

at two points 1’ – 00” (305 mm) above the rake shaft flanges.

c.

The measurements must be within 1/32" (0.79 mm).

d. CHECK in two places (90o) on the rake shaft.

5. Adjust the lower rake shaft for alignment, if necessary. See Figure 6.

a. Shim between the connecting flanges of the rake shafts.

b. Place the shims (not by FLSmidth) adjacent the H.S. bolts.

c. Snug tighten the H.S. Bolts only. Do not torque tighten them at this time.

d. RECHECK rake shaft alignment.

e. Continues process until the upper and lower rake shafts are aligned.

6. After the rake shafts are aligned, torque tighten the H.S. Bolts at the lower rake-to-upper rake shaft connections. Refer to the “High Strength Bolts (H.S. Bolts)

Tightening Instructions” instruction (see Table of Contents).



Rev. 2

08-2010



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Figure 6

1- To align the rake shaft, place shims adjacent to the H.S. bolts, as necessary

B. PLACE THE GUIDE POCKET AND RAKE SHAFT ASSEMBLY IN THE TANK

(See Figure 7)

1. Place the guide pocket in the bottom of the discharge cylinder.

2. Lift the rake shaft assembly.

3. Place the rake shaft assembly into the tank in the discharge cylinder; insert the bottom of the rake shaft assembly into the guide pocket. Refer to the GeneralErection drawing.

4. Use temporary shoring, as required to support the rake shaft assembly in position.

5. Do not install the wear plates on the guide pocket at this time. Do not weld the

guide pocket to the discharge cylinder at this time.

1



Rev. 2

08-2010



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Figure 7

1- Tank 2- Discharge cylinder 3- Guide pocket

Reference drawing: General Erection 4- Rake shaft assembly

1

2

3

4



Rev. 2

08-2010SUPERSTRUCTURE INSTALLATION

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Reference Drawings: Superstructure Erection, Grating Clip Assembly, Connection and

Fastener List, General Arrangement Plan, General Arrangement Elevation, Torque Values

– Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions” (see Table ofContents) for information on snug tightening and torque tightening the H.S. Bolts.

– Refer to the “Hold Back Paint Instruction” (see Table of Contents).

A. SUPERSTRUCTURE INSTALLATION

1. Pre-Installation CHECKS

a. CHECK the elevation of the superstructure mounting surfaces. Refer tothe “CHECK the Tank” instruction (see Table of Contents).

b. CHECK the alignment of the superstructure support columns and the

superstructure mounting surfaces with relationship to the centerline of the

tank. Refer to the General Arrangement Plan drawing.

2. Superstructure Erection

a. Outside of the Tank

1) The superstructure sections may be completely assembled on theground and then, lifted into place on the tank.

a) If the superstructure is assembled on the ground, it must

be assembled on supports (blocking) that are level in the

same plane and that simulate the surfaces of the tank.

b) Blocking must be used from the ground to support the

center span of the superstructure and to hold the shop

provided camber during assembly.

c) Splice plates, High Strength bolts, and welds will join andhold the superstructure sections together.

b. In Position on the Tank

1) The superstructure sections may be completely assembled in position on the tank.

a) If the superstructure is assembled in position on the tank,

the sections must be supported with shoring.



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b) The shoring must fully support the sections of the

superstructure and be assembled so that the sections hold

the shop provided camber of the superstructure during

assembly.

c) Splice plates, High Strength bolts, and welds will join and

hold the superstructure sections together.

Figure 8

1- Superstructure support column 4- Superstructure end 8- Washer

2- High strength bolt 5- Mounting plate 9- Nut

3- Superstructure 6- Slide plate (UHMWPE) 10- FIXED END

Reference drawing: Superstructure Erection 7- Floating plate 11- SLIDING END

4

2

5 6

1

7

10 11

9

8

3

2

1

9

8



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3. Slide, Floating, and Mounting Plates (See Figure 8)

Regardless of where the superstructure is assembled (outside or in position on the

tank), the slide, floating, and mounting plates must be placed in position on thesuperstructure support columns.

a. Slide and Floating Plates (See Figure 8)

Refer to Illustrative Elevation on the Superstructure Erection drawing.

1) The slide and floating plates are located at the sliding end of the

superstructure; opposite the fixed end of the superstructure and on

the same end of the superstructure as the feed tank (E-Ducsystem). Refer to the General Arrangement Elevation drawing.

2) Place the slide plates in position on top of the superstructure

support columns.

a) CHECK to make sure that the holes in the slide plates are

aligned with the mounting holes in the superstructuresupport columns.

b) Because the slide plates are made from an UHMWPE

material, it does not matter which side is up or down.

3) Place the floating plates on top of the slide plates.

a) CHECK to make sure that the holes in the floating plates

are aligned with the holes in the slide plates and supportcolumns.

b. Mounting Plates (See Figure 8)

Refer to Illustrative Elevation on the Superstructure Erection drawing.

1) The mounting plates are located at the fixed end of the

superstructure; opposite the feed tank end of the superstructure.Refer to the General Arrangement Elevation drawing

2) Place the mounting plates in position on top of the superstructuresupport columns.

3) CHECK to make sure that the holes in the mounting plates are

aligned with the mounting holes in the support columns.



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4. Assemble the Superstructure Sections (See Figures 9 and 10)

Assemble the superstructure sections outside the tank on blocking or inside the

tank on shoring, depending on the method of assembly.

a. Camber

The superstructure sections must be cambered during assembly. See

Figure 9. Refer to Superstructure Camber Diagram on the Superstructure

Erection drawing.

Figure 9: Camber Diagram

1- 66' – 1" (20,142 mm) 3- Superstructure End: 24' – 11 ¼" (7,600 mm) 5- Splice centerline

2- Superstructure: 41' – 1 ¾" (12,541 mm) 4- 1" (25 mm) camber

Refer to Superstructure Camber Diagram on the Superstructure Erection drawing

b. Bottom and Top Chord Splice Connections

Use the H.S. Bolts, nuts, and washers specified to connect the

superstructure to the superstructure end. Refer to View ‘A’ – ‘A’ andSection B – B on the Superstructure Erection drawing.

c. Splice Plates (Chord and Diagonal) [See Figure 10]

Use the splice plates (chord) and splice plates (diagonal), along with theH.S. bolts, nuts, and washers specified to connect the superstructure to the

superstructure end. Refer to Illustrative Elevation, Detail ‘1’, Detail ‘2’,

and Detail ‘3’ on the Superstructure Erection drawing.

12 3

4

5



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Figure 10

1- Superstructure 5- Splice plate (chord) 9- Weld as specified

2- Superstructure End 6- Splice plate (diagonal) 10- Detail ‘1’

3- Splice plate (chord) 7- Splice plate (diagonal) 11- Detail ‘2’

4- Splice plate (chord) 8- H.S. Bolt, nut, and washer 12- Detail ‘3’

Reference drawing: Superstructure Erection

d. Top Chord Struts

Do not install the top chord struts with splice plates (top chord) at this

time. They will be installed with the monorail after the drive andhydraulic power unit have been installed on the superstructure. Refer tothe “Install the Top Chords and Monorail” instruction (see Table of

Contents).

1

1

1

2

2

2

3

3

4

4

3

3

4

4

5

5

6

6

7

8

8 8

8

8

8

88

89

9

9

9

9

9

1011

12



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e. Top Chord Diagonal

Do not install the top chord diagonal at this time. It will be installed after

the feed tank has been installed on the superstructure. Refer to the “Installthe E-Duc System” instruction (see Table of Contents).

f. High Strength Bolts (H.S. Bolts)

1) Snug tighten the H. S. bolts only at this time; do not torque

tighten them. They will be torque tightened after thesuperstructure has been checked for camber.

2) Refer to the “High Strength Bolts (H.S. Bolts) TighteningInstructions” instruction (see Table of Contents).

5. CHECK for Camber (See Figure 9)

a. Before the before the H.S. bolts are torque tightened and the splice plate

connections are final welded, CHECK the superstructure for camber.

b. Adjust the superstructure and superstructure end, as needed.

6. Torque Tighten the High Strength Bolts

a. After the superstructure has been checked for camber, and before theshoring is removed or the superstructure is lifted off the blocking for

installation on the tank, torque tighten the H. S. bolts.

b. Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions”instruction (see Table of Contents).

7. Final Welds (See Figure 10)

a. After the H.S. Bolts have been torque tightened, and before the shoring is

removed or the superstructure is lifted off the blocking for installation onthe tank, final weld:

1- The splice plates (chord and diagonal) connections

2- The superstructure-to-superstructure end bottom and top chord

splice connections

b. Refer to the Superstructure Erection drawing.

c. Refer to the “Hold Back Paint Instruction” (see Table of Contents).



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8. Remove the Shoring or Install the Superstructure

a. If the superstructure was erected in position on the tank, remove the

shoring.

b. If the superstructure was erected on blocking outside the tank, install the

assembled superstructure on the tank.

c. Use multi-point lifting to lift the assembled superstructure.

9. Tighten the Anchor Bolts (See Figure 8)

a. Slide and Floating Plate End of the Superstructure Anchor Bolts

The anchor bolts at the slide and floating plate end of the superstructure

must only be finger tightened to allow for expansion and contraction of

the superstructure during temperature changes.

1) Finger tighten the anchor bolts at the end of the superstructure

where the slide and floating plates are located.

2) After the anchor bolts are finger tightened, peen the threads of the

bolts. Refer the Superstructure Erection drawing.

b. Mounting Plate/Fixed End of the Superstructure Anchor Nuts

1) Torque tighten the anchor bolts at the fixed end of the

superstructure where the mounting plates are located.

2) Refer to the “High Strength Bolts (H.S. Bolts) Tightening

Instructions” instruction (see Table of Contents).

3) After the anchor bolts are torque tightened, peen the threads of the

bolts.

B. SUPERSTRUCTURE GRATING

See Figure 11. Refer to section B-B on the Superstructure Erection drawing. Refer to the

Grating Clip Assembly drawing.

1. Install the grating for the superstructure. Refer to the part numbers and match

marks, if used.



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2. Use the grating clip assemblies (clamps, machine screws, and nuts) specified to

secure the grating to the walkway and platform sections of the superstructure.

3. CHECK to make sure that the grating fits together without any dangerous gaps oropenings.

4. The grating must fit flush without sharp corners or edges, and the grating must

be secure.

Figure 11

1- Superstructure (reference) 3- Top clip 5- Machine screw

2- Grating (reference) 4- Bottom clip 6- Nut

Reference drawing: Grating Clip Assembly

14

235

6



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C. SUPERSTRUCTURE HANDRAILS

Refer to the Superstructure Erection drawing. See Figures 12 and 13.

1. Install the handrails and handrail ends for the superstructure.

a. Refer to View H – H, Section F – F, Section G – G, and Section B – B on

the Superstructure Erection drawing. See Figure 12.

Figure 12

1- Superstructure 5- Grating (reference) 9- Capscrew, nut, washer, and bevel washer

2- Superstructure end 6- Splice plate – WW 10- View H – H

3- Handrail 7- H.S. bolt, nut, and washer 11- Section F – F

4- Handrail end 8- Capscrew, nut, and washer 12- View G – G


1 2

1 2

3 3

4 4

5

6

7

8

8 9

11

10 12



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b. Because some of the handrail sections will be joined with splice locks, it

will be necessary to install the splice locks on the handrails specified

before these handrails are attached to the superstructure. Refer to

Illustrative Elevation on the Superstructure Erection drawing.

Figure 13

1- Handrail 2- Handrail 3- Splice lock

4- Screws

2. Handrail Splice Lock Installation (See Figure 13)

a. Remove the screws from the splice lock fitting. Insert the splice lock intoone end of the handrail.

b. Line up the tapped hole with the matching hole in the handrail. Replace

the screw for that side, but do not tighten it.

c. Install this section of handrail on the superstructure.

d. Install the next handrail section.

1

3

2

4



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e. Slide the mating handrail over the projecting end of the splice lock.

Replace the second screw of the splice lock fitting.

f. Once the handrail sections are all installed and adjusted, tighten bothscrews in the splice lock.

1) When the screws are tightened, this causes the lock to expand and

grip the inside of the handrail.

2) The screws are always on the underside of the handrail.

3. Use the capscrews, nuts, washers, bevel washers specified to secure the handrails

and handrail ends to the superstructure.

4. Snug tighten the capscrew only at this time; do not torque tighten them.

5. Handrail Toe Plate Splices (See Figure 12)

a. Connect the platform handrail toe plate splices. Refer to Section F – F on

the Superstructure Erection drawing.

b. Use the splice plates - ww, H.S. bolts, nuts, and washers specified to

secure the handrail toe plate splices together.

c. Snug tighten the H.S. bolts only at this time; do not torque tighten them.

6. CHECK to make sure that the handrails are plumb, square, and level. CHECK to

make sure that all edges and corners are smooth.

7. Tighten the Fasteners

After the handrails have been checked and adjusted, tighten all fasteners.

a. Capscrew

1) Torque tighten the capscrews at the handrail-to-superstructure

connections.

2) Refer to the Torque Values drawing.

b. H.S. Bolts

1) Torque tighten the H.S. Bolts at the handrail toe plates-to-splice

plate - ww connections.



Rev. 2


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Instructions” instruction (see Table of Contents).

c. Splice Lock Screws

Tighten the screws in the splice locks that are connecting the handrails.

D. NAMEPLATE

Refer to the Superstructure Erection drawing.

1. Install the FLSmidth nameplate on the handrail at the fixed end of the

superstructure.

2. Use the capscrews and nuts specified to secure the nameplate to the handrail.



Rev. 2

08-2010DRIVE UNIT INSTALLATION

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The drive unit is shipped fully assembled.

A. LIFT THE DRIVE UNIT

1. Use all of the lifting eyes on the drive base (at the sides of the drive housing) to

lift the drive unit.

2. Keep the drive unit level at all times.

B. INSTALL THE DRIVE UNIT

1. Before Drive Unit Installation

a. CHECK the bottom of the drive base housing for foreign matter.

b. CHECK the mating surface of the drive platform on the superstructure for

spatter or other foreign matter.

c. Remove spatter and foreign matter, as necessary, for clean flat surfaces.

2. Set the Drive Unit in Position on the Superstructure

a. Carefully, place the drive unit in position on the superstructure.

b. Orient the drive unit as shown on the General Arrangement Plan andElevation drawings.

c. Align the drive mounting holes with the mounting holes in the

superstructure.

d. Install the drive mounting High Strength bolts, nuts, and washers but,

leave the bolts loose. Refer to Detail -4- on the Superstructure Erection

drawing.

C. CHECK THE DRIVE UNIT FOR CONCENTRICITY

1. CHECK the center of the drive-to-true center of the tank for concentricity.

2. Adjust the drive unit, as required.



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D. LEVEL THE DRIVE UNITS

At this point in the erection, the drive will be checked for near level by using a

carpenter’s level, and it will be adjusted, as needed. After the installation of the rakeshaft and the rake arms the drive unit will be adjusted for final level by shimming.

1. Do not walk on the superstructure during the leveling process. Stand straddling

the superstructure centerline to ensure the accuracy of the leveling.

2. CHECK the Drive Unit for Level

a. Use a carpenter’s level placed on the top surface of the main drive cover

to check the drive unit for level. See Figures 14 and 15.

Note: CHECK the level for accuracy by turning the level 180° and

rechecking. Remove points, burrs, etc for greater accuracy.

b. CHECK the drive unit for level in two directions (90o).

Figure 14

1- Carpenter’s level 2- Drive cover 3- Drive unit

The input drive assemblies and upper bearing housings are not shown for clarity.

1

3

2



Rev. 2


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Figure 15

1- Leveling instruments 2- Drive cover

3. Level the Drive Unit

a. Remove, clean, and lubricate the jackscrews in the drive base. Reinstall

the jackscrews.

b. Use the leveling jackscrews to level the drive. See Figure 16.

Note: The drive mounting bolts must be loose.

c. After leveling adjustments have been made to the drive, use wedges at the jackscrews to support the drive unit.

4. Secure the Drive Unit

a. Snug tighten the drive-to-superstructure H.S. bolts.

b. Do not torque tighten the H.S. bolts at this time. The H.S. bolts will betorque tightened after the final leveling of the drive unit.

c. Final leveling of the drive will follow installation of the rake arms. Refer

to the “CHECK the Drive for Final Level” instructions (see Table of

Contents).

1

2



Rev. 2


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Figure 16

1- Leveling jack screw 3- Drive-to-drive mount bolts, nuts, and washers 5- Drive mount on the superstructure

2- Wedge (typical each corner) 4- Drive housing

WARNING: The drive is shipped from the factory without lubricant.


The EIMCO® main drive unit, each of the drive’s input drive (reducer and

hydraulic motor) and upper bearing housing assemblies, and hydraulic power unit

must be fully covered and sealed off to protect against sand and dust whensandblasting in the vicinity.

All external openings, vents, breathers and areas between the rotating parts must

be covered with air tight covers and taped closed, especially the hydraulic powerunit, its accessories and the hydraulic motors.

After sandblasting and before start-up, drain a portion of oil from the main drive

housing, each upper bearing housing assembly, each input drive reducer, and the

hydraulic power unit to be sure that dust has not penetrated any of the drivesystem components. Remove all protective covers.

Sand dust or other foreign material must not enter into the main drive mechanismor the hydraulic power unit.

1

2

3

4

3

2

5



Rev. 2

08-2010

HYDRAULIC POWER UNIT

INSTALLATION

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A. INSTALL THE HYDRAULIC POWER UNIT

– The hydraulic power unit was assembled and checked at the factory. It should be

free of leaks and ready for operation.

– Refer to the manufacturer’s instructions and drawings for details regarding

hydraulic power unit lifting, installation, leveling, hydraulic fluid line installation,

priming the pump, filling the oil reservoir, etc.

1. Hydraulic Power Unit Location

The power unit must be located on the superstructure within hose length to the

drive unit as shown on the General Arrangement Elevation and SuperstructureErection drawings.

