ksp poppet manual 2011

KSP Poppet Manual

2011

FACTORY TRAINING

Schwing BiosetParts and Service

(715) 247-3433

OR

Fax (715) 247-3438

Paul Katka - Parts/Service Manager

Dave Larson - Quality Control Specialist

Service TechniciansChris KohnenJack Koehler

Jeff JoyJohn Christenson

Mike Smith

PartsBrad Dopp

Larry LarsonZach Anderson

TABLE OF CONTENTS

KSP Poppet Training Manual i

SECTION 1 GENERAL

1.1 PURPOSE OF THIS MANUAL ..................................................................................1 - 1

1.2 DESCRIPTION OF EQUIPMENT ..............................................................................1 - 1

1.2.1 General Description ....................................................................................1 - 11.2.2 Sludge Pump With Poppet Valves..............................................................1 - 81.2.3 Sludge Flow Measuring System (SFMS) - Poppet Valve KSP ................1 - 101.2.4 Screw Feeder .............................................................................................1 - 121.2.5 Hydraulic Power Pack.................................................................................1 - 131.2.6 Material Pipeline .........................................................................................1 - 211.2.7 Sliding Frame Silos.....................................................................................1 - 221.2.8 Push Floor ..................................................................................................1 - 231.2.9 Pipeline Lubrication System .......................................................................1 - 241.2.10 Automatic Greaser System.........................................................................1 - 25

1.3 INSTALLED EQUIPMENT LIST ................................................................................1 - 26

1.3.1 General With Data Sheets ..........................................................................1 - 261.3.2 Sliding Frame Receiving Bin.......................................................................1 - 261.3.3 Receiving Bin Conveyor .............................................................................1 - 261.3.4 Sludge Pump - KSP 140 (HD)XL................................................................1 - 271.3.5 Screw Feeder - SD 500 HD........................................................................1 - 271.3.6 Agitator Hopper - MODEL HHH..................................................................1 - 271.3.7 Hydraulic Power Pack - MODEL 2000, 200/150 HP...................................1 - 271.3.8 Agitator Hopper - MODEL HHH..................................................................1 - 281.3.9 Hydraulic Power Pack - MODEL 230, 40 HP..............................................1 - 281.3.10 Pipeline Lubrication System .......................................................................1 - 281.3.11 Automatic Greaser System.........................................................................1 - 28

1.4 SAFETY REGULATIONS ..........................................................................................1 - 29

SECTION 2 SAFETY REGULATIONS

2.1 SAFETY REGULATIONS ..........................................................................................2 - 1

2.2 SAFETY DURING INSTALLATION ...........................................................................2 - 2

2.3 SAFETY PRECAUTIONS - STARTUP ......................................................................2 - 3

2.4 SAFETY INSTRUCTIONS - ADJUSTMENTS AND CHECKS ...................................2 - 4

2.5 SAFETY DURING MAINTENANCE ...........................................................................2 - 4

SECTION 3 HYDRAULICS

3.1 RULES OF HYDRAULICS .........................................................................................3 - 1

3.2 HYDRAULIC PUMPS ................................................................................................3 - 8

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ii KSP Poppet Training Manual

3.3 VALVES .....................................................................................................................3 - 12

3.3.1 Control Valves ............................................................................................ 3 - 123.3.2 Relief Valves............................................................................................... 3 - 123.3.3 The Basic Relief Valve ............................................................................... 3 - 14

3.4 HYDRAULIC SYMBOLS ............................................................................................ 3 - 16

SECTION 4 OPERATION

4.1 BEFORE OPERATING SLUDGE PUMPS IN ANY MODE - POPPET ...................... 4 - 1

4.2 NOTES - POPPET ..................................................................................................... 4 - 2

4.3 PREVENTIVE MAINTENANCE NOTES - POPPET .................................................. 4 - 2

4.4 PRE-START-UP CHECKS ........................................................................................ 4 - 4

4.4.1 Sludge Pump .............................................................................................. 4 - 54.4.2 Screw Feeder ............................................................................................. 4 - 64.4.3 Hydraulic Power Pack ................................................................................ 4 - 74.4.4 Material Pipeline ......................................................................................... 4 - 84.4.5 Push Floor/Sliding Frames ......................................................................... 4 - 94.4.6 Pipeline Lubrication .................................................................................... 4 - 10