2. Lift the Hydraulic Power Unit

For hydraulic power unit lifting recommendations, refer to the manufacturer’s

instructions.

3. CHECK the Hydraulic Power Unit for Level and Full Support

a. For hydraulic power unit leveling and support recommendations, refer to

the manufacturer’s instructions.

b. Adjust the hydraulic power unit, as necessary.

4. Secure the Hydraulic Power Unit

For information on securing the hydraulic power unit, refer to the manufacturer’s

instructions.

5. Connect the Hydraulic Hoses

a. Connect the hydraulic fluid hoses between the hydraulic power unit andthe hydraulic motors on the drive unit. Refer to the hydraulic power unit

manufacturer’s instructions.

b. Hose connections must be tightened only until they are tight, not more.

Do not use tape or pipe dope as the connections will have O-rings ortapered seals.



Rev. 2

08-2010


INSTALLATION

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6. CHECK the Hydraulic Pump for Prime

Refer to the hydraulic pump manufacturer’s instructions.

7. Fill the Hydraulic Power Unit with Hydraulic Oil

a. Fill the hydraulic power unit reservoir with clean hydraulic oil.

Note: Make sure to pre-filter the hydraulic oil. The hydraulic oil must

be cleaned before it is used.

b. Refer to the hydraulic power unit manufacturer’s instructions for filling

the hydraulic power unit with hydraulic oil.

8. Start-Up Preparations

a. For instructions on preparing the hydraulic power unit for start-up, refer to

the manufacturer’s instructions.

Note: Do not start a hydraulic pump against a blocked system.


The EIMCO® main drive unit, each of the drive’s input drive (reducer andhydraulic motor) and upper bearing housing assemblies, and hydraulic power unit

must be fully covered and sealed off to protect against sand and dust when

sandblasting in the vicinity.

All external openings, vents, breathers and areas between the rotating parts must

be covered with air tight covers and taped closed, especially the hydraulic power

unit, its accessories and the hydraulic motors.

After sandblasting and before start-up, drain a portion of oil from the main drive

housing, each upper bearing housing assembly, each input drive reducer, and the

hydraulic power unit to be sure that dust has not penetrated any of the drive

system components. Remove all protective covers.Sand dust or other foreign material must not enter into the main drive mechanism

or hydraulic power unit.



Rev. 2

08-2010

LUBRICATION, WIRING,

HYDRAULIC POWER UNIT CHECK,

AND DRIVE ROTATION

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A. LUBRICATION

LUBRICATION WARNING:

The drive unit is shipped from the factory without lubricating oil and/or grease.

Prior to being operated for the first time, the drive unit, including all accessory

equipment components, must be lubricated.

Refer to the “Drive Lubrication” instruction (see Table of Contents).

Refer to the accessory equipment manufacturer’s instructions.

B. CONNECT ELECTRICAL WIRING

In order to rotate the drive unit for the final leveling check, the hydraulic power unit must

be connected to power.

1. Refer to the hydraulic power unit and accessory equipment manufacturer’s

instructions and wiring diagrams. Refer to the wiring diagram drawings.

2. Connect the electrical wiring to the hydraulic power unit and its accessories, as

required.

a. FLSmidth does not furnish, locate, or install the interconnecting wiring,etc.

b. All interconnecting wiring must meet Local and National ElectricalCodes.

c. Connect the electrical wiring to the hydraulic pump motor.

d. Connect the electrical wiring to the oil cooler and oil heater, low oil level

switch, rake drive starter switches, etc, as provided by the hydraulic

power unit manufacturer.

3. Connect electrical wiring to the Control Panel. Refer to the wiring diagram

drawings.

4. CHECK that the primary drive torque control has been installed, that its wiring

has been connected, and that it has been checked for operation. Refer to the




Rev. 2

08-2010



AND DRIVE ROTATION

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TORQUE CONTROL/DRIVE CONTROL WARNING: Before the drive unit is operated, the primary drive torque control must be

properly installed and checked for operation. Refer to the “General Drive

Maintenance” instructions (see Table of Contents).

Electrical wiring must be installed, as specified in wiring diagrams and the

individual components manufacturer’s instructions.

All interconnecting wiring must meet Local and National Electrical Codes.

The hydraulic pump motor must be wired so that an automatic restarting of the

pump motor cannot occur after a shutdown, following a torque overload.

C. CHECK THE HYDRAULIC POWER UNIT

1. Do not start the hydraulic pump and allow it to run without first checking to

make sure that the pump is primed and that it is being properly supplied with

hydraulic oil.

CAUTION:

If the hydraulic pump runs without being primed or without an adequate

hydraulic oil supply, the results will be cavitations, which will produce loud noise

and can cause possible damage to the pump.

2. Start the hydraulic power unit.

a. CHECK the direction of hydraulic pump rotation, which is shown by the

arrow on the coupling guard or on the hydraulic pump housing.

b. If rotation is not correct, reverse 2 lead wires to the hydraulic pump

motor. CHECK direction of hydraulic pump rotation again.

CAUTION:

Severe damage can occur to hydraulic pump by operating it in the wrong

direction.

c. CHECK the hydraulic power unit for pressure.

1) Watch the pressure gauge.

2) If the pressure gauge shows pressure, the hydraulic power unit is

ready to operate.



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AND DRIVE ROTATION

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3) If the pressure gauge shows no pressure, refer to the


3. Hydraulic Oil Flow Volume

a. Hydraulic oil flow volume (rate of flow) determines the speed of the

hydraulic motor.

b. The “stroke adjustment” for the required maximum rate of flow is made at

the pump on the hydraulic power unit.

c. Stroke adjustment (maximum motor speed) for this unit is factory set for

proper operation. Do not tamper with it.

d. If the original stroke (maximum motor speed) setting is not satisfactory

for the conditions, contact an FLSmidth representative before attempting

any adjustments.

e. A flow control valve, furnished on the hydraulic power unit, provides

control of variable rake speed.

D. CHECK DRIVE ROTATION

1. CHECK to be sure that all hydraulic piping/lines to the hydraulic motors on thedrive unit have been connected to the proper ports on the motors. Refer to thehydraulic power unit manufacturer’s instructions and drawings.

CAUTION:

All of the hydraulic motors (one on each input drive assembly) must be plumbed

the same to ensure that they turn in the same direction when hydraulic pressure is

supplied.

2. Start the hydraulic power unit and allow it to run.

Note: The hydraulic motors may operate erratically for a moment as air is

forced out of the hydraulic oil lines and the hydraulic motors.

3. Verify that the hydraulic motors rotate in the proper direction. Refer to the

manufacturer’s instructions and drawings and to the General Arrangement Plandrawing.



Rev. 2

08-2010



AND DRIVE ROTATION

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4. If the direction of the hydraulic motors rotation is wrong, the hydraulic fluid lines

are not connected properly.

a. Refer to the hydraulic power unit and hydraulic motor manufacturer’sinstructions.

b. Make corrections, as necessary.

5. If hydraulic pressure to the drive unit’s hydraulic motors should exceed the relief

valve pressure setting, due to torque overload, improperly connected hydraulicfluid lines, or blocked hydraulic fluid lines, the pressure relief valve will open and

recycle hydraulic oil flow back to the power unit reservoir.

Note: Refer to the hydraulic power unit manufacturer’s instructions and

drawings for relief valve setting.

6. CHECK all hydraulic fluid line connections for leakage. Fix or repair leaks, as

necessary.



Rev. 2

08-2010RAKE SHAFT INSTALLATION

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Reference Drawings: General Erection, Connection and Fastener List

– Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions” (see Table of

Contents) for information on snug tightening and torque tightening the H.S. Bolts.

Figure 17

1- To align rake shaft: Place shimsadjacent H.S. bolts, as necessary

2- Gear Adapter Plate 3- Rake Shaft

A. RAKE SHAFT INSTALLATION AND ADJUSTMENTS

The rake shaft is bolted to the bottom drive unit’s gear adapter plate where it is adjusted

for alignment by shimming.

1. Raise the rake shaft assembly.

1

2

3



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08-2010RAKE SHAFT INSTALLATION

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2. Connect the rake shaft to the gear adapter plate on the drive. See Figure 17.

Refer to the General Erection drawing.

a. Clean all flanges before installation.

b. Use the H.S. Bolts, nuts, and washers specified to secure the rake shaft to

the gear adapter plate.

c. Snug tighten the H.S. Bolts only at this time; do not torque tighten them.

3. CHECK the Rake Shaft for Alignment (Run-Out)

a. CHECK the rake shaft for alignment (run-out) at a point just above theguide pocket.

b. The rake shaft must be in alignment within ¼" (6.35 mm) at this point.

4. Adjust the Rake Shaft for Alignment (See Figure 17)

a. To adjust the rake shaft for alignment, shim between the connectingflange of the rake shaft and the gear adapter plate.

b. Place the shims (not by FLSmidth Minerals) adjacent the H.S. Bolts.

c. Snug tighten the H.S. Bolts only at this time; do not torque tighten them.

d. RECHECK rake shaft alignment.

5. Torque Tighten the High Strength Bolts

a. After the rake shaft is aligned, tighten the H. S. Bolts at the rake shaft-to-

gear adapter plate connections.



6. Do not install the wear plates on the guide pocket at this time. Do not weld theguide pocket to the discharge cylinder at this time.



Rev. 2

08-2010

RAKE ARM

INSTALLATION

6017M

53



Reference Drawings: General Erection, Connection and Fastener List, General Arrangement

Elevation

– Do not final weld the rake arm-to-rake shaft and rake arm support-to-rake shaftconnections, at this time. These connections will be final welded after the rake arms are

final leveled. Refer to the “CHECK the Rake Arms for Final Level and Alignment”


Figure 18

1- Rake shaft 4- Blocking 7- Take-up studs, nuts and washers

2- Rake arm 5- Nominal blade clearance: 3 15/16" (100 mm) A- See Figure 19

3- Rake arm support 6- All thread studs, nuts, and washers B- See Figure 19

Reference drawings: General Erection, General Arrangement Elevation

'C' 'C'

1

2

3

4

5

6

67A B



Rev. 2

08-2010

RAKE ARM

INSTALLATION

6017M

54



Figure 19


2- Rake arm 5- Nominal blade clearance: 3 15/16" (100 mm) 8- ¼" (6.35 mm) weld prep gap (typical)

3- Rake arm support 6- All thread studs, nuts, and washers 9- Weld as specified

Reference drawings: General Erection

A. INSTALL THE RAKE ARMS

To prevent misalignment and damage, the rake arms must be supported on blocking andthe rake arms must be connected in pairs.

1. Set the Rake Arms in the Tank (See Figures 18 and 19)

a. Set up the blocking for the rake connections to the rake shaft and for the

specified clearance of the rake arms with the tank bottom.

A

1

3

3 7

78

9

B

9

9

62

3

8

'C' - 'C'

93

31

6

6



Rev. 2

08-2010

RAKE ARM

INSTALLATION

6017M

55



b. Nominal rake blade clearance is 3 15/16" (100 mm) at the radial beams.

Refer to the General Arrangement Elevation drawing.

2. Connect the Rake Arms (See Figures 18 and 19)

a. Slide the inner ends of the rake arms over the rake arm connections on the

rake shaft.

b. Use the all thread studs, nuts, and washers to connect the rake arms to the

rake shaft.

Note: Do not weld the rake arm-to-rake shaft connections at this time.

3. Connect the Rake Arm Supports (See Figures 18 and 19)

a. Attach the rake arm supports to the rake shaft. Use the take-up studs, nuts

and washers specified to loosely secure the rake arm supports to the rake

shaft.

Note: Do not weld the rake arm support-to-rake shaft connections at thistime.

b. Line up the other end of the rake arm supports with the connection on the

rake arms.

c. Attach the rake arm supports to the rake arms. Use the all thread studs,

nuts, and washer specified to secure the rake arm supports to the rake

arms.

Note: Loosen or tighten the studs and nuts as necessary so that the ends

of the rake arm supports butt up tight against the rake arm

connections.

d. Weld the rake arm support-to-rake arm connections, as specified. See

WELDING WARNING.

WELDING WARNING:



e. Refer to the “Hold Back Paint Instruction” (See Table of Contents).



Rev. 2

08-2010

RAKE ARM

INSTALLATION

6017M

56



f. After welding the rake arm support-to rake arm connections, remove the

all thread studs, nuts, and washers.

4. Remove the Blocking

a. Remove the blocking equally from under each rake arm.

b. Begin at the rake shaft and work towards the tank wall.

c. Use jacks at the ends of the rake arms to assist in the removal of the blocking.

5. CHECK the Rake Arms for Clearance

a. CHECK the rake arms for clearance with the tank bottom on top of the

radial beams.

Note: All rake blades should have a nominal 3 15/16" (100 mm)

clearance with the tank bottom on top of the radial beams.

b. Adjust the rake arms as necessary.

1) Use jacks under the ends of the rake arms to assist in adjustments.

2) Along with the jacks, use the take-up studs at the rake armsupport-to-rake shaft connections to adjust the rake arms for

clearance.

3) The rake arms will deflect so it may help to calculate the numberof turns on the take-up nuts before a jack is used to elevate the

rake arm.

B. CHECK FOR FINAL LEVEL

1. A final check for rake arm final level will be made later. At that time, the finalwelding at the rake arm-to-rake shaft and rake arm support-to-rake arm

connections will be completed.

2. Refer to the “CHECK the Rake Arms for Final Level and Alignment” instruction

(see Table of Contents).



Rev. 2

08-2010

FEEDWELL

INSTALLATION

6017M

57



Reference Drawings: General Erection Connection and Fastener List, General Arrangement

Elevation

– Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions” (see Table ofContents) for information about snug tightening and torque tightening the H.S. bolts.

Figure 20

1- Superstructure 3- Feedwell segment 5- Mix trough connection

2- Feedwell segment 4- H.S. bolts, nuts, and washers 6- Section ‘A’ – ‘A’

Reference drawing: General Erection

1

2

2

2

3

4

4

6

5



Rev. 2

08-2010

FEEDWELL

INSTALLATION

6017M

58



A. ASSEMBLE THE FEEDWELL

Refer to Section ‘A’ – ‘A’ on the General Erection drawing.

1. Assemble the feedwell on shoring above the rake arm supports. See Figure 20.

a. Use the H.S. bolts, nuts, and washers specified to connect the feedwell

segments to each other.

b. During assembly, snug tighten the H.S. bolts only, until all adjustmentsare completed.

2. Orient the pieces for final position and for the feedwell-to-mix trough connection.Refer to the General Arrangement Elevation drawing.

3. Lifting the Feedwell Segments

When lifting the feedwell segments, care must be taken to prevent changing the

radius (curve) of the segments. Lift the feedwell segments as follow:

Figure 21: Lifting Rigid Sections

1- Lifting Lug (if furnished) 3- Lifting Clamp (not by FLSmidth Minerals)

2- Lifting Cables or Chains (not by FLSmidth Minerals) 4- Feedwell Segment

a. If separate lifting lugs are provided, mount them to the predrilled holes

located just below the rim angle at approximately ¼+ the total length ofthe feedwell segment from each end of the segment. Refer to Figure 21.

1/4+

1

1/4+1/2-

2

4

3



Rev. 2

08-2010

FEEDWELL

INSTALLATION

6017M

59



b. If lifting lugs are not provided, attach the lifting cables or chains with

lifting clamps to the feedwell segment at the rim angle at this same

distance (¼+) from each end of the feedwell segment.

CAUTION:

Do not attach the lifting cables or chains to the ends of the feedwell segment.

This will cause bending of the rim angle and feedwell plate, will change the

radius of the segment, and will prevent proper fit-up of the segments.

c. When lifting large, less rigid feedwell segments, a spreader beam should

be used to provide a vertical lift. See Figure 22.

Figure 22: Lifting Less Rigid Sections

1- Spreader Beam (not by FLSmidth Minerals) 3- Lifting Lug (if furnished)

2- Lifting Cables or chains (not by FLSmidth Minerals) 4- Feedwell Section

d. Remove the lifting lugs, if used, after the feedwell segment is in place.

e. The mounting holes for the lifting lugs may be closed, if desired.

1) Use round headed bolts and nuts.

Note: The bolt heads must be on the outside of the feedwell.

1/2-1/4+

1/4+

4

3

2

1



Rev. 2

08-2010

FEEDWELL

INSTALLATION

6017M

60



2) Plug weld the holes and grind (not by FLSmidth Minerals) for a

smooth surface (both sides).

f. Leaving the holes open will not affect the process performance of thisequipment.

4. CHECK the feedwell for alignment of the segments and the upper rim.

a. Adjust the feedwell segments, if necessary.

b. Torque tighten the H.S. bolts.

c. Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions”instruction (see Table of Contents).

B. INSTALL THE FEEDWELL

Refer to Section ‘A’ – ‘A’ on the General Erection drawing. Refer to the General

Arrangement Elevation drawing.

1. Raise the feedwell; use multi-point lifting.

2. Attach the feedwell to the underside of the bottom of the superstructure.

a. Use the H.S. Bolts, nuts, and washers specified to secure the feedwell tothe superstructure.

b. Snug tighten the H.S. Bolts only at this time; do not torque tighten them.

3. CHECK the Feedwell

a. CHECK the feedwell for concentricity with the rake shaft and for

orientation.

b. CHECK the feedwell upper rim for elevation and level all around.

c. Adjust as necessary.

d. After the adjustments are complete, torque tighten the H.S. Bolts at the

feedwell-to-superstructure connections.

e. Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions”instruction (see Table of Contents).



Rev. 1

08-2010

E-DUC® SYSTEM INSTALLATION:

FEED TANK, MIX TROUGH

AND E-DUC NOZZLE

6017M

61




Elevation, Torque Values, Superstructure Erection

– Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions” (see Table ofContents) for information about snug tightening and torque tightening the H.S. bolts.

Figure 23

1- Superstructure 3- Feed tank 5- E-Duc nozzle

2- Mix trough connection on the feedwell 4- Mix trough 6- H.S. bolts, nuts, and washers

Reference drawing: General Erection

A. INSTALL THE E-DUC SYSTEM

1. Install the Feed Tank (See Figures 23 and 24)

Refer to Section ‘A’ – ‘A’ and Section ‘H’ – ‘H’ on the General Erection

drawing.

a. Lift the feed tank and carefully set it in position on the feed tank supports

on the superstructure.

b. Use the H.S. bolts, nuts, and washers specified to anchor the feed tank tothe superstructure.

c. Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions”


1

2

3

4

5

6

6



Rev. 1

08-2010



AND E-DUC NOZZLE

6017M

62



Figure 24

1- Superstructure 5- E-Duc nozzle 8- E-Duc nozzle hanger

3- Feed tank 6- H.S. bolts, nuts, and washers 9- Capscrews, nuts, and washers

4- Mix trough 7- Mix trough hanger Reference drawing: General Erection

1

1

1

3

4

4

5

5

6

6

6

6

6

6

6

7

8

8

9



Rev. 1

08-2010



AND E-DUC NOZZLE

6017M

63



2. Install the Mix Trough (See Figures 23 and 24)

Refer to Section ‘A’ – ‘A’, Section ‘F’ – ‘F’, and Section ‘G’ – ‘G’ on the

General Erection drawing.

a. Mix Trough Hanger

1) Locate and attach the mix trough hanger to the underside of the

bottom of the superstructure.

2) Use the H.S. bolts, nuts, and washers specified to secure the

hanger to the superstructure.

Note: Snug tighten the H.S. bolts only at this time; do not torque

tighten them yet.

b. Mix Trough

1) Place the mix trough into position at the feedwell.

2) Use the H.S. bolts, nuts, and washers specified to secure the mix

trough to the mix trough hanger and the mix trough connection on

the feedwell.

Note: Snug tighten the H.S. bolts only at this time; do not torquetighten them yet.

3. Install the E-Duc Nozzle (See Figures 23 and 24)

Refer to Section ‘A’ – ‘A’, Section ‘F’ – ‘F’, and Section ‘H’ – ‘H’ on the

General Erection drawing.

a. E-Duc Nozzle Hanger

1) Locate and attach the E-Duc nozzle hanger to the underside of the bottom of the superstructure.

2) Use the H.S. bolts, nuts, and washers specified to secure the

hanger to the superstructure.


tighten them yet.



Rev. 1

08-2010



AND E-DUC NOZZLE

6017M

64



b. E-Duc Nozzle

1) Place the E-Duc nozzle into position between the feed tank and

the mix trough.

2) Insert the end of the E-Duc nozzle into the mix trough first before

positioning the E-Duc nozzle for its connection at the feed tank.

3) Use the H.S. bolts, nuts, and washers specified to secure the E-

Duc nozzle to the E-Duc nozzle hanger.


tighten them yet.

4) Use the capscrews, nuts, and jam nuts specified to secure the E-

Duc nozzle to the E-Duc nozzle connection on the feed tank.

Note: Tighten the nuts first and then, secure the nuts with the

jam nuts.

4. CHECK the E-Duc System

a. CHECK the E-Duc nozzle and mix trough for alignment, level, and

specified clearance of the nozzle with the throat of the mix trough.

Note: It is critical to maintain the specified spacing between the end of

the E-Duc nozzle and the throat of the mix trough. Inaccurate

installation of the E-Duc nozzle and mix trough will result in poor

operation of the E-Duc system.

b. Make adjustments, if necessary.

5. Secure all Fasteners (See Figures 23 and 24)

a. Toque tighten the H.S. bolts at these connections.

1- Mix trough-to-feedwell connections2- Mix trough hanger-to-superstructure connections

3- Mix trough-to-mix trough hanger connections

4- E-Duc nozzle hanger-to-superstructure connections5- E-Duc nozzle-to-E-Duc nozzle hanger connections





Rev. 1

08-2010



AND E-DUC NOZZLE

6017M

65



B. INSTALL THE TOP CHORD DIAGONAL

Refer to View ‘A’ – ‘A’ on the Superstructure Erection drawing. See Figure 25.

1. Locate and install the top chord diagonal on the superstructure above the feed

tank.

2. Use the H.S. bolts, nuts, and washers specified to secure the diagonal to the

superstructure.

3. Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions” (see

Table of Contents).

Figure 25

1- Superstructure 2- Top chord diagonal 3- H.S. bolts, nuts, and washers


1

2

3



Rev. 2

08-2010FINAL LEVEL THE DRIVE

6017M

66



A. CHECK THE DRIVE FOR LEVEL

Figure 26

1- "d1" 3- Mark four level bench marks at the same elevation around the tank 5- Surveyor’s level

2- "d2" 4- Rake arm 6- Note: d1 and d2 are 180o opposite

1. The main bearing of the rake drive must be level for proper operation of themechanism and maximum bearing life.

2. The drive will be checked for level by measuring the level of the drive at the endof one of the rake arms, at various points around the tank. The drive will then be

adjusted for level by shimming.

Note: Checking the drive for level and leveling the drive must be done when

the steel is a uniform temperature, such as during the early morning or anovercast day.

3. The drive must be leveled within a maximum out-of-level tolerance of .005"

(0.127 mm) in a 12" (304.8 mm) distance.

4. This tolerance will be measured on a large scale by using one of the rake arms,

rather than by using the relatively small area of the drive cover.

5. Set up a transit or surveyor’s level outside of tank. See Figure 26.

5

1

4

3

2

6



Rev. 2


6017M

67



6. Use this instrument to mark four level benchmarks (d1) on the tank wall at the

same height and spaced approximately 90o apart. Refer to Figures 26 and 27.

7. The benchmarks should be aligned with the superstructure centerline and centerof the tank, as shown in Figure 27.

Figure 27

1- "d1" 4- Jackscrews (drive leveling screws) 7- Superstructure centerline

2- "d2" 5- Bridge mounted drive unit 8- 45°

3- 90° 6- Tank 9- Center of the tank

WARNING:

Refer to the “WARNINGS” on drive rotation and lubrication in the “Lubricate

the Drive Unit” instructions (see Table of Contents).

5

6

1

4

2

3

1

2

3

7

3

4

88

9



Rev. 2


6017M

68



8. Rotate the drive. Stop the same long rake arm at each of the four level points that

are marked around the tank.

a. Option One

Use the transit to shoot and record the elevation of the very end of the

rake arm (d2).

b. Option Two

Use the same rake arm each time and a straight edge as an extension fromthat rake arm to the tank wall to make the second marks (d2). These are

the “Reference Marks” in Figure 26.

9. To ensure accuracy, do not walk on the superstructure’s walkway during the

checking. Anyone on the superstructure should stand straddling the centerline.

10. Refer to Figures 26 and 27. Compare the difference in dimensions between the

level benchmarks and the rake arm reference marks at diametrically opposite

sides of the tank: two directions and 90° apart.

11. The difference between the two observed dimensions (d1 minus d2) must not

exceed the maximum out-of-level dimension below:

MECHANISM

DIAMETER

MAXIMUM OUT-OF-LEVEL

TOLERANCE (d1 MINUS d2)

66' (20, 000 mm) ½" (12.7 mm)

B. LEVEL THE DRIVE

1. Shim for Level

a. Shimming May be Necessary to Level the Drive

Maximum bearing life of the drive unit main bearing is dependent on

proper leveling and shimming. Perfect final leveling is not practical;

however, it should be as accurate as possible.

Note: As the diameter of the mechanism increases, it becomes

increasingly difficult to obtain an accurate adjustment.



Rev. 2


6017M

69



b. Final Shimming Adjustment

In making a final shimming adjustment, care should be taken to tighten

the drive mounting bolts equally and to support each drive mounting bolt,as necessary, with the proper thickness of shims.

Note: Uneven tightening and shimming may cause deformation of the

bearing race and cause shortened bearing life.

2. Shims

a. Use only the stainless steel shims furnished by FLSmidth, which are

attached to the drive unit. They are provided in sizes and quantities to

satisfy most requirements.

b. If more shims are needed, contact the FLSmidth Minerals Customer

Services Department.

1) Refer to the Parts List for the shim package part number.

2) Refer to the “Office” pages (see Table of Contents) for contactinformation.

Figure 28

1- Drive base 3- Shim

2- Leveling screw (drive leveling screw) 4- Mounting bolts (H.S. bolts)

5- Example of trimming shims for unevenmounting surface

2

3

4 5

1

1

3



Rev. 2


6017M

70



3. Shimming (See Figure 28)

a. Use the jackscrews (drive leveling screws) that are provided in the base

casting to level the drive.

1) Be sure to release the drive mounting bolts (H.S. bolts).

2) Remove the support wedges, if used.

b. CHECK drive clearances with a feeler gauge at the bolts and mark theclearances on the drive base for ready reference.

c. Use the FLSmidth furnished shims to shim at the drive mounting bolts.

d. Because the shims insure the level of the drive for optimum service life of

the main bearing, use only those stainless steel shims that are provided by

FLSmidth. Do not use any other type of shims or shim material.

e. Snug tighten the drive mounting bolts (H.S. bolts).

f. Back off the jackscrews so that the drive is supported only by the shims.

g. RECHECK the level of the drive by rotating the rake arm to the level

marks.

h. Adjust, if necessary, until the drive is within the specified level tolerance.

i. When all adjustments are complete, torque tighten the drive mounting

bolts (H.S bolts). Refer to the “High Strength Bolt (H.S. Bolts)Tightening Instruction” (see Table of Contents).



Rev. 2

08-2010

CHECK THE RAKE ARMS

FOR FINAL LEVEL AND ALIGNMENT

6017M

71



A. RAKE ARM FINAL ALIGNMENT AND ADJUSTMENTS

– The purpose of this rake arm check and adjustments is to ensure that both of the

rake arms have proper and equal clearance with the tank bottom on top of the radial beams, so that each of the rake arms sweeps in the same plane, shares its load, and

does not cause the mechanism to operate with an unbalanced load.

Figure 29

1- Rake shaft 4- Markers (piles of sand) 7- Take-up studs, nuts and washers

2- Rake arm 5- Nominal blade clearance: 3 15/16" (100 mm) A- See Figure 30

3- Rake arm support 6- All thread studs, nuts, and washers B- See Figure 30

Reference drawings: General Erection, General Arrangement Elevation

– Final leveling and alignment must follow the final check for level of the drive unit.


'C' 'C'

1

2

3

4

5

6

67A B



Rev. 2

08-2010

CHECK THE RAKE ARMS


6017M

72



Figure 30


2- Rake arm 5- Nominal blade clearance: 3 15/16" (100 mm) 8- ¼" (6.35 mm) weld prep gap (typical)

3- Rake arm support 6- All thread studs, nuts, and washers 9- Weld as specified

Reference drawings: General Erection

CAUTION:

The final rake arm check must follow the leveling and final leveling of the drive

unit.

Checking the rake arms for final level and leveling the rake arms should be donewhen the steel is at a uniform temperature, such as the early morning or an

overcast day.

A

1

3

3 7

78

9

B

9

9

62

3

8

'C' - 'C'

93

31

6

6



Rev. 2

08-2010

CHECK THE RAKE ARMS


6017M

73



Figure 31

1- Radial beam 2- Scallop bottom plate 3- Markers (piles of sand)

1. Rake Arm Clearance with Tank Bottom (See Figures 29 and 31)

a. CHECK each of the rake arms for a 3 15/16" (100 mm) clearance with the

tank bottom on top of the radial beams.

b. The rake arms must be adjusted so the rake blades will sweep at the

proper slope and in the same plane.

c. The exact clearance of the rake arms from the tank floor can bedetermined by using a reference “clearance” device on the radial beams

on the tank floor, such as piles of sand.

1) Place several markers (piles of sand) in a straight line radially

from the center of the tank along a radial beam.

2) Rotate each rake arm to the reference markers (piles of sand).

3) CHECK for clearances.

1

2

3



Rev. 2

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CHECK THE RAKE ARMS


6017M

74



d. If the rake arms are set at the proper clearance, no adjustments will be

required. Proceed to step “4.After Rake Arm Adjustments are Complete.”

2. Rake Arms Adjustments for Clearance (See Figures 29, 30 and 31)

a. To adjust the rake arms for clearance, rotate each rake arm to the

reference devices (piles of sand).

b. Use jacks under the rake arms and the take-up studs at the rake arm

support-to-rake shaft connections to adjust each rake arm according to thereference dimensions (or piles of sand) to obtain the same rake blade

clearance.

Note: Do not attempt to lift the rake arms with the take-up studs at the

rake arm support to-rake arm connections. Use jacks under the

rake arms to assist in adjustments.

c. The rake arms will deflect, so it may help to calculate the number of turns

on the take-up stud nuts before a jack is used to elevate the rake arms.

d. Do not adjust the all thread studs at the rake arm-to-rake shaft

connections.

3. RECHECK the Rake Arm Adjustments for Rake Blade Clearance

The rake arms must be adjusted so that eac.h of the rake arms will be brought to

the exact same clearance with the tank bottom on top of the radial beams.

4. After Rake Arm Adjustments are Complete (See Figure 30)

Refer to Section ‘C’ – ‘C’ and Detail ‘1’on the General Erection drawing.

WELDING WARNING:

Use the piece being welded as the ground to prevent drive unit damage due toelectrical circuit contact.

a. Final weld the rake arm-to-rake shaft connections as specified. See

WELDING WARNING.

1) CHECK to make sure that there is a ¼" (6.35 mm) weld prep gap

at the rake arm-to-rake shaft connections.



Rev. 2

08-2010

CHECK THE RAKE ARMS


6017M

75



2) After welding the rake arm-to-rake shaft connections, remove the

all thread studs, nuts, and washers.

b. Final weld the rake arm support-to-rake shaft connections as specified.See WELDING WARNING.


at the rake arm support-to-rake shaft connections.

2) After welding the rake arm support-to-rake shaft connections,remove the take up studs, nuts, and washers.

WELDING WARNING:





Rev. 2

08-2010PICKET INSTALLATION

6017M

76



Figure 32

1- Rake shaft 3- Rake arm support 5- Picket brace

2- Picket support 4- Rake arm 6- Picket

Reference drawing: General Erection 7- Weld as specified

A

A

B

1

2

22

2

33

44

55

66666

666

7

7



Rev. 2


6017M

77




Elevation



Figure 33

1- Rake shaft 5- Picket brace 8- All thread studs, nuts, and washers

2- Picket support 7- Weld as specified 9- H.S. bolts, nuts and washers

Reference drawing: General Erection 10- ¼" (6.35 mm) weld prep gap (typical)

A. PICKET SUPPORT INSTALLATION

To prevent misalignment and damage, the picket supports must be supported on

blocking/shoring, and they must be connected in pairs.

1. Lower Picket Supports (See Figures 32 and 33)

Refer to Detail ‘2’ on the General Erection drawing.

a. Mount the lower pair of picket supports onto the rake shaft.

b. Support the first picket support with temporary blocking/shoring until the

second picket support has been attached to the rake shaft.

A

1

B

2

2

2

5

8

8910

7



Rev. 2


6017M

78



c. Use the all thread studs, nuts, and washers to secure the picket supports to

the rake shaft.

d. Do not weld the picket support-to-rake shaft connections at this time.

2. Upper Picket Supports (See Figures 32 and 33)


a. Mount the upper pair of picket supports onto the rake shaft.

b. Support the first picket support with temporary blocking/shoring until the

second picket support has been attached to the rake shaft.

1) Use the all thread studs, nuts, and washers to secure the picket

supports to the rake shaft.

2) Do not weld the picket support-to-rake shaft connections at this

time.

c. Picket Braces (See Figures 32 and 33)


1) Use the picket braces to secure the upper picket supports to therake shaft

2) Use the H.S. bolts, nuts, and washers to secure the picket braces to

the rake shaft and picket supports.

3) Snug tighten the H.S. bolts only at this time; do not torque tighten

them yet.

B. PICKET INSTALLATION

Refer to the part numbers on the General Erection drawing.

1. Insert the pickets down through the picket sleeves on the picket supports and rake

arm supports and into position on the rake arms.

2. Adjust the picket supports, as needed.



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C. TIGHTEN H.S. BOLTS AND FINAL WELD

1. H.S. Bolts (See Figure 33)

a. Tighten the H.S. bolts at the picket brace-to-rake shaft and picket brace-

to-picket support connections.



2. Final Welds (See Figures 32 and 33)

Refer to the General Erection drawing. Refer to the “Hold Back PaintInstruction” (see Table of Contents).

a. Final weld all of the picket support-to-rake shaft connections as specified.

See WELDING WARNING. See Figure 33.


at the picket support-to-rake shaft connections.

2) After welding the picket support-to-rake shaft connections,

remove the all thread studs, nuts, and washers.

WELDING WARNING:

Use the piece being welded as the ground to prevent drive unit damage due toelectrical circuit contact.

b. Final weld all the picket-to-rake arm and picket-to-rake arms support

connections as specified. See WELDING WARNING. See Figure 32.

c. Final weld all of the picket-to-picket supports connections as specified.

See WELDING WARNING. See Figure 32.



Rev. 2

08-2010

GUIDE POCKET AND WEAR PLATE

INSTALLATION

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80



Reference Drawings: General Erection, Connection and Fasteners List, Torque Values


A. INSTALL THE WEAR PLATES AND GUIDE POCKET

The guide pocket should already be positioned in the discharge cylinder. Refer to the

“Place the Rake Shaft Assembly in Position in the Tank” instruction (see Table of

Contents).

Figure 34

1- Rake shaft 3- Discharge cylinder 5- Wear plate

2- Guide pocket 4- Discharge cylinder floor (reference) 6- Capscrew, nut, and washer

Reference drawing: General Erection 7- Weld as specified

1. Wear Plates (See Figure 34)

a. Install the wear plates onto the guide pocket.

b. Use the capscrew, nuts, and washers specified to secure the wear plates to

the guide pocket.

c. Refer to the Torque Values drawing.