4.5 START-UP PROCEDURE ......................................................................................... 4 - 11

4.5.1 General With Safety Precautions - Start-up................................................ 4 - 114.5.2 Starting and Stopping ................................................................................. 4 - 114.5.3 Emergency Stop ......................................................................................... 4 - 13

4.6 MATERIAL PUMP OPERATION ............................................................................... 4 - 14

4.6.1 The Control Panel....................................................................................... 4 - 144.6.2 SFMS and Transition Pressure Setpoint Selection..................................... 4 - 154.6.3 Screw Feeder Modes ................................................................................. 4 - 164.6.4 Mode Selection........................................................................................... 4 - 164.6.5 HMI Screens............................................................................................... 4 - 18

4.7 LUBRICATION SYSTEM OPERATION ..................................................................... 4 - 25

4.7.1 Mode Selection........................................................................................... 4 - 25

4.8 MATERIAL PUMP AND SCREW FEEDER ALARM CONDITIONS........................... 4 - 26

4.9 LUBRICATION SYSTEM ALARM CONDITIONS ...................................................... 4 - 28

4.10 ADJUSTMENTS AND CHECKS DURING OPERATION .......................................... 4 - 29

4.10.1 Safety Instructions - Adjustments & Checks............................................... 4 - 294.10.2 Sludge Pump Output Adjustment - Electric ................................................ 4 - 294.10.3 Sludge Pump Output Adjustment - Manual Handwheel ............................. 4 - 304.10.4 Screw Feeder Output Adjustment - Electric................................................ 4 - 304.10.5 Screw Feeder Output Adjustment - Manual Handwheel............................. 4 - 314.10.6 Hydraulic System Checks - Rock Valve ..................................................... 4 - 324.10.7 Hydraulic System Checks/Adjust. - Poppet Valve ...................................... 4 - 324.10.8 Mechanical Checks .................................................................................... 4 - 324.10.9 Other Controls and Instruments ................................................................. 4 - 32

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KSP Poppet Training Manual iii

4.11 SHUTDOWN PROCEDURE ......................................................................................4 - 33

4.11.1 Shutdown For General Maintenance ..........................................................4 - 334.11.2 Short-Term Shutdown.................................................................................4 - 354.11.3 Long Term Shutdown .................................................................................4 - 354.11.4 Long-Term Storage.....................................................................................4 - 364.7.5 EMERGENCY STOP..................................................................................4 - 37

SECTION 5 PLANNED MAINTENANCE

5.1 SAFETY DURING MAINTENANCE ...........................................................................5 - 1

5.2 PERIODIC MAINTENANCE SCHEDULE ..................................................................5 - 3

5.2.1 General Maintenance .................................................................................5 - 75.2.2 Hydraulic power pack .................................................................................5 - 105.2.3 Push Floor Silo ...........................................................................................5 - 185.2.4 Screw Feeder .............................................................................................5 - 215.2.5 Material Pump.............................................................................................5 - 265.2.5 Pipeline Lubrication System .......................................................................5 - 33

5.3 LUBRICANT RECOMMENDATIONS .........................................................................5 - 35

5.3.1 Hydraulic oil recommendations (hydraulic power pack) .............................5 - 365.3.2 Gear-lubricant recommendations ...............................................................5 - 375.3.3 Grease recommendations ..........................................................................5 - 37

5.4 TROUBLESHOOTING ...............................................................................................5 - 38

5.4.1 Hydraulic Power Pack.................................................................................5 - 385.4.2 Push Floor Silo ...........................................................................................5 - 405.4.3 Screw Feeder .............................................................................................5 - 41

5.5 BOLT TORQUE TABLES ...........................................................................................5 - 45

5.5.1 Metric: normal threads ................................................................................5 - 455.5.2 Metric: fine threads .....................................................................................5 - 46

SECTION 6 SPECIAL MAINTENANCESERVICE AND REPAIR INSTRUCTIONS

6.1 SAFETY DURING MAINTENANCE (From you O&M Manual) ...................................6 - 2

6.2 MAINTAINING HYDRAULIC SYSTEM PRESSURES................................................6 - 3

6.3 SCREW FEEDER.......................................................................................................6 - 4