'B' - 'B'

'B' 'B'

11

22

3

4

5

6

7



Rev. 2

08-2010

GUIDE POCKET AND WEAR PLATE

INSTALLATION

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2. CHECK the Guide Pocket for Concentricity

a. Check the wear plates of the guide pocket for concentricity with the rake

shaft.

b. The wear plates must be concentric with the rake shaft within ± ⅛" (31.75

mm).

c. Adjust the guide pocket, as needed.

3. Tack weld the guide pocket to the discharge cylinder floor. See WELDING

WARNING.

WELDING WARNING:



4. RECHECK Guide Pocket for Concentricity

a. Rotate the rake shaft.

b. CHECK the wear plates of the guide pocket for concentricity with therake shaft.

Note: The wear plates must not contact the rake shaft.

c. Adjust the guide pocket, if necessary by breaking the tack welds,

repositioning the guide pocket, and tack welding the guide pocket to the

discharge cylinder floor. See WELDING WARNING.

d. If adjusting the position of the guide pocket does not work, it may be

necessary to adjust the rake shaft for run-out as well. Refer to the “Install

and Align the Rake Shaft” instructions (see Table of Contents).

5. Final Weld (See Figure 34)

a. Final weld the guide pocket to the discharge cylinder floor as specified.

Refer to the General Erection drawing.

b. See WELDING WARNING.



Rev. 2

08-2010MONORAIL INSTALLATION

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Reference Drawings: Superstructure Erection, Connection and Fastener List, General

Arrangement Elevation, Torque Values



Figure 35

1- Superstructure 5- Splice plate (top chord) 9- H.S. bolt, nut, washer and beveled washer

2- Superstructure end 6- Monorail stop 10- Capscrew, nut, and washer

3- Top chord strut 7- H.S. bolt, nut, and beveled washer 11- Specified welds4- Monorail beam 8- H.S. bolt, nut, and washer 12- Typical both ends of monorail


A. INSTALL THE TOP CHORD STRUTS (See Figure 35)

Refer to View ‘A’ – ‘A’ and Section ‘D’ – ‘D’ on the Superstructure Erection drawing.

1. Install the top chord struts across the top of the superstructure.

'C''C'

'D'

'D'

1 2

33

4

2

4

'C' - 'C'

1

'D' - 'D'

35

5

5

6

7 7

8

8

8

9

1011

12



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2. Use the splice plates (top chord), H.S. bolts, nuts, and washers to secure the top

chord struts to the superstructure.

3. Refer to the “High Strength Bolts (H.S. Bolts) Tightening Instructions” (seeTable of Contents).

B. INSTALL THE MONORAIL BEAM (See Figure 35)

Refer to View ‘A’ – ‘A’ and View ‘C’ – ‘C’ on the Superstructure Erection drawing.

1. Install the Monorail Beam

a. Mount the monorail beam to the underside of the top of thesuperstructure. Refer to View ‘A’ – ‘A’ on the Superstructure Erection

drawing.

b. Use the H.S. bolts, nuts, and beveled washers to secure the monorail beam

to the superstructure and top chord struts.

c. Snug tighten the H. S. bolts only at this time; do not torque tighten them.

2. Connect the Monorail Beam to the Superstructure

a. Connect the monorail beam to the monorail beam connection onunderside of the top of the superstructure. Refer to View ‘C’ – ‘C’ on theSuperstructure Erection drawing.

b. Use the H.S. bolts, nuts, washers, and beveled washers to secure the

monorail beam to the monorail beam connection on the superstructure.

c. Snug tighten the H. S. bolts only at this time; do not torque tighten them.

3. CHECK Monorail Alignment

a. CHECK to make sure that the monorail beams are properly aligned (i.e.for smooth travel of the monorail 2 ton hoist [not by FLSmidth).

b. Adjust the monorail beam, if necessary.

4. 2 Ton Hoist (not by FLSmidth) and Monorail Stops

Refer to the Superstructure Erection drawing.

a. Install the 2 ton hoist on the monorail.



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b. Attach the monorail stops to the ends of the monorail. See Figure 35.

Note: Do not attach the monorail stops to the monorail until after the 2

ton hoist has been installed. The monorail stops are to prevent the2 ton hoist from coming off either end of the assembled monorail.

c. Use the capscrews, nuts, and washers specified to secure the monorail

stops to the monorail. Refer to the Torque Values drawing.

d. CHECK the 2 ton hoist for smooth travel along the monorail from end toend.

e. Adjust the monorail beam, if necessary.

5. H.S. Bolts and Welds (See Figure 35)

After adjustments to the monorail have been completed,

a. H.S. Bolts

1) Torque tighten the H.S. bolts at the monorail beam-to-

superstructure connections, at the monorail beam-to-top chord

strut connections, and the monorail beam-to-monorail beam (on

the superstructure) connections.


Instructions” (see Table of Contents).

WELDING WARNING:



b. Welds

1) Weld the monorail beam-to-monorail beam (on the

superstructure) connections as specified. See the WELDING

WARNING.

2) Grind the welds smooth if necessary for smooth travel of the 2 tonhoist (not by FLSmidth Minerals).



Rev. 2

08-2010

FLOCCULENT PIPING

INSTALLATION

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Reference Drawings: Flocculent Erection, General Erection, General Arrangement Elevation


A. FLOCCULATION PIPING

Refer to the Flocculation Erection drawing.

1. Field cut, assemble, and install the flocculation piping, as needed.

2. Use the flocculation header, splitter pipe, piping, fittings (90° and 45° ells), ball

valves, flanges, deflectors, pipe supports, gaskets, U-bolts, capscrews, and nuts

specified to assemble and install the flocculation piping.

a. Pipes (part number 1021973-01) are to be field cut and welded to suit.

b. Piping must be supported, as required. More supports may be required

than shown on the Flocculation Erection drawing.

c. Gaskets are to be used at the ball valve flange-to-pipe flange connections.

d. Dimensions for locating the flocculation header are provided on the

Flocculation Erection drawing.

3. All field welding on flocculation piping must be continuous seal welds. SeeWELDING WARNING.

WELDING WARNING:



4. All field welding on plates and shapes must be continuous. See WELDING

WARNING.

5. Use pipe dope (not by FLSmidth) at all threaded pipe connections.

6. Flanges are to be orientated with the bolt holes straddling natural centerlines.



Rev. 2

08-2010

INSTALL AND LEVEL

THE WEIRS

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A. INSTALL AND LEVEL THE WEIRS

Figure 36

1- Weir 2- Seal 3- Launder

1. Install the weirs on the tank launder. See Figure 36.

a. Launder, weirs, and fasteners are furnished with the tank.

b. Adjust the weirs in their mounting holes for the liquid level shown on the

General Arrangement Elevation drawing.

c. Snug tighten the fasteners.

2

3

1

2



Rev. 2

08-2010

INSTALL AND LEVEL

THE WEIRS

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2. If the weirs do not fit flush with the launder, apply a mastic sealer or silicone

sealant (not by FLSmidth) between the launder and the top and/or bottom of the

weirs.

a. This is to prevent leakage when the tank is full.

b. This is only a recommendation.

c. If the weir will be welded, apply the sealant after final leveling and

welding. Weld the splices as specified.

3. CHECK the weirs for level.

a. Use a surveyor’s level to check the weirs for level.

Note: CHECK the weirs for level in a dry tank.

b. Adjust for level as necessary.

c. After adjustments are complete, CHECK to make sure that all fastenersare secure.



Rev. 2

08-2010

FINAL FIELD

MECHANICAL CHECK

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A. FINAL FIELD MECHANICAL CHECK

1. At the completion of erection or installation of the equipment, an FLSmidth

Service Representative must complete a final field mechanical check of the

equipment.

2. Unless the final field mechanical check is accepted and signed-off by the Service

Representative at the completion of the installation, the warranty will not be ineffect.

3. Previous inspections will not count towards this final acceptance, unless a sign-

off is obtained, in writing, from the Service Representative.

4. Depending on any previous inspections, this final check may be an additional paid service call.

B. ARRANGEMENTS FOR SERVICE

1. The Final Mechanical Checklist, which is included in this manual, must be

completed for each of the mechanisms that have been furnished, before

contacting the FLSmidth representative to arrange for the final field mechanical

check.

2. Arrangements for the final field mechanical check should be made at least twoweeks in advance with an FLSmidth representative. Refer to the “Office” pagesfor contact information (see Table of Contents).

C. DO NOT FILL THE TANK WITH WATER

1. The final field mechanical check cannot be done if the tank is filled with water.

2. If the final field mechanical check cannot be performed, an additional paid

service day will be charged.



Rev. 2

08-2010DRIVE LUBRICATION

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A. LUBRICATION

1. The drives are a combination of FLSmidth manufactured drive components and

accessory equipment (hydraulic motors and reducers) that have been purchasedfrom others.

Note: EIMCO® drive units are shipped without oil.

2. Fill the drives, initially, to the level indicated on the sight glass. Refer to

section “B.5.c.Oil Fill Procedure” in this instruction.

Figure 37 Figure 38

3. A lubricant plate is mounted to the main drive housing on the drive at the oil fillopening. See Figure 37. Lubricant No. 1 is shown as an example in Figure 37.

4. The “LUBRICANT NO.” (No. 1 or No. 2) on this plate refers to the “Lubricant

Number” that is shown on the lubrication plate, which is mounted on the

Nameplate assembly that is mounted on the input drive assembly. See Figure 38.

5. Use the “Lubricant Number” specified (No.1 or No. 2) to determine the type of

oil to be used in the drive.

a. The type of oil will vary based on the “Ambient Temperature Range” to

be expected at the equipment installation site.

b. For temperatures outside of those ranges shown on the Lubrication Plate,

contact the FLSmidth Dorr-Oliver Eimco Inc Engineering Department.

Refer to the “Office” pages (see Table of Contents).

6. Although a Mobil product is specified, any equivalent product can be used. Referto the “Lubricant Equivalents List” (see Table of Contents). Contact the lubricant

supplier if the desired equivalent is not listed.

SEE FLSMIDTH MINERALS

LUBRICATION PLATE FOR LUB.

SPEC. & INSTRUCTIONS

LUBRICANT No.2

TO BE USED IN

THIS HOUSING



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B. LUBRICATE THE DRIVE

1. CHECK Oil Levels, Weekly

A general oil level check can be made while the drive is operating. To be more

accurate, stop the drive a few minutes to allow the oil to settle.

Note: Adding oil in excess of the amount required will cause oil to over flow.

2. Drain Condensate, Weekly

a. Draining the condensate will keep the oil free of water and other

contaminants.

b. Refill the drive unit with oil to operating level.

3. Clean the Sight Glass Vent Opening

a. If the vent opening in the top screw plug is clogged or dirty, a sight glass

will not show the correct oil level, and it may not show an oil level at all.If the sight glass becomes clogged or dirty, clean it.

b. CHECK the sight glass vent opening, monthly.

4. CHECK Drive Oil Condition

a. CHECK the condition of the drive oil 500 hours after the initial start-up.

CHECK the condition of the drive oil every six months thereafter.

b. Take oil samples (100 ml, or 4 oz.) from the main gear housing’s and

each upper bearing housing assembly’s drain piping. Use a clean

receptacle to collect each sample

c. Allow the oil to flow from the drain until water and other settled

contaminants are no longer present, and the oil consistency is uniform.

d. Refill the main gear housing and the upper bearing housing assemblies tooperating level.

e. Send the samples to a commercial lubricant laboratory for analysis. Thesamples of Mobil oil must conform to the “Lubricant Used Oil Analysis

Specifications” Table on a following page in this instruction.



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5. Replace the Oil (If Required)

If the oil is not tested by qualified oil analysis, then oil change intervals are as

follows:

a. Initial Replacement:

The main gear housing and each upper bearing housing assembly must be

drained and must be refilled with fresh oil, after the first 500 operating

hours. Refer to section “B.5.c.Oil Fill Procedure” in this instruction.

b. Regular Oil Replacement:

Mineral oil must be replaced each year, unless ambient temperatures

dictate otherwise. Synthetic oil must be replaced every two years.

c. Oil Fill Procedure:

1) Stop the drive.

2) Drain each of the housings and refill them with fresh oil.

Note: At first, until the oil settles, a sight glass will not show an

accurate oil level, due to settling time, trapped air, andother factors.

3) Allow the drive to sit at least 10 – 15 minutes after filling it with

oil, before checking the oil level.

4) RECHECK the oil level while the drive is operating. Refer to

section “B.1.CHECK Oil Levels, Weekly” in this instruction.

Note: Be aware that too much oil added will overflow.

DRIVE UNIT VENT CAUTION:

Vent holes in vented pipe plugs must be kept clear of dirt, paint, and other foreign

material.



Rev. 2


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*LUBRICANT USED OIL ANALYSIS SPECIFICATIONS

Mobil SHC636:

Appearance Bright and clear, not cloudy

Kinematic Viscosity at 40° C per ASTM D445 551-784cSt

Total Acid Number (TAN) < 2.0 increase from new

Oxidation by FTIR < 10

Karl Fischer H2O per ASTM D 1744 < 0.1

CU FT-IR < 30 ppm

FE FT-IR < 50 ppm

SN FT-IR < 30 ppm

SI FT-IR < 45 ppm

AL FT-IR < 30 ppm

Mobil Mobilgear 600 XP 150:






CU FT-IR < 30 ppm

FE FT-IR < 50 ppm

SN FT-IR < 30 ppm

SI FT-IR < 70 ppm

AL FT-IR < 30 ppm

Mobil Mobilgear 600 XP 460:






CU FT-IR < 30 ppm

FE FT-IR < 50 ppm

SN FT-IR < 30 ppm

SI FT-IR < 70 ppm

AL FT-IR < 30 ppm

Possible sources of contamination:

Cu = Copper (bearing cages, bronze worm gears)

Fe = Iron (steel gears & other components, bearings, corrosion)

Sn = Tin (bronze worm gears, bearings)

Si = Silicon (bronze worm gears, casting sand)

Al = Aluminum (bronze worm gears)

*Note: The “Lubricant Used Oil Analysis Specifications” Table is not an all-inclusive list. For

additional information regarding used oil analysis, contact your local Mobil distributor,or call Mobil Customer Service at 1-800-662-4525.

5) Mobil oil that does not meet the “Lubricant Used Oil AnalysisSpecifications” Table specifications must be replaced.

6) Although a Mobil product is specified, any equivalent product can

be used.



Rev. 2


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7) Alternative oil manufacturers will have their own test

qualifications. The manufacturers should be consulted for

requirements when testing those brands of oil.

6. Lubrication of other Equipment

a. Input Drive Assemblies’ Reducers:

Refer to the manufacturer’s instructions.

b. Accessory Equipment:

For equipment (hydraulic motors, reducers, etc) that is supplied but is not built by FLSmidth, refer to the manufacturer’s instructions.

CAUTION:

To maintain the equipment warranty, the accessory equipment must be properlylubricated, as specified in the manufacturer’s instructions.

If you have any questions regarding proper lubrication of the accessory

equipment that has been furnished by FLSmidth, contact an FLSmidth

representative. Refer to the “Office” pages (see Table of Contents).

7. Sight Glass Replacement

If the oil level sight glasses are replaced, they must be notched to show the

correct oil level, as shown on the drawings.

Note: Do likewise for drives that are shipped without the oil level notched on

the oil level sight glasses.

DRIVE OIL QUANTITIES IN APPROXIMATE U.S. GALLONS

MODEL UPPER BEARING HOUSING ASSEMBLY MAIN GEAR

B60P-4 ½ gallon (1.9 liters) 68 gallons (257 liters)



Rev. 2

08-2010LUBRICANT EQUIVALENTS LIST

6017M

94


permission in writing by FLSmidth. All Rights Reserved.

A. LUBRICANTS

SYNTHETIC OILS 2 SYN - 5 SYN

AGMA EQUIVALENT NUMBER/VISCOSITY cSt AT 40oC MANUFACTURER

2 SYN/ISO 68 4 SYN/ISO 150 5 SYN/ISO 220

MOBIL *SHC 626 *SHC 629 *SHC 630

TRIBOL 800/150 800/220

* Synthesized hydrocarbon

SYNTHETIC OILS 6 SYN - 8 SYN

AGMA EQUIVALENT NUMBER/VISCOSITY CST AT 40oC MANUFACTURER

6 SYN/ISO 320 7 SYN/ISO 460 8 SYN/ISO 680

MOBIL *SHC 632 *SHC 634 *SHC 636

TRIBOL 800/320 800/460 800/680

* Synthesized hydrocarbon

Consult a qualified lubrication engineer or your FLSmidth representative before using a synthetic

bearing and gear oil that is not listed above as an equivalent. Physical characteristics of Mobil

SHC® 600 series synthetic oils are listed below:

Mobil

SHC 626

Mobil

SHC 629

Mobil

SHC 630

Mobil

SHC 632

Mobil

SHC 634

Mobil

SHC 636

Product Number 60293-8 60294-6 60295-3 60298-7 60291-2 60299-5

ISO Viscosity Grade 68 150 220 320 460 680

Specific Gravity 0.858 0.866 0.866 0.867 0.867 0.867

Gravity, API 33.16 32.4 331.9 31.7 31.4 31.7

Pour Point, °C (°F) max, ASTMD 97

-54 (-65) -45 (-49) -45 (-49) -42 (-44) -42 (-44) -42 (-44)

Flash Point, °C (°F) min, ASTM

D 92

245 (473) 245 (473) 250 (482) 250 (482) 250 (482) 250 (482)

Viscosity, ASTM D445

cSt at 40° C

cSt at 100° C

69.910.9

142.818.3

217.725.9

325.838.6

436.444.9

663.862.8

Viscosity Index, ASTM D 2270 147 144 152 169 159 165

Copper Corrosion 24 Hrs at

121° C, ASTM D130 1B 1B 1B 1B 1B 1B

Rust ProtectionASTM D665A and 665B,

Distilled and Synthetic sea water

Pass Pass Pass Pass Pass Pass

FZG Scuffing, Fail stage, DIN51534

11 13 13+ 13+ 13+ 13+

Color, ASTM D1500, Max 3.5 3.5 3.5 3.5 3.5 3.5

TOST Life, Hrs., ASTM D943-2 10,000+ 10,000+ 10,000+ 10,000+ 10,000+ 10,000+

For additional Mobil Product information, please visit www.mobilindustrial.com.



Rev. 2


6017M

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PETROLEUM BASED OILS 2EP - 5EPAGMA EQUIVALENT NUMBER/VISCOSITY cSt AT 40oC MANUFACTURER

2EP/ISO 68 4EP/ISO 150 5EP/ISO 220

MOBIL/EXXON Mobilgear 600 XP 68Spartan EP 68

Mobilgear SHC 150Mobilgear 600XP 150,Spartan EP 150

Mobilgear SHC 220Mobilgear 600 XP 220Spartan EP 220

AMOCO Permagear EP #68 Permagear EP #150 Permagear EP #220

GULF OIL EP Lubricant H.D. 68 EP Lubricant H.D. 150 EP Lubricant H.D. 220

TEXACO Meropa 68 Meropa 150 Meropa 220

PHILLIPS All Purpose Philgear (ISO

Grade 68)

All Purpose Philgear (ISO

Grade 150)

All Purpose Philgear (ISO

Grade 220)

SHELL Omala 68 Omala 150 Omala 220

STANDARD OF CALIFORNIACHEVRON USA

Chevron Gear Compound NL68



SUN OIL Sunep 68 Sunep 150 Sunep 220

KEYSTONE Zeniplex - 2 Keygear 90 Keygear 110

LUBRICATION ENGINEERS Monolec 300 Almasol 604 Almasol 607

PETROLEUM BASED OILS 6EP - 8EP

AGMA EQUIVALENT NUMBER/VISCOSITY cSt AT 40oC MANUFACTURER

6EP/ISO 320 7EP/ISO 460 8EP/ISO 680

MOBIL/EXXON Mobilgear SHC 320

Mobilgear 600 XP 320

Spartan EP 320

Mobilgear SHC 460Mobilgear 600 XP 460,Spartan EP 460

Mobilgear SHC 680Mobilgear 600 XP 680Spartan EP 680

AMOCO Pearmagear EP #320 Permagear EP #460 Permagear EP #680

GULF OIL EP Lubricant H.D. 320 EP Lubricant H.D. 460 EP Lubricant H.D. 680

TEXACO Meropa 320 Meropa 460 Meropa 680

PHILLIPS All Purpose Philgear (ISOGrade 320)

All Purpose Philgear (ISOGrade 460)

SHELL Omala 320 Omala 460 Omala 680

STANDARD OF CALIFORNIACHEVRON USA




SUN OIL Sunep 320 Sunep 460

KEYSTONE None Keygear 140 None

LUBRICATION ENGINEERS Almasol 605 Almasol 608 Almasol 609



Rev. 2


6017M

96



MANUFACTURER GREASE MANUFACTURER GREASE

NLGI No. 2** EQUIVALENT

NLGI No. 2** EQUIVALENT

MOBIL Mobilgrease XHP 222 SHELL Darina EP2

AMOCO Rykon #2 STANDARD OFCALIFORNIACHEVRON USA

RPM Multimotive #2

EXXON Ronnex MP

GULF OIL High Temperature Grease SUN OIL Sunaplex 992 EP

TEXACO Multipak EP2 KEYSTONE 81 EP-2

PHILLIPS PET Philube 2 EP LUBRICATION ENGINEERS Alma-Gard 3752

CAUTION:

Do not mix lubricant types without first verifying product compatibility.

Consult a qualified lubrication engineer or your FLSmidth representative.

When changing to a product that is not compatible with the existing lubricant, the

existing lubricant (oil or grease) must be completely removed before the new

lubricant type is used.

** NLGI #2 anti-wear (EP) lithium complex (high temperature) grease



Rev. 2

08-2010


LUBRICATION

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97



A. HYDRAULIC OIL SYSTEM

1. Hydraulic Power Unit and System

A drive motor and hydraulic pump on the hydraulic power unit power the drive

unit’s hydraulic motors.

a. Installation and adjustment of the power unit and system should have

been completed previously during the installation of the equipment.

Refer to the “Install the Hydraulic Power Unit” installation instructionsand to the hydraulic power unit manufacturer’s instructions.

b. Before Start-Up:

1) CHECK to make sure that all the hydraulic power unit valves are

open. Refer to the manufacturer’s instructions.

2) CHECK to make sure that the hydraulic power unit and system

are ready to be operated. Refer to the manufacturer’s instructions.

2. Hydraulic Oil

a. Make sure to pre-filter the hydraulic oil before adding any hydraulic oil.

The hydraulic oil must be cleaned before it is used.

b. Use clean hydraulic oil.

Refer to the hydraulic power unit manufacturer’s instructions for the

recommended and the types of oils to be used in the hydraulic power unit.

c. Fill the hydraulic oil reservoir with clean hydraulic oil.

CAUTION: The oil must be clean. Do not reuse hydraulic oil. Do not store

the oil in dirty containers. Do not store oil out in the open.

d. The hydraulic oil reservoir should have an oil level gauge (refer to the

manufacturer’s instructions) to show the correct oil level. CHECK the

hydraulic oil level gauge on the reservoir.

e. Do not allow the hydraulic oil level to fall below the oil level gauge at

any time, especially when the paste thickener is initially started up.



Rev. 2

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LUBRICATION

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3. Oil Equivalents (Substitutes)

If the Mobil hydraulic oil recommended is not used, the hydraulic oil that is

selected must fall into the viscosity range recommended by the hydraulic pumpmanufacturer, at both running and start-up. Refer to the hydraulic pump


Note: Any hydraulic oil used must be anti-wear hydraulic oil. Refer to the

Hydraulic Oil Equivalents List.

4. Oil fill

Refer to the hydraulic power unit manufacturer’s instructions for filling thehydraulic power unit with hydraulic oil.

5. Oil Filters

a. The hydraulic power unit should be furnished with an oil return filter and

a filter breather cap to keep the oil clean.

Note: Because the reservoir suction line does not have a strainer, it is

important to prevent any contaminants from entering into thereservoir by checking the filler breather cap and return filter

regularly and by replacing them when necessary.

b. Do not replace the filters/filter elements without first shutting down the

hydraulic power unit.

HYDRAULIC OIL EQUIVALENTS LIST

ISO GRADE

MANUFACTURER32 46 68

MOBIL DTE 24 DTE 25 DTE 26

AMOCO AW #32 AW #46 AW #68

EXXON NUTO H 32 NUTO H 46 NUTO H 68

TEXACO RANDO HD 32 RANDO HD 46 RANDO HD 68

SHELL TELLUS 32 TELLUS 46 TELLUS 68

KEYSTONE KLC-10 KLC-15 KLC 10/30



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c. Return filter:

Refer to the manufacturer’s instructions for how often to check the return

filter, when to replace the return filter, and how to replace the return filter.

d. Filler breather cap:

Refer to the manufacturer’s instructions for how often to check the filler

breather cap, when to replace the filler breather cap, and how to replace

the filler breather cap.

6. Oil Change

a. CHECK hydraulic oil level, monthly. Add oil, as necessary.

b. Replace the hydraulic oil whenever tests indicate that it is contaminated

with water, oxidation, dirt, dust, etc.

c. Only a testing laboratory can determine the chemical condition of the oil.

Refer to section “7.Oil Replacement” in this instruction.

Note: The hydraulic oil supplier oil will usually perform the test at little

or no charge.

d. Field Tests

Some field tests can help determine when the hydraulic oil should be

changed or sent to a laboratory for testing

1) CHECK for Grit

CHECK for any evidence of grit by rubbing a sample of the

hydraulic oil between thumb and finger.

2) CHECK for Water

a) Draw a sample of hydraulic oil from the reservoir into aclean bottle.

b) Cover the bottle and let it stand for a day.

c) CHECK to see if any water has settled out.



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3) CHECK for Contamination

a) Draw a sample of hydraulic oil from the reservoir and a

sample of new hydraulic oil into clean separate bottles.

b) Compare the new oil with the reservoir oil.

c) The color should be about the same (the reservoir oil may

be slightly darker).

d) A change in the color of the hydraulic oil indicates

contamination.

7. Oil Replacement

Refer to the hydraulic power unit manufacturer’s instructions for replacing the

hydraulic oil in the hydraulic power unit.

a. Start by locking out the power to the power unit.

b. Close the valves between the hydraulic pump and the reservoir.

Note: Refer to the hydraulic power unit manufacturer’s instructions for

keeping the pump primed.

c. Drain the oil.

Refer to the hydraulic power unit manufacturer’s instructions for draining

the hydraulic oil.

d. After the reservoir is filled to proper level, be sure to open the valves

between the reservoir and the hydraulic pump.

Refer to the hydraulic power unit manufacturer’s instructions.

e. Allow the hydraulic oil to reach proper operating temperature before

starting the hydraulic pump.



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8. Low Oil Level Alarm


This alarm sounds when the oil level in the reservoir drops to an unsafe low level.

When the alarm sounds, an alarm relay will be activated and the hydraulic power

unit (and rake drive) will stop. The drive will be inoperable until the oil is

brought up to proper level.

9. Oil Temperature Control


The hydraulic power unit is also furnished with an automatic oil cooler and an oil

heater to maintain the oil at a proper operating temperature to prolong its

operating life. These are both powered separately from the Control Panel.

10. Hydraulic Oil Precautions

a. Storage:

1) Store the hydraulic oil in the original containers.

2) Keep the hydraulic oil containers tightly sealed.

3) Do not store hydraulic oil in open containers.

4) Store containers in a clean dry area, protected from rain, dust, etc.

b. Transferring Hydraulic Oil:

1) CHECK to make sure that the containers are clean and dry before

they are opened.

2) CHECK to make sure that the areas around the reservoir oil capand the filters are clean before removing filler caps, plugs or

filters.

3) All equipment used to transfer oil, such as funnel, pumps, etc,

must be clean. Wipe them clean and wrap them in protectivecovers after use.

4) Use a 10-micron filter when pouring oil into the reservoir to trap

any contaminates that might be in the oil.



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5) Do not reuse hydraulic oil.

6) Clean up all hydraulic oil spills, immediately.

c. Types of Oils:


a. Use only one brand of oil, as some brands are not compatible with

each other.

b. The reservoir and system must be completely drained before

adding a different brand/type of hydraulic oil.



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MAINTENANCE AND OPERATION

WARNINGS

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A. SAFETY STATEMENT

Do not depend entirely on safety devices to prevent accidents. Safety features and

devices are meant only to supplement proper, careful, and safe practices on the part of theindividual.

WARNING:

If the safety procedures given in this manual are compromised or ignored, severe personal injury or death may occur. Safety practices accepted by the industry, as

well as those dictated by the responsible regulatory agencies must be followed.

WARNING:

Use extreme care when working around rotating or other moving parts, to preventinjuries to yourself or others.

Anyone entering the area of this equipment must be wearing adequate safetyequipment, such as safety glasses, safety shoes, hardhat, etc.

Loose fitting clothing, uncovered long hair, or jewelry must not be worn when

working around rotating or moving equipment.

WARNING:

Keep foreign objects, hands, etc. away from moving parts.

Do not operate this equipment if guards have been removed or are damaged.

All guards and safety devices must be properly installed and functional before

operating this equipment.

WARNING:

Use a manual breaker or a disconnect switch to lockout power from electrical

equipment before starting any work or maintenance on the equipment. Lock and

tag the disconnect switch so that it cannot be closed.

PERSONNEL SAFETY WARNINGS



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A. CHECK POINTS BEFORE START-UP

1. The drive and mechanism must be level and must be checked by an authorized

FLSmidth Representative before start-up.

Refer to the “CHECK the Drive for Final Level,” “CHECK the Rake Arms for

Final Level and Alignment,” and the “Final Mechanical Check by FLSmidth

Service Personnel” instructions (see Table of Contents).

2. Remove any foreign matter from inside the tank.

3. Remove any blocking or shoring used in the erection of the equipment.

4. CHECK the oil levels in the main drive and in the upper bearing housing

assemblies. Refer to the “Drive Lubrication” instructions (see Table of Contents).

5. CHECK the input drive assemblies’ components (reducer and hydraulic motor).


6. CHECK the Hydraulic System

a. CHECK the hydraulic oil level in the hydraulic power unit.

b. CHECK (verify) that all hydraulic oil lines are connected.

c. CHECK hydraulic oil lines and connections for leaks.

d. CHECK that the hydraulic power unit has been primed.

e. CHECK that the hydraulic oil temperature is within operating range at the

time of start-up.

7. CHECK to make sure that the drive/torque control was checked for proper

operation. Refer to the drive control instructions in the “General Drive

Maintenance” instructions (see Table of Contents).

8. CHECK to make sure that the superstructure’s drive platform and walkway areasare clean and free of oil, debris, and tools.

9. CHECK to make sure that all drive cover guards are in place.



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WARNING:

Do not operate this equipment if the guards have been removed or are damaged.

All guards and safety devices must be properly installed and must be functional

before operating this equipment.

10. Rotate the rake arms for at least four or five revolutions. Make all observationsfrom outside the tank.

a. This procedure should be conducted when distortion from sunlight would

be at a minimum, such as, early morning or an overcast day.

b. CHECK for clearance of the rake arm blades with the tank bottom.

c. CHECK for loose parts, bolts, and nuts.



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MAINTENANCE/ OPERATION FREQUENCY LUBRICANT(if applicable) COMMENTS/REFERENCES

THICKENER MECHANISM:

CHECK to make sure that thesuperstructure’s drive platform andwalkway areas are clean of oil, debris,and tools.

Weekly Clean up oil spills immediately

CHECK to make sure that all coverguards are in place.

Weekly None CHECK guards after maintenance.

CHECK the superstructure for loosenuts, bolts, grating, grating clips,handrails, and for broken welds.

Monthly None Refer to the “Install the Superstructure”instructions (see Table of Contents).

CHECK connections between the upperrake shaft and the drive (gear adapter plate).

Yearly None Refer to the “Install and Align the RakeShaft” instructions (see Table of Contents).

CHECK connections between the upperand lower rake shafts.

Yearly None Refer to the “Place the Rake Shaft Assemblyin Position in the Tank” instructions (seeTable of Contents).

CHECK the rake arms-to-rake shaft,rake arm supports-to-rake shaft, and rakearm supports-to-rake arms connectionsfor broken welds.

Yearly None Refer to the “Install the Rake Arms” and“CHECK the Rake Arms for Final Level andAlignment” instructions (see Table ofContents).

CHECK the feedwell-to-feedwell andthe feedwell-to-superstructure

connections for loose nuts and bolts.

Yearly None Refer to the “Install the Feedwell”instructions (see Table of Contents).

CHECK the feed tank-to-superstructure,top chord diagonal-to-superstructure,feed tank-to-E-Duc nozzle, E-Duc

nozzle hanger-to-superstructure, E-Ducnozzle hanger-to-E-Duc nozzle, mixtrough hanger-to-superstructure, mixtrough hanger to mix trough, and mixtough to feedwell connections for loosenuts and bolts.

Yearly None Refer to the “Install E-Duc System”instructions (see Table of Contents).

CHECK the picket supports-to-rakeshaft, picket braces-to-rake shaft, picket braces-to-picket supports, pickets-to- picket supports, pickets-to-rake armsupports, and picket-to-rake armsconnections for loose nut and bolts and

for broken welds.

Yearly None Refer to the “Install the Pickets” instructions(see Table of Contents).

CHECK the wear plates-to-guide pocketand guide pocket-to-discharge cylinderfloor for loose nuts and bolts and for

broken welds.

Yearly None Refer to the “Final Weld the Guide Pockets”instructions (see Table of Contents).

CHECK the top chord struts-to-superstructure, monorail-to-superstructure, monorail-to-top chordstruts, and monorail-to-monorail beamon the superstructure connections forloose nuts and bolts and for brokenwelds.

Yearly None Refer to the “Install the Top Chord Struts andMonorail” instructions (see Table ofContents).



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CHECK the flocculent piping systemconnections for loose bolts and nuts andfor broken welds

Yearly None Refer to the “Install the Flocculent Piping”instructions (see Table of Contents).

Remove rust spots and repaint, asnecessary.

Yearly or whentank is drained

None



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For confidential use only. Not for circulation, distribution or reproduction without prior permission, in writing, by FLSmidth. All Rights Reserved.


DRIVE UNIT:

CHECK the condition of the drive’s oil(all housings).

As necessary Refer to the lubrication plate that is mounted onthe drive unit.

Replace oil, as necessary. The oil must bekept clean.

CHECK the drive’s oil level (main gearand upper bearing housings).

Weekly Refer to the lubrication plate that is mounted onthe drive unit.

Add oil, as necessary. Refer to the “DriveLubrication” instructions (see Table ofContents).

Drain condensate from the drive (maingear and upper bearing housing).

Weekly Refer to the lubrication plate that is mounted onthe drive unit.

Refill with oil, as necessary. Refer to the“Drive Lubrication” instructions (see Tableof Contents).

CHECK drive/torque control. Monthly, then asnecessarydepending onoperatingconditions

None Refer to the “General Drive Maintenance”instructions (see Table of Contents).

CHECK to make sure that the vent holesin the vented pipe plugs and sight glassvent openings are clear.

Monthly Vent holes in vented pipe plugs and sightglass vent openings must be kept clean of dirt, paint, and other foreign material.

CHECK samples of the drive oil (maingear and upper bearing housings) forcondition.

After first 500operating hoursand then, every 6months thereafter.

Refer to the “Lubricant Used Oil AnalysisSpecifications” Table in the “DriveLubrication” instructions (see Table ofContents).

Change oil. When indicated by

a qualified oilanalysis orannually/bi-annually, if oilanalysis is not used

Refer to the lubrication

plate on the drive unit.

Replace oil as necessary. The oil must be

kept clean. Refer to the “Drive Lubrication”instructions (see Table of Contents).