6.3.1 Auger replacement .....................................................................................6 - 4

6.4 MATERIAL PUMP.......................................................................................................6 - 6

6.4.1 Replacing piston heads ..............................................................................6 - 66.4.2 Replacing poppet valves.............................................................................6 - 14

TABLE OF CONTENTS

iv KSP Poppet Training Manual

SECTION 7 INSPECTIONS & CALIBRATIONS

7.1 SLUDGE FLOW MEASURING SYSTEM (SFMS) SET-UP .................................... 4

7.1.1 Overview of the SFMS and the Schwing Pump ....................................... 47.1.2 SFMS Calculations .................................................................................. 77.1.3 Throttle Valve Adjustment .......................................................................... 87.1.4 Throttle Check Valve Adjustment ............................................................... 97.1.5 Proximity Switch Set-up.............................................................................. 107.1.6 SFMS Functional Test #1 -KSP ............................................................... 127.1.7 SFMS Functional Test #2 - EKSP............................................................ 127.1.8 SFMS Calibration.....................................................................................137.1.9 Testing and Calibration of SFMS ............................................................. 14

SECTION 8 KSP COMPONENTS

8.1 SCREW FEEDER COMPONENTS ........................................................................... 8 - 1

8.1.1 Screw Feeder Gear Box ............................................................................. 8 - 2

8.2 SCREW FEEDER SHAFT TIMING ............................................................................ 8 - 8

8.3 SLUDGE PUMP COMPONENTS .............................................................................. 8 - 27

SECTION 9 HYDRAULIC OIL & FILTERS

9.1 RESERVOIRS ........................................................................................................... 9 - 1

9.2 HYDRAULIC OILS AND LUBRICANTS ..................................................................... 9 - 1

9.3 FLUID CONTAMINATION AND CONTROL .............................................................. 9 - 3

9.3.1 Handling, Storing, and Dispensing of Lubricating Fluids ............................ 9 - 4

9.4 FILTERS ....................................................................................................................9 - 6

9.5 TECHNICAL INFORMATION - FILTRATION RATINGS ...........................................9 - 6

9.5.1 Nominal Filtration Ratings .......................................................................... 9 - 69.5.2 Absolute Filtration Ratings.......................................................................... 9 - 69.5.3 Beta Filtration Ratio (bn)............................................................................. 9 - 69.5.4 Filter Facts.................................................................................................. 9 - 79.5.5 Technical Information - Beta Ratings ......................................................... 9 - 8

9.6 SCHWING BIOSET FILTERS ................................................................................... 9 - 9

9.6.1 KSP Return Filter........................................................................................ 9 - 99.6.2 Conditioning Loop Filter.............................................................................. 9 - 11

9.7 HYDRAULIC PUMPS ................................................................................................ 9 - 12

9.8 REXROTH VT 2000 AMPLIFIER CARD .................................................................... 9 - 18

9.8.1 Functional Description of the Rexroth VT2000 Amplifier Card ................... 9 - 18

9.9 PRESSURE SWITCHES ........................................................................................... 9 - 21

9.9.1 How To Set Pressure Switches .................................................................. 9 - 21

TABLE OF CONTENTS

KSP Poppet Training Manual v

9.9.2 Switch Adjustments ....................................................................................9 - 269.9.3 Temperature Switch Adjustment.................................................................9 - 299.9.4 Combination Level and Temperature Switch..............................................9 - 319.9.5 Dirty Oil Filter Switch ..................................................................................9 - 32

9.10 TYPES OF HEAT EXCHANGERS ............................................................................9 - 35

9.11 HYDRAULIC SCHEMATIC SERIES - KSP POPPET ................................................9 - 38

9.11.1 KSP Poppet Valve - Series #1....................................................................9 - 389.11.2 KSP Poppet Valve - Series #2....................................................................9 - 409.11.3 KSP Poppet Valve - Series #3....................................................................9 - 429.11.4 KSP Poppet Valve - Series #4....................................................................9 - 449.11.5 KSP Poppet Valve - Series #5....................................................................9 - 469.11.6 KSP Poppet Valve - Series #6....................................................................9 - 489.11.7 KSP Poppet Valve - Series #7....................................................................9 - 50