INPUT DRIVE ASSEMBLIES:(Hydraulic Motors and Reducers)

Lubrication. Refer to the manufacturer’s instructions.

Maintenance. Refer to the manufacturer’s instructions.

HYDRAULIC POWER UNIT AND SYSTEM:

CHECK hydraulic oil level in reservoir. Monthly Refer to manufacturer’s

instructions.

Refer to the “Hydraulic Power Unit

Lubrication” instructions (see Table ofContents).

Replace hydraulic oil. Depends oncondition of oil

after testing.

Refer to manufacturer’sinstructions.

Refer to the "Hydraulic Power UnitLubrication” instructions (see Table of

Contents).

Oil return filter. Refer tomanufacturer’s

instructions.

Replace element, as needed. Refer to the“Hydraulic Power Unit Lubrication”

instructions (see Table of Contents).



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Filler breather cap. Yearly, or asrequired. Refer tomanufacturer’sinstructions

Replace filler breather cap, as needed. Referto the “Hydraulic Power Unit Lubrication”instructions (see Table of Contents).

CHECK hydraulic fluid lines (hoses). Monthly CHECK for leaks or loose connections

Keep hydraulic power unit andsurrounding area clean.

Monthly Hydraulic oil collects dirt. Keep surroundingarea wiped up.

Hydraulic pump motor. Refer tomanufacturer’sinstructions.

Refer to manufacturer’sinstructions




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A. FOUR-HYDRAULIC MOTOR BALANCED DRIVE UNIT

1. The drive unit is a combination of FLSmidth Minerals manufactured parts,

hydraulic motors, and reducers that have been purchased from othermanufacturers.

2. These maintenance instructions apply only to the EIMCO® main drive unit.They do not cover hydraulic motors or reducers that have been built bymanufacturers other than FLSmidth; although, those drive units may be furnished

integrally as part of the main drive.

3. Refer to the respective manufacturer’s instructions.

B. CHECK DRIVE ROTATION

1. CHECK each input drive assembly’s hydraulic motor for proper direction of

rotation before the hydraulic motor is attached to the reducer assembly.

WARNING:

If the hydraulic motors are not connected for the proper direction of rotation, thedrive unit warranty will be void and FLSmidth will not be responsible for drive

unit damages.

C. DRIVE UNIT COMPONENTS

1. This drive unit consists of a main gear on the bottom, which drives the rake shaft,

and four upper bearing housing assemblies on top, which are driven by the inputdrive assemblies.

2. Each input drive assembly consists of a reducer assembly with a hydraulic motor

drive.

3. Hydraulic oil flow volume (rate of flow) determines the speed of the hydraulicmotors.

4. The “stroke adjustment” for the required maximum rate of flow is normally madeat the hydraulic pump on the hydraulic power unit.

5. Stroke adjustment (maximum motor speed) for hydraulic power units are

normally factory set for proper operation. Do not tamper with it.



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6. If the original stroke (maximum motor speed) setting is not satisfactory for the

conditions, contact your FLSmidth Representative before attempting any

adjustments.

Note: A flow control valve, if furnished on the hydraulic power unit, provides

control of variable rake drive speed. Refer to the manufacturer’s

instructions.

D. THE DRIVE CONTROL/TORQUE CONTROL

1. The drive/torque control is provided by pressure switches on the hydraulic power

unit.

2. At set points, the alarm should sound and the hydraulic power unit should stop.

Refer to the manufacturers’ instructions, drawings and diagrams for set point

settings.

DRIVE CONTROL /TORQUE CONTROL CAUTION:

The drive control/torque control is the overload cut-out device for the drive.

Because the drive control/torque control is installed and adjusted at the factory for

proper operation, do not tamper with it.

If the original settings are not considered satisfactory for the operating conditions,contact your FLSmidth Representative before attempting any adjustment.

3. If hydraulic pressure to the drive hydraulic motors should exceed the maximum

allowed psi/kpa due to torque overload, improperly connected hydraulic piping,

or blocked hydraulic piping, the pressure relief valve will open and recycle

hydraulic oil flow back to the hydraulic oil reservoir on the hydraulic power unit.

Note: Refer to the hydraulic power unit manufacturer’ instructions for hydraulic

motors maximum psi/kpa settings.

WARNING:

If the drive unit stops due to an overload do not attempt to restart the drive unit

until the cause of the overload has been located and corrected.

Refer to the “Drive Maintenance WARNING” instruction (see Table of

Contents).



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E. ELECTRICAL EQUIPMENT AND ENCLOSURES

1. Electrical enclosures for the motors, Control Panels, etc, if furnished by

FLSmidth, are listed on the drawings and FLSmidth Parts List.

2. If any electrical equipment, including motors, is to be replaced, it must be of

equal or better rating.

3. Refer to the latest edition of the NEMA ICS (National Electrical Manufacturer’s

Association Industrial Control Standards) and NEMA MG 1 (NEMA Motors andGenerators) for a description of those enclosure designations.

F. LUBRICATION

Refer to the “Drive Lubrication” and Hydraulic Power Unit Lubrication” instructions (see

Table of Contents).



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WARNING!

A. STORED ENERGY

1. When a raking mechanism drive shuts down due to high torque load, it may havestored energy.

2. If this stored energy is not relieved in a safe way, this energy can be dangerous tothose who service the drive unit when returning it to operation.

3. The stored energy is most likely in the elastic deformation of the rake arms andrake shaft assembly, which is caused by the torsional load.

4. Do not attempt to disassemble the drive unit while there is stored energy in the

mechanism or in the drive. When some of the fasteners are loosened, parts of the

mechanism and/or drive may suddenly release, which will cause serious injuriesand machine damage.

Note: Torque indication at the hydraulic power unit is based on hydraulic oil

pressure and is shown only when the hydraulic power unit is operating.

5. Before the cause of stoppage (high torque load shutdown) is corrected, the stored

energy must be relieved. Refer to section “B. How to Relieve Stored Energy.”

See WARNING.

WARNING:

The hydraulic power unit must be shutdown, and the hydraulic pressure to themotor must be at 0 psi/kpa before disconnecting any hydraulic hose/piping, or

attempting to make any repairs on the mechanism.



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B. HOW TO RELIEVE STORED ENERGY:

Refer to the hydraulic power unit and hydraulic motors manufacturer’s instructions.

1. In the event of a torque overload, the hydraulic power unit is equipped with a

check valve and a needle valve that prevent back pressure from damaging the

hydraulic motors.

2. The needle valve must remain closed during normal operation, but if a high

torque shutdown occurs, open the needle valve slowly to relieve any residualhydraulic pressure (stored energy).

3. If hydraulic pressure to the hydraulic drive motors should exceed the maximumallowed psi/kpa, due to (1) torque, (2) improperly connected hydraulic piping, or

(3) blocked hydraulic piping, the pressure relief valve will open and recycle

hydraulic oil flow back to the hydraulic oil reservoir on the hydraulic power unit.

WARNING:

The hydraulic power unit must be shutdown, and the hydraulic pressure to the

motor must be at 0 psi/kpa before disconnecting any hydraulic hose/piping, or

attempting to make any repairs on the mechanism.



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INSTRUCTIONS

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A. DRIVE DISASSEMBLY (See Figures 39 and 40)

The drive can be disassembled and reassembled in place, or the drive can removed and

sent to a shop for repairs. If the drive is to be removed, refer to the “Install the DriveUnit” instruction for lifting (see Table of Contents).

1. CHECK the drive for torque. See WARNING. Refer to the “Drive Maintenance

WARNING” instruction (see Table of Contents).

WARNING:

CHECK the drive for torque before starting any disassembly on the drive. Refer

to the “Drive Maintenance WARNING” instruction (see Table of Contents).

2. Block the rake arms and rake shaft assembly (picket supports, etc) in position.

WARNING:

CHECK to make sure that the electrical the hydraulic power unit has been

disconnected or blocked out to prevent the drive from being accidentally started.

3. Hydraulic Power Unit:

a. Disconnect and lock out all electrical power to the hydraulic power unit.

b. Disconnect hydraulic lines (hoses) to the drive unit’s hydraulic motors

(input drive assemblies). Match mark the hydraulic fluid lines (hoses)

for easier reconnection later.

c. Remove the hydraulic piping (hoses), as required, for drivedisassembly.

d. Cover the hydraulic fluid hose connections on the hydraulic motors

(input drive assemblies).

e. Cover the hydraulic motors.

f. Cover any open ends of the hydraulic oil system piping (hoses) to prevent contamination or spilling of the hydraulic oil.

g. Cover the hydraulic power unit.



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4. Disconnect the rake shaft from the gear adapter plate (3).

Note: Match mark the connecting flange and gear adapter plate and any shims

that were used for aligning the rake shaft, so that they can be reassembledin their original position.

5. Drain the Oil

Drain the oil from the main drive, each upper bearing housing assembly, and each

input drive assembly’s reducer.

6. Remove each input drive’s oil drain piping (5), as required, for input drive

assemblies (4) removal.

Figure 39

1- Upper bearing housing 4- Input drive assembly

2- Main gear housing (drive base) 5- Input drive oil drain piping7- Drive cover

3- Gear adapter plate 6- Input drive assembly-to-upper bearing housing assembly connection socket head capscrews

7. Match mark the reducer mounting plate (4) to the upper bearing housing

assembly (1) from which it is removed. This will ensure that each input drive

assembly (4) is re-installed on the same upper bearing housing assembly (1) fromwhich it was removed, and will ensure that the original input drive assemblies’

orientation is maintained.

6

4

5

1

37

2



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Figure 40

1 – Upper bearing housing 6 – Input drive-to-upper bearing housingconnection socket head capscrew

11 – Lip seal with band and worm clamps

2 – Main gear housing (drive base) 7 – Reducer assembly 12 – Precision ball bearing capscrew

3 – Gear adapter 8 – Hydraulic motor 13 – Main gear

4 – Input drive assembly 9 – Drive cover 14 – Precision ball bearing

5 – Input drive oil drain piping 10 – Socket head capscrew 15 – Socket head capscrew

8. Remove the Input Drive Assemblies

a. Remove the input drive assemblies from the upper bearing housings.

b. Remove the socket head capscrews (6) that are connecting the input drive

assemblies to the upper bearing housing assemblies.

1

6

511

10

12

14 15

132

3 9

4

7

8



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c. Remove the input drive assemblies (4) [four total reducers and hydraulic

motors] from the upper bearing housing assemblies (1).

d. Refer to the manufacturer's instructions for reducer disassembly andreassembly instructions.

9. Remove the upper bearing housing assemblies (1). Refer to section “E. Upper

Bearing Housing Assembly” in this instruction.

10. Remove the drive cover (9).

11. Removal of Gear Adapter Plate

a. Remove the capscrews (10) that are securing the gear adapter plate (3) to

the main gear (13).

b. Remove the gear adapter plate (3) from the drive base (2).

B. DISASSEMBLY OF THE MAIN GEAR AND BEARING

Refer to Figure 40.

1. Remove the lip seal (11) with band and screw clamps from the drive base (2)

[main gear housing].

a. The lip seal should be replaced if there is an indication of wear or

deterioration.

b. The lip seal should be replaced when the drive unit is disassembled aftera year of operation.

2. Use a socket head wrench to remove the precision ball bearing capscrews (12).

3. Remove the main gear (13) and precision ball bearing (14) from the drive base.

4. Remove capscrews (15) and remove the precision ball bearing (14) from the main

gear (13).

Note: Do not remove the drive base (2) [main gear housing] from the

superstructure.



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C. INSPECTION

1. Clean the main gear (13) with solvent and blow dry.

a. CHECK the Teeth of the Main Gear for the Following:

1) ABRASIVE WEAR:

Wear on the teeth will show at random spacing across the teeth.

Normally, caused by dirt or other foreign material in the lube oil.

2) SCORING:

Shown by vertical scratches and/or grooves running from the pitch

line (approx. center of tooth) to the top of the tooth. Can result

from improper lubrication.

3) PITTING:

Evident in large or numerous pits in the gear teeth. Caused byoverload on gear or poor lubrication.

Note: Small pits may occur during run-in of a new gear, but

these will smooth out as the gear wears in.

4) GALLING:

Appears on the gear teeth as numerous deep grooves. Caused by

overload of the gear for the lubricant used.

b. Replace the main gear, as necessary, depending on the severity and extent

of these conditions (scoring, pitting, etc).

2. Clean the main gear precision ball bearing (14) and coat it with oil. See Figure

40.

a. CHECK the main gear precision ball bearing by rotating the outer bearingrace by hand.

b. CHECK for smooth noiseless operation.

c. Depending on the smoothness, the precision ball bearing may or may notneed to be replaced.



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d. If the bearing will not rotate freely, or if it is rough in rotation, the bearing

must be replaced.

3. CHECK the gear adapter-to-drive cover’s lip seal (16) for condition. See Figure41.

a. Replace, if necessary.

b. Refer to section “D.8.a. Lip Seal Installation” in this instruction.

Figure 41

3- Gear adapter plate 11- Lip seal 17- ⅛” (3.175 mm) prior to installation of gear adapter plate

9- Drive cover 16- Lip seal 18- Band clamp and screw clamp

9

16

3

17

11

18



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D. REASSEMBLY OF THE DRIVE ASSEMBLY

Refer to Figures 40, 41 and 42.

CAUTION:

Gaskets in the drive unit are not to be used, except where specified on the

assembly drawings and parts list.

1. Set the precision ball bearing (14) in place on the main gear (13).

2. Install the capscrews (15).

a. Lubricate and secure the capscrews (15) in equal stages and in a cross

diameter sequence.

b. The final torque on all capscrews (15) must be 245 ± 10 ft-lb, lubricated.

Note: Take care to prevent dirt or foreign matter from getting into the

precision ball bearing and drive assembly.

3. Set the main gear (13) and precision ball bearing (14) assembly in place in the

drive housing (2). Refer to the drawings for orientation of the loading plug.

Note: Provide oil tight seal at the loading plug on precision bearing by coveringthe loading plug bore I.D. (inside diameter) groove with Ultra Blue RTV-Silicone.

4. Install the precision ball bearing capscrews (12).

a. Lubricate and secure the capscrews (12) in equal stages and in a cross-

diameter sequence to avoid precision ball bearing warpage.



bearing and drive assembly.

5. Install the drive base-to-gear adapter lip seal (11).

a. The lip seals should be replaced whenever the unit is disassembled.

b. Use a straight edge to locate the seal.



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c. Use the band clamp and screw clamps to secure the lip seal. Refer to

Figure 41.

d. Lubricate the seal with anti-seize.

6. Set the gear adapter plate (3) in place on the main gear (13). See Figure 40.

7. Install and secure the capscrews (10) that attach the gear adapter plate (3) to the

main gear (13).

a. Lubricate and secure the capscrews (10) in equal stages and in a cross

diameter sequence to avoid warpage.



bearing and drive assembly.

8. Install the drive cover to gear adapter lip seal (16). Refer to Figures 41 and 42.

Note: The lip seals should be replaced whenever the unit is disassembled.

a. Lip Seal Installation

1) Clean the surfaces thoroughly where the lip seal is to be applied.

Note: Surfaces must be free of dirt, grease, weld spatter, mill

scale, and any foreign material.

2) Apply cement over the metal surfaces where the seal is to be

placed.

3) Before setting the seal into place, make a square cut on the end of

the seal material.

4) Apply cement to seal bottom, except for the last 12” (304.8 mm).

5) Orient the seal with the sealing lip as shown on the drawings.

6) Set the lip seal into place, except for the 12” (304.8 mm) un- bonded seal material.

a) Lay the un-bonded seal material over the opposite end.



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b) Mark the un-bonded seal material and cut it off square so

that the two ends touch.

7) Apply cement to ONE END ONLY on the remaining un-bondedseal bottom and set it into place.

8) Press ends firmly together until a sufficient bond is made.

9) At the joint, where the ends of the seal come together for bonding,

add wire rope, equally spaced on each side of the joint, and bondin place as shown on the drawings.

Figure 42

3- Gear adapter plate 16- Lip seal 20- Wire rope

9- Drive Cover 19- Bonding agent

9

16

3

1619

20



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9. Install the drive cover. See Figure 40.

Note: Use RTV-Silicone between the drive cover and housing to obtain a liquid

tight seal, as specified on the drawings.

10. Reinstall the Upper Bearing Housing Assemblies. See Figures 39 and 40.

Refer to section “E. Upper Bearing Housing Assembly” in this instruction.

CAUTION:

CHECK to make sure that the input drive assemblies are installed on the same

upper bearing housings from which they were removed.

CAUTION:

Gaskets in the drive unit are not to be used, except where specified on the

assembly drawings and Parts List.

11. Install the input drive assemblies (4) [reducer and hydraulic motor] on the upper

bearing housing assemblies (1). Orient them as match marked duringdisassembly and as shown on the drawings. See Figures 39 and 40.

a. Lubricate the pinion splines on the upper bearing housing assemblies withgrease, before setting the input drive assemblies in position.

b. Reinstall each input drive assembly’s (4) oil drain piping (5).

c. Install the input drive retaining capscrews (6).

1) Apply white silicone to input drive-to-upper bearing housing

connections to obtain a liquid tight seal.

2) Install the capscrews and torque tighten in two stages and in across diameter sequence.

3). For final tightness of the capscrews, refer to drawings.

12. Lubricate the drive assembly. Refer to the “Drive Lubrication” instructions (seeTable of Contents).



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13. Hydraulic System

a. Connect the hydraulic piping (hoses) to the hydraulic drive motors. Use

the match marks.

b. Connect any hydraulic piping that was removed for drive disassembly.

c. Refer to the manufacturer’s instructions.

14. Reconnect the electrical power to the hydraulic power unit. CHECK for properdrive rotation.

15. Reconnect the rake shaft to the gear adapter plate.

a. Use the shims and match marks.

b. New H.S. bolts will be needed at the rake shaft-to-gear adapter plate

connection. Refer to the “High Strength Bolts (H.S. Bolts) Tightening


c. Refer to the “Install and Align the Rake Shaft” instructions (see Table of

Contents).

16. Remove the temporary blocking and shoring from the tank.



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E. UPPER BEARING HOUSING ASSEMBLY

Figure 43

19- Oil reservoir cover 22- Housing 25- “Lower” retaining ring

20- Pinion and shaft 23- Spherical roller bearing 26- Cylindrical roller bearing

21- “Upper” retaining ring 24- Oil seals

1920

22

25

26

21

23

24



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1. Removal:

a. Remove the capscrews and washers that are connecting the upper bearing

housing assembly to the main drive.

b. To avoid cocking the pinion gear in the main gear pinion pocket, the

upper bearing housing assembly must be lifted straight up. Refer to

Figure 40.

CAUTION:

Use care when removing the upper bearing housing assemblies from the main

gear to prevent damage to the pinion, main gear, and bearings.

c. Remove the Upper Bearing Housing Assembly

1) Place the upper bearing housing assembly on saw-horse typesupports. CHECK to make sure that this device will support the

weight of the assembly.

2) Place blocking under the pinion and shaft of the upper bearing

housing assembly to prevent it from falling from the upper

bearing housing when the retaining ring is removed.

2. Disassembly:

See Figure 43.

a. Remove the oil reservoir cover (19) from the pinion and shaft (20).

b. Remove the “upper” retaining ring (21).

c. Use an eyebolt in the top of the pinion shaft and shaft (20) to lower it

down through the housing (22), as the blocking is removed.

d. Remove the spherical roller bearing (23) and oil seals (24). A puller may

be required for the bearing.

e. Remove the “lower” retaining ring (25) and the cylindrical roller bearing

(26) from the end of the pinion and shaft (20).

f. CHECK the bearings by rotating the outer race by hand.



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1) CHECK for smooth noiseless operation.

2) If there is any question about the condition of a bearing, it should

be replaced.

g. All parts should be cleaned with a solvent and coated with light oil for

inspection.

Note: Do not rotate a dry bearing.

3. Reassembly:

See Figure 43.

CAUTION:

Gaskets are not to be used, except where specified on the assembly drawings and

parts list.

a. Preassembly Checklist:

1) Take care to prevent dirt or foreign matter from getting into the

upper bearing housing and drive assembly.

2) All parts must be cleaned with a solvent and blown dry beforereassembly.

3) CHECK all parts for damage or wear. Replace them, as

necessary.

4) CHECK all bearings for pitting, roughness of rotation or scoring.

5) Replace all bearings on a shaft if one is defective.

6) Coat all bearings liberally with grease or oil before they are

installed.

7) Oil seals are subject to deterioration and should be replaced with

new seals when the unit is reassembled, even though the

deterioration may not show.

b. Mount the cylindrical roller bearing (26) on the bottom end of the pinionand shaft (20). Install the “lower” retaining ring (25).



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c. Pull the pinion (20) up through the upper bearing housing (22) with the

eyebolt and support the pinion from below with blocking.

d. Install the oil seals (24) inside the upper bearing housing (22). Refer tothe drawings for oil seals orientation.

Note: The oil seals (24) must be installed with the lips facing upward.

e. Install the spherical roller bearing (23) over the shaft.

Note: Tap the bearing as necessary to seat. Use a tubular driver.

f. Install the “upper” retaining ring (21).

g. Place the oil reservoir cover (19) in position over the pinion shaft (20).

h. Turn the pinion and shaft by hand to be sure that all parts are properly

installed. Turn the pinion and shaft smoothly.

4. Install the Upper Bearing Housing Assembly

a. Apply Ultra Blue RTV-Silicone Sealant to the upper bearing housing

lower mounting face.

b. Silicone should be applied around each bolt hole and between bolt holesto obtain a water tight seal.

c. Install the upper bearing housing assembly.

1) Lift the upper bearing housing assembly and set it in position on

the main drive.

2) Align the upper bearing housing with the main drive. Refer to the

drawings for orientation.

3) Install and secure two of the upper bearing housing assembly-to-

drive housing capscrews. Refer to the drawings.

4) Install and secure nine of the upper bearing housing assembly-to-

drive housing capscrews. Refer to the drawings.

Note: Take care to prevent dirt or foreign matter from gettinginto the bearing and drive assembly.



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a) Lubricate and secure the capscrews in equal stages and in

a cross diameter sequence to avoid warpage.

b) The final torque on all capscrews must be 215 ± 10 ft-lb, lubricated.

d. Apply a bead of Ultra Blue RTV-Silicone around the base of the upper

bearing housing assembly to ensure a liquid tight seal between the upper

bearing housing and main drive cover.



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OIL SEAL INSTALLATION

PROCEDURE

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A. OIL SEAL INSTALLATION PROCEDURE

Careless installation is one of the most common reasons for seal problems. The

installation mechanic can prevent these problems by reviewing and following these

instructions.

Figure 44

1- Outer Shell (Case) 4- Primary Lip 6- Garter Spring

2- Inner Shell (Case) 5- Secondary Lip (Auxiliary Lip) 7- Head Section

3- Sealing Element

B. SEAL COMPONENTS

Seals are made up of the following basic components, with each component performing a particular function.

1. Outer Shell (Case):

The outer, cup-shaped, rigid structure of the lip seal assembly acts as a protective

cover for the head of the sealing element.

2. Inner Shell (Case):

A rigid cup-shaped component of a seal assembly, which is placed inside theouter seal case. It can function as a reinforcing member, shield, and spring

retainer, or lip clamping device.

13

5

7

6

2

4



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3. Sealing Element:

The normally flexible elastomeric component of a lip seal assembly, which rides

against the shaft

4. Primary Lip:

The flexible elastomeric component of a lip seal which contacts the rotating

surface.

5. Secondary Lip (Auxiliary Lip):

A short, non-spring loaded lip, which is located at the outside, seal face of a radiallip seal. Used to exclude contaminants.

6. Garter Spring:

A coiled wire spring with its ends connected. It is used for maintaining a sealing

force between the sealing element and sealing surface.

C. PROPER INSTALLATION PROCEDURES

The seal is ready to be installed in the bore once the old seal has been removed, and once

the shaft and bore have been checked and cleaned.

Note: The seal should be pre-lubricated before installation.

D. PRE-LUBRICATION

1. Pre-Lube the Lip Seal

a. Pre-lube the lip of the seal, before the seal is installed. This step isimportant because pre-lubrication provides a film on which the seal ridesuntil there is ample lubricant in the seal cavity.

b. The best pre-lube to use is the lubricant that is being used in the drive

unit. Refer to the “Drive Lubrication” instructions (see Table of

Contents).

E. TOOLS

1. A hydraulic press that applies uniform pressure against the seal is recommended.

However, if a press is not available or not practical, a round tool, such as a

bearing cup, is excellent.



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2. The installation tool must follow the seal into the bore. It should be slightly

smaller that the outside diameter of the seal.

Note: An installation tool with an O.D. ten thousandths of an inch smaller than

the bore is ideal.

3. For best results, the center of the tool should be open so that pressure is appliedonly at the outer edge of the seal case.

4. The tools used to install seals can often affect seal performance.

For Example:

A screwdriver may easily cut the seal lip or bend the case and cause the seal to

leak. Even blunt-end drifts can damage the seal case or distort the seal from its proper working position.

CAUTION:

Sealing damage may result when:

a. Using a steel hammer

b. Using a drift or punch

c. Using a chisel or screwdriver

d. Using direct hammer blows on the face of the seale. Starting seal into bore at an angle (cocked)

Figure 45

1- Tool 2- Soft Faced Mallet

1 2



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F. HAMMERING

1. Use a soft-faced or dead-blow hammer or mallet against an installation tool when

installing seals. See Figure 45.

a. This type of tool, like a block of wood, absorbs the shock wave created by

the tool's impact.

b. A hammer blow without any material to absorb the shock wave can

dislodge the garter spring from its proper operating position, and once the

spring is out of position, the seal will fail.

d. The spring can interfere with the action of the seal lip, or it can find itsway into the bearing.

2. Whatever tool is used, remember that seating force must be applied and spread

out around the entire circumference of the seal.

a. A direct blow on one side of the seal distorts the case and can cause the

lip to be pressed against the shaft.

b. This action produces increased friction between the lip and the shaft

surface.

3. If installation pressure is applied to the seal’s inside diameter, the case is forced

upward, which lifts the lip from the shaft surface.

a. If the seal is cocked, not perpendicular to the shaft and bore, the result

will be too much contact on one side, and not enough contact on the other

side.

b. The seal will leak as the shaft is deflected by shaft-to-bore misalignmentor run-out.

c. Seals must be seated up against the bore shoulder to achieve perpendicularity of sealing lip to shaft.

4. Sealing Lips Must Not Be Painted

Shaft seal surfaces, including those seal surfaces that move axially, must be freefrom paint, nicks, scratches, etc in the area where the seals are to function.

Note: Coating the seal case is acceptable after installation.



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MAINTENANCE,

START-UP SERVICES,

PARTS AND REPAIR ORDERS

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A. MAINTENANCE AND START-UP SERVICES

1. Experienced FLSmidth engineers and service personnel are available to assist in

the start-up and maintenance of the equipment.

2. They offer the benefits of their technical expertise and firsthand knowledge of the

equipment, plus the backing of FLSmidth’ entire engineering and research

facilities.

3. They can instruct on proper operating and maintenance procedures, offer advice

on troubleshooting, and if necessary, supervise the entire start-up, depending onrequirements.

4. If such assistance is desired, arrangements must be made at the earliest possible

date.

a. The arrangements must outline the services required and provide theapproximate duration of such services.

b. Charges for the services will be arranged at the time the arrangements aremade.

5. Contact an FLSmidth representative. Refer to the “Office” pages (see Table of

Contents).

B. PARTS AND REPAIR ORDERS

To make sure that the right replacement parts are received and to avoid undue delay, it isimportant to provide the following information with each order.

1. Size and Type of Unit:

This information is found on the cover page of this manual and on the Parts List

pages.

2. Serial Number:

The Serial Number is found on the unit nameplate, on the Top Level drawing,

and on the Parts List.

Note: In case the Serial Number is omitted on the Parts List, use the Order

Number; the Serial Number and the Order Number are similar.



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3. Part Number and Descriptions:

The part numbers and descriptions are listed on Parts List.

4. Special Field Modifications:

a. This information is important if the original material or design has been

changed.

b. Include drawings and/or other descriptive information.

5. Please, contact FLSmidth for parts, repair orders, and/or equipment service.

Refer to the “Office” pages (see Table of Contents).



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SUGGESTED OPERATION

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A. THE THICKENER

The deep paste thickener is designed to concentrate (thicken) the feed solids to the

consistency of a paste. Successful operation of the deep paste thickener requires

controlling two general parameters: (1) effective flocculation of the feed and (2)

controlling the rheology1 of the paste inside the thickener tank.

1. The flotation tailings feed stream enters the deep cone paste thickener through thefeed pipe, mix tank, E-Duc® nozzle, and mix trough.

Note: The E-Duc nozzle enhances flocculation by diluting the feed slurry using

internal dilution.

2. As the feed stream is injected into the funnel end of the mix trough, a low pressure “draft” is created in the funnel.

3. Clear liquid from the deep cone paste thickener tank is drawn into the funnel end

of the mix trough to mix with and dilute the incoming stream as it travels throughthe mix trough.

4. Flocculation piping is located, as specified on the drawings, to allow the addition

of polymer to the feed stream at various points to enhance flocculation of the feed

solids at the E-Duc nozzle, in the mix trough, and in the feedwell. Refer to the

General Arrangement Elevation, General Erection, and Flocculation Erectiondrawings.

5. The feedwell directs the feed downward, where the thickening of the solids takes

place, while the clearer liquid moves outward and upwards to the effluentlaunder.

6. Flocculent is metered into various locations in the E-Duc feed system and the

feedwell by a variable speed pump at a rate adequate to flocculate and settle the

solids.

7. Rheology

The rheology of the paste is the primary control method; since, it is very

important to produce a paste with rheological properties that can be transported in

a pipeline from the thickener to the point of deposition (underground in a mine or

into a tailings impoundment area). The rheology may be specific to the

application.

1 “Rheology” is defined as “The quality or state of being able to be deformed or to flow.” The EIMCO® Deep Cone PasteThickener is used to create a paste that deforms and flows out of the thickener.



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a. A control system should be provided with control logic to produce the

desired paste rheological properties using the minimum quantity of

flocculent.

b. Rheological properties of the paste are measured continuously by the

torque produced on the rake drive mechanism.

1) If the torque increases to greater than desired, control logic should be implemented to remove more solids from the thickener to

reduce the pulp residence time within the thickener and thus,

reduce the rheological properties of the paste.

2) If the torque decreases to less than desired, control logic will beimplemented to remove fewer solids from the thickener toincrease the pulp residence time within the thickener and thus,

increase the rheological properties of the paste.

c. Underflow volumetric removal rate is controlled as a consequence of theinventory and rheological properties of the paste inside the deep cone

paste thickener.

1) If the rheological properties are below set point, the underflow

volumetric rate is decreased.

2) If the rheological properties are above set point the underflowvolumetric rate is increased.

8. Rake speed is normally kept low, as long as the drive torque is at or below a predetermined set point. I

Note: If the drive torque exceeds the predetermined set point, the rake speed is

can be increased to facilitate rapid discharge of the paste.

B. PRELIMINARY PREPARATION FOR START-UP

1. CHECK to make sure that all measurement devices for thickener feed pulp flow

and density, feed dilution water flow, pulp level, rake speed, rake (drive) torque,

thickener bed level, overflow liquor specific gravity, underflow pulp flow,

underflow pulp density, flocculent flow and hydrostatic head inside the deep cone

paste thickener, are properly calibrated and operational.

2. CHECK to make sure that the thickener control system is installed and ready togo on line immediately after preliminary start-up.



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a. It is possible to operate the thickener in a stabilizing control mode without

the control system functional. However, an eventual consequence of

manual operation will be less underflow density.

b. Refer to the control system manufacturer’s instructions.

3. Pumps for flocculent flow control, deep cone paste thickener feed, underflowremoval, underflow recirculation, and process water (and/or other source), must

all be operational.

4. Know the location and operating requirements of all pumps, valves, and the

layout of the plant piping.

5. Flocculent must be available at the proper concentration.

Note: Flocculent must always be available. Unflocculated or improperly

flocculated solids will not produce paste in the deep cone paste thickener.

6. Verify that the drive has been lubricated in accordance with the “Drive

Lubrication” instructions (see Table of Contents), that the hydraulic power unit

has been properly installed, and that the hydraulic power unit is ready for

operation.

7. CHECK to make sure that the rake arms are free to move, that the tank is clear of blocking, shoring, tools, debris, etc, and that the movement of the equipment can

be done safely.

8. CHECK the area for safety hazards, such as loose or missing cover guards,

debris, tools, oil spills, mud, ice, etc. CHECK walkways, platform, railings,

ladders, etc.

C. START-UP PROCEDURE

During the initial start-up of the deep cone past thickener, control of feed, flocculation,recycle, pulp discharge and overflow liquor discharge will be done manually.

Engagement of the control system should occur as soon as operating conditions allow.

1. Fill the thickener tank with water or solution, preferably to the overflow.

2. Start the rake drive mechanism and adjust for a rake speed of approximately 0.1

RPM.



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8. Engage the control system and begin normal operation, as covered in this

instruction. Engagement of the control system should occur as soon as operating

conditions allow.

D. NORMAL OPERATION

1. For normal operation, the thickener control system should be programmed and

used to produce and maintain the desired rheological properties of the paste at thelowest flocculent consumption. Refer to the control system manufacturer’s

instructions.

2. The set point for the control system should be the torque developed by the rake

drive mechanism while rotating. Refer to “General Drive Maintenance”instructions (see Table of Contents).

3. The pulp level in the thickener tank will be controlled by the flocculent dose

(grams of flocculent per ton of solids) that is added to the incoming feed in the E-

Duc feed system and at the feedwell to maintain the solids settling rate, as well asthe mass balance of solids in the feed and underflow withdrawal.

4. Solids Withdrawal Rate

a. Changing the solids withdrawal rate will control the rheological properties

of the pulp (paste).

b. The control system should increase the underflow withdrawal rate upon

sensing increasing rake drive torque to the maximum limit of one

underflow pump.

c. This includes the option to start a second underflow pump in cases where

the rake drive torque goes above the set-point, or when nearing

consolidation of the pulp bed within the thickener.

d. The control system should decrease the underflow withdrawal rate upon

sensing decreasing rake drive torque to the minimum limit of one positivedisplacement underflow pump.

E. PROCESS OPTIMIZATION

1. One major difference of the EIMCO deep cone paste thickener from conventional

thickeners is the level of control utilized. To achieve thick underflow, or “paste,”

the operation of the deep cone paste thickener must be controlled more closelythan that of conventional thickeners.



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PERFORMANCE INDICATORS CONTROL INDICATORS CONTROL VARIABLES

Effluent Clarity Torque Indicator Flocculent Dosage

Underflow Density Bed Level sensor Underflow Pumping Rate

Bed Pressure Transmitter Rake Speed

Feed Rate

2. The Table shows the performance indicators for the deep paste thickener as wellas the control indicators and control variables used to maintain acceptable

performance.

For Example:

The objective of the deep cone paste thickener operation is to achieve a high

underflow solids density while maintaining an acceptable effluent clarity. To

achieve the desired results, the control indicators are used to monitor the state of

the deep cone paste thickener, which will determine what adjustments must be

made to the control variables to achieve the desired performance.

3. Following is a discussion of how information from the control indicators can be

used to determine what adjustments must be made to the control variables to

achieve the desired underflow concentration from the deep cone paste thickener.

F. TORQUE INDICATOR

The torque reading is a measure of the quantity of solids in the thickener and the density

of the slurry.

1. A high torque reading likely means that the quantity of solids in the deep cone

paste thickener is too high.

a. This reading should be evaluated in conjunction with the underflow

density reading.

b. A high torque reading usually coincides with a high underflow

consistency.

2. When this occurs, the underflow-pumping rate should be increased to reduce thequantity of solids in the deep cone paste thickener.



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3. It is possible that high torque will not coincide with a high underflow density.

a. In such cases, an excessive flocculent dosage may have caused the

underflow to become overly viscous, causing the underflow to not flow

freely.

b. Under these conditions, the flocculent dosage should be decreased and

the rake speed increased.

G. BED LEVEL

The level sensor determines the height of the solids in the deep cone paste thickener; this

is referred to as “bed level.” This indication must be used in conjunction with othercontrol parameters to evaluate the action that should be taken.

1. If the bed level continues to rise, as indicated by the level sensor, the solids will

eventually reach the overflow launder and contaminate the effluent.

2. The bed level can rise for a number of reasons; thus, the underflow concentration

and bed pressure must be monitored in conjunction with the bed level to

determine the exact cause.

a. An inadequate amount of flocculent added to the feed will result in a slow

settling rate, and an increase in bed level.

b. If the bed level is high, despite the underflow density and bed pressure

being low, it is likely that insufficient flocculent is being added to the

feed.

c. An increase in solids inventory in the deep cone paste thickener may

cause an increase in bed level.

d. If solids are being fed to the thickener at a higher rate than they are

removed, the bed level will rise.

e. If the underflow density and bed pressures are high, it is likely that the

solids inventory in the deep cone paste thickener is too high and the

underflow pumping must be increased.



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H. BED PRESSURE

The bed pressure is a measure of the weight of the slurry in the thickener.

1. A high bed level does not necessarily mean that the bed pressure will also be

high.

a. If insufficient flocculent is being added, a very light and fluffy bed maydevelop, which will have a low density.

b. A bed of this type of material may be very deep, but have a low density.

c. Therefore, if the bed level is high yet the bed pressure is still quite low,the flocculent dosage must be increased.

2. The increase in flocculent should cause the solids to consolidate and settle more

quickly.

3. This will result in a more shallow bed, which allows the underflow-pumping rate

to be slowed down to increase the inventory of solids in the deep cone paste

thickener.

4. The increased bed depth at higher flocculent dosage will result in an increase in

underflow solids concentration.

I. Underflow Density

It is desirable to produce an underflow concentration that is as dense as possible, yet stillfluid enough to be pumped from the deep cone paste thickener underflow. The

underflow density is measured with the density meter.

1. There are a number of control parameters, which can be changed to optimize the

underflow density.

a. Underflow-Pumping Rate Reduced

1) By allowing the solids in the deep cone paste thickener to build,

the residence time for compaction is increased, which can result in

an increase in underflow density.

2) When decreasing the underflow-pumping rate, the thickener

torque, bed level, and bed pressure must be monitored to ensurethat these parameters do not rise too quickly or beyond a safeoperating range.



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b. Flocculent Dosage Increased

1) Increasing the flocculent dosage allows the solids to settle faster

and also creates a better separation of the solids and liquid.

2) Increasing the flocculent dosage will increase the underflow

concentration that is achievable, to a point.

3) Increasing the flocculent concentration beyond normal operating

ranges can cause the flocculated solids to become viscous and

eventually this will limit the underflow concentration that can be

achieved.

J. EFFLUENT CLARITY

The flocculent dosage and bed level controls the effluent clarity that is achieved.

1. Insufficient Flocculent/Flocculent Dosage Too Low

a. If insufficient flocculent is used, some fine solids may not be bound in the

floc structure and will not settle.

b. A flocculent dosage that is too low may result in the growth of very small

floc particles that again do not settle quickly.c. In both of these instances, increasing the flocculent dosage should help to

produce a clear effluent.

2. Bed Level Too High/High Torque/High Bed Pressure/High Underflow

Concentration

a. If the flocculent dosage is adequate, yet the effluent still contains

excessive solids, the bed level in the deep cone paste thickener may be too

high.

b. This condition may also coincide with high torque readings, high bed pressure, or high underflow concentration.

c. In either case, the underflow-pumping rate should be increased or,

alternatively, the feed rate to the deep cone paste thickener decreased.



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K. EMERGENCY CONDITIONS

1. Consolidation of Solids

a. Consolidation of the pulp (paste) solids in the deep cone paste thickener

tank must be avoided at all costs.

b. With consolidation, the paste will no longer deform or flow. Solids willnot be able to be removed from the underflow, and the thickener rake

drive could overload and stop.

c. In case of drive stoppage due to an overload (drive control cuts the

electrical power to the hydraulic power unit), immediately drain the tank.

Note: In some cases, it may be necessary to remove the paste by sluicing

or digging before the drive can be restarted.

d. Refer to the “Drive Maintenance WARNING” instruction (see Table ofContents).

e. Do not tamper with the overload alarm switch adjustment.

f. Do not start-up with a load of paste in the deep cone paste thickener tank.

2. Loss of Flocculent

a. Adequate quantities of flocculent must be available at all times, at the

proper concentration.

b. Unflocculated or improperly flocculated solids will not produce paste.

c. Careful monitoring of flocculent reserves will ensure that an adequate

quantity of flocculent is available for the anticipated feed rate to the

thickener.

d. Proper flocculent addition must be maintained at all times. No feed must

go into the deep cone paste thickener without proper flocculent addition.

3. Loss of Control System

a. The control system requires constant input from a variety of measuring

devices in order to maintain process balance.



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b. The loss of any measurement requires the repair of the defective

measuring device as soon and quickly as possible.

c. If, at any time, it is necessary to shut down the control system, then a

more conservative underflow rheology must be achieved by manually

increasing the underflow withdrawal rate (and increasing the rake drive

speed) to decrease the solids residence time.

L SHUTDOWN PROCEDURES

Shutdown can be for emergencies, maintenance, scheduled holidays, or long term. In

each case the circumstances are different due to the nature of the shutdown and the

characteristics of the pulp that is being thickened.

M. EMERGENCY PROCEDURES

Emergency procedures may be required as a result of a mechanical or electrical failure of

a certain piece of equipment, but the emergency situation that occurs most often andrequires immediate action is the partial or total loss of electrical power.

1. Power Failure: No Power to the Hydraulic Power Unit

If the power failure will be of a short duration, less than an hour, the following

steps should be taken; preparations should go ahead in the event the outage may be longer than an hour.

a. Less Than an Hour:

HYDRAULIC POWER UNIT WARNING:

At the Control Panel, shut off the drive unit’s hydraulic power unit. If power isrestored suddenly and the drive starts without warning, serious injury could result.

1) Stop the feed to the deep cone paste thickener and slow the

underflow pump(s) down to minimum speed in a withdrawal

mode.

Note: In a wide spread outage, the feed entering the tank willstop, so the feed should not cause a problem.

2) If it appears that the power failure will continue for several hours,

prepare to drain the tank.



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3) Start-Up After Power Restored:

a) Start the hydraulic power unit.

b) Start the rake drive at slow speed. Jog, if possible, to

check operation.

c) Resume operation.

b. After Several Hours:

1) See the HYDRAULIC POWER UNIT WARNING.

2) Stop withdrawing paste from the deep cone paste thickener afterthe residence time has been reduced.

3) Maintain operation of the underflow shear thinning system, if

possible.

4) If the loss of power is indefinite, start draining the tank and shut

off the main power switch.

5) Start-Up After Power Restored:

Refer to section “C. Start-up Procedure” in this instruction.

2. Underflow Pump Failure

Whether it is due to the motor, motor control or pump, a second pump should be

available; otherwise, the same conditions apply as for a loss of electrical power

until the pump can be restarted.

WARNING: Shut off and lock out power to the pump while performing

maintenance.

3. Choked or Plugged Paste Underflow Line

No shutdown is required. Back flush underflow line by using process water from

overflow or other source.



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4. Drive Overload Shutdown

a. Immediately shut off the feed to the deep cone paste thickener and shut

off the flocculent feed.

b. Shut off the power to the rake drive’s hydraulic power unit.

c. Pump the underflow from the deep cone paste thickener and drain thetank.

d. Drain the underflow lines and pump(s).

e. Start-Up After Rake Arms are Free and Drive Torque is Zero:

1) Start the rake drive.

2) Jog the rake drive, if possible, to check operation.

3) Refer to section “C. Start-up Procedure” in this instruction.

N. SCHEDULED MAINTENANCE SHUTDOWN

If the duration of a shutdown is several hours and it will not require the tank to be

drained, proceed as follows. If the shutdown will be longer or it will be necessary to drainthe tank, refer above to section “M. Emergency Procedures” in this instruction.

CAUTION:

Do not, under any circumstances, shut down the drive under high torque or heavy

sludge conditions (above set point).

Delay shutdown until torque is below set point.

1. Shut off the feed to the deep cone paste thickener several hours before the

shutdown, depending on the pulp level in the deep cone paste thickener and thetime required for maintenance.

2. Stop withdrawing paste from the deep cone paste thickener after the pulp level

has been reduced.

Note: Do not add additional flocculent to the recycled paste.

3. Shut off and lock out power to the rake drive’s hydraulic power unit while performing the required maintenance. See the CAUTION.



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4. Pump the underflow from the deep cone paste thickener and drain the tank.

5. Drain and flush the underflow lines and pump(s).

6. Start-up after shutdown should proceed as covered in section “M.4.Drive

Overload Shutdown” in this instruction.

O. Long Term Shutdown

1. Refer to section “N. Scheduled Maintenance Shutdown for the start of the

shutdown and then, proceed with the section “M.4.Drive Overload Shutdown” in

this instruction.

2. Refer to the “Storage and PRECAUTIONS” instructions (see Table of Contents)and to the other accessory equipment manufacturer’s instruction manuals for

drives, pumps, etc.



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A. PROCESS PERFORMANCE

1. The process performance of the equipment, which is referred to in this instruction

manual, is dependent upon many factors: influent or feed quality and quantity,

additives required, time, temperature, rates of change, sizing criteria used,

operating conditions, etc.

2. Unless a written Process Performance Warranty has been included,

FLSmidth cannot assume any liability or responsibility for performance results

that the user of the equipment is expecting or has predicted.

3. Should assistance be required in the operation of the equipment, due to

unexpected conditions, or should accessory, add on components, or changes berequired to meet performance needs, FLSmidth can, at an additional cost, provide

the service of experts to assist in determining what actions should be taken.



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PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

a. Torque builds up on drive andmechanism.

(1) Stop feed to deep cone paste thickener andCHECK for operating problem. Refer to“Operating Instructions” (see Table ofContents).

(2) CHECK for foreign object in tank.

b. Heavy build up of solids due toshutdown.

(1) Agitate sludge in front of rake arms with rodsor air.

(2) Shut down deep cone paste thickener and

drain the tank.

1. Overload Alarm Sounds or

Drive Operates at High

Torque for Several Days

c. Overloading the thickener. (1) Paste thickeners are not designed for storage;change operation. Refer to the “Operating

Instructions” (see Table of Contents).(2) Reduce feed solids. Refer to the “Operating


(3) Sludge bed too high or excessive. Increaseunderflow. See Problem 4. Refer to the“Operating Instructions” (see Table ofContents).

a. Loss of electrical power to thehydraulic power unit.

(1) CHECK power source.

(2) CHECK control fuse.

(3) CHECK control circuit fuse.

(4) CHECK for short or ground fault.

(5) CHECK all wiring for breaks or looseconnections.

b. Torque overload. (1) CHECK the cause of the overload and correctthe problem before restarting the deep cone

paste thickener.

(2) Close the circuit by resetting the hydraulic power unit.

2. Drive Stops

c. Mechanical stop. (1) CHECK oil level in hydraulic power unit.Bring oil up to proper level.

(2) CHECK hydraulic oil temperature. The

hydraulic power unit has a hydraulic oil coolerand oil heater.

(a) Hydraulic oil too hot. Refer to hydraulic power unit manufacturer’s instructions.

(b) Hydraulic oil too cold. Refer to hydraulic power unit manufacturer’s instructions.

(3) Loss of electrical power requires that thehydraulic power unit be reset and deep cone

paste thickener operations restarted.



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d. Hydraulic pressure lost or drops. (1) CHECK for torque overload stop ormechanical stop.

(2) CHECK hydraulic oil level in hydraulic powerunit. Bring hydraulic oil up to proper level.

(3) CHECK for leaks in hydraulic fluid lines or atconnections.

(4) CHECK hydraulic power unit. Refer tomanufacturer’s instructions.

2. Drive Stops

e. Hydraulic power unit is off or“stopped” at the Control Panel.

(1) Start the hydraulic power unit at the ControlPanel.

(2) CHECK to make sure that the hydraulic powerunit’s local switches are turned “ON.”

a. Sludge withdrawal rate too high (1) Decrease removal of thickened sludge.

(2) Increase sludge detention time

b. Inadequate sludge bed (slurryconcentration in tank).

(1) Reduce sludge withdrawal rate or increasedetention. Refer to the “OperatingInstructions” (see Table of Contents).

(2) CHECK flow rate. Refer to the “OperatingInstructions” (see Table of Contents).

(3) CHECK chemical feed. Refer to the“Operating Instructions” (see Table of

Contents).

(4) Increase sludge detention time.

c. Overflow rate is too high or toohigh in places.

(1) Decrease sludge influent flow rate (feed rate).

(2) If the overflow rate is high in places, it isshort-circuiting. CHECK launders, weirs, andeffluent nozzles.

d. Inadequate flocculation. (1) CHECK for finely dispersed solids. Increasechemicals. Refer to the “OperatingInstructions” (see Table of Contents).

(2) Insufficient solids concentration, refer to the“Operating Instructions” (see Table of

Contents).

(3) CHECK chemical feed manufacturer’sinstructions

3. Sludge Too Thin

e. Flow through tank is short

circuiting.

(1) Adjust weirs for even overflow or convergent

leakage

a. Overloading of deep cone pastethickener.

(1) CHECK flow rate and feed solids content.Refer to “Operating Instructions” (see Table ofContents).

(2) CHECK sludge withdrawal rate; bed levelmay be too high.

4. Solids in Effluent

b. Inadequate flocculation. (1) CHECK for finely dispersed solids. Increasechemicals. Refer to “Operating Instructions”(see Table of Contents).

(2) CHECK chemical feed manufacturer’sinstructions.



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c. Sludge bed too high or too low intank.

(1) Sludge withdrawal not adequate or excessive.Refer to the “Operating Instructions” (seeTable of Contents).

(2) See Problem 4.b.

4. Solids in Effluent

d. Sudden change in feed quality. (1) Change flow rate or chemical feed. Refer tothe “Operating Instructions” (see Table of

Contents).

5. Excessive Growth on Weirs a. Accumulation of solids causesalgae.

(1) Increase frequency of cleaning.



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FLSmidth SAC

FLSmidth Dorr-Oliver Eimco Inc.2850 South Decker Lake Drive

Salt Lake City, Utah 84119-2300

Telephone: 801-526-2000

Toll Free: 1-800-826-6461

Facsimile: 801-526-2001

After completion of the contract, the Latin American Region Headquarters will support all service and spare parts.

North American Region Headquarters:

FLSmidth MineralsFLSmidth Dorr-Oliver Eimco Inc.2850 South Decker Lake DriveSalt Lake City, Utah 84119-2300, U.S.A.

Telephone: 1 + 801-526-2000Toll Free: 1 + 800-826-6461Facsimile: 1 + 801-526-2001

Europe, Africa, Mid-East Region Headquarters:

FLSmidth MineralsFLSmidth Dorr-Oliver Eimco UK Limited11 Mitchell CourtCastle Mound Way

Central ParkRugby, WarwickshireCV23 0UYUnited KingdomTelephone: +44 (0) 1788 555777Facsimile: +44 (0) 1788 560738

FLSmidth Minerals, S.A. de C.V.Av. Benito Juarez #4055 int. “E”Cuartel CasanovaVilla de Pozos San Luis Potosi, Mexico

C.P. 78421Telephone: 52+444-811-1848Facsimile: 52+444-811-1776

FLSmidth Minerals (Pty.) Ltd.Cnr Constantia Boulevard & Albert Schweitzer StreetsConstantia Kloof, Roodepoort, 1709, Gauteng, South AfricaTelephone: +27 (0)10-210-4000

Facsimile: +27 (0)10-210-4050

Latin American Region Headquarters:

FLSmidth Minerals

FLSmidth Dorr-Oliver Eimco Chile S.A. Nueva de Lyon 072 – Office 1102

Providencia, Santiago – 751-0078 ChileTelephone: 56 + 2-290-0000

Facsimile: 56 + 2-334-3949

Asia-Pacific Region Headquarters:

FLSmidth MineralsFLSmidth Dorr-Oliver Eimco Australia Pty.

Ltd.

5 Comserv Close

West Gosford. NSW 2250, AustraliaTelephone: 61+ 2-4320-4700Facsimile: 61+ 2-4320-4777

FLSmidth MineralsFLSmidth Dorr-Oliver Eimco Brasil Equipamentos e ServicosLtda. Avenida Antonio Carlos Comitre1.100-Parque Campolim ·18047-620 · Sorocaba Sao Paulo - S.P. - BrazilTelephone: 55+15-3414-7800Facsimile: 55+15-3414-7833

FLSmidth MineralsFLSmidth Dorr-Oliver Eimco Germany GmbH3rd Floor, Office Building J, East Lake Office Building35 Dong Zhi Men Wai Da Jie,

Beijing 100027Peoples Republic Of ChinaTelephone: 86+10-6468-1085Facsimile: 86+10-6597-8133



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Canada Region Headquarters:

FLSmidth Minerals

FLSmidth Dorr-Oliver Eimco Ltd.174 West Street SouthOrillia, Ontario L3V 6L4 CanadaTelephone: (705) 325-6181

Facsimile: (705) 325-3363

Local Sales Office:

FLSmidth S.A.C.

Av. Republica de Panama 3030Office 701-BSan Isidro, Lima 27 – PeruTelephone: 51+1-708-0500Facsimile: 51+1-708-0547

Note: All telephone/facsimile numbers are preceded by a country code (e.g. Mexico 52 +).