9.12 UNIT IS IN REVERSE ...............................................................................................9 - 52

9.12.1 KSP Poppet Valve - Series #8....................................................................9 - 52

9.13 EXCESS ROCKING OIL CONDITION .......................................................................9 - 54

9.13.1 KSP Poppet Valve - Series #9....................................................................9 - 54

9.14 ADDING ROCKING OIL CONDITION .......................................................................9 - 56

9.14.1 KSP Poppet Valve - Series #10..................................................................9 - 56

SECTION 10 SPECIAL TOOLS

10.1 HYDRAULIC TROUBLE SHOOTING KITS ...............................................................10 - 1

10.2 FLOW METERS AND ACCESSORIES .....................................................................10 - 2

10.3 MATERIAL CYLINDER ALIGNMENT TOOLS ...........................................................10 - 3

10.4 PISTON INSTALLATION TOOLS ..............................................................................10 - 4

10.5 ROD GLAND PACKING INSTALLATION TOOLS .....................................................10 - 5

10.6 RAM TOOLS ..............................................................................................................10 - 6

10.7 TORQUE SPECIFICATIONS FOR METERIC BOLTS AND SCREWS USED ON SCHWING EQUIPMENT ..........................................................................10 - 7

10.6.1 Dacromet 500 Screws and Nuts DIN 912, 931, 933, 934 (Hexagon, Machine Screws, and Hexagon Nuts).......................................10 - 8

10.6.2 Dacromet 500 Screws and Nuts DIN 6914, 6915 (HV Screws)..................10 - 1010.6.3 Black Screws and Nuts DIN 912, 931, 933, 934

(Hexagon, Machine Screws, and Hexagon Nuts).......................................10 - 11

10.8 CONVERSION CHART .............................................................................................10 - 13

10.9 FLUID POWER FORMULAS .....................................................................................10 - 16

10.10 DRILL SIZES FOR METRIC TAPS ............................................................................10 - 18

TABLE OF CONTENTS

vi KSP Poppet Training Manual

GENERAL SECTION 1

KSP Training Manual 1 - 1

SECTION 1 GENERAL

1.1 PURPOSE OF THIS MANUAL

This manual is designed to assist you in the Installation, Operation, and Maintenance of your custom designed Schwing Bioset Sludge Pump system. It describes storage, installation, start-up, normal operation, shut-down, periodic maintenance, and trouble shooting procedures. It also contains detailed layout drawings, hydraulic schematics, electrical schematics, and parts book drawings. The installers, operators, maintenance personnel, and everyone involved with these systems should study this manual carefully. We hope that it can help in your ongoing training and maintenance program.

1.2 DESCRIPTION OF EQUIPMENT

1.2.1 General Description

A specially sized and configured Sludge Pump System supplied by Schwing Bioset consists of one or more sets of the following equipment:

Hydraulically Driven Piston Pump

Screw Feeder/Agitator Hopper.

Hydraulic Power Pack, to power the pump and screw feeder/agitator hopper.

Special Feed hoppers or Hopper Adapters.

Material Pipeline, steel with pressure tight seals. (OPTIONAL)

Control Systems

Sliding Frames

Push Floors

Pipeline Lubrication System

They are described further in the following paragraphs and detailed specifications for the installed equipment in your O&M manual.

The system is custom designed to pump dewatered sludges or slurries through pressurized steel pipelines to dryers, incinerators, or distribution systems. The electric motor of the Hydraulic Power Pack drives hydraulic pumps that drive the cylinders of the Sludge Pump and the hydraulic motors of the Screw Feeder or Hopper Agitator.

Custom controls, monitors and sensors are installed to specifications to provide automatic, dependable operation.

SECTION 1 GENERAL

1 - 2 KSP Training Manual

Figure 1.1 - Typical KSP Installation #1 (A10V Hydraulic Pumps)

39000001

GENERAL SECTION 1


Figure 1.2 - Typical KSP Installation #2 (A11VO Hydraulic Pumps)

SECTION 1 GENERAL


Figure 1.3 - Typical KSP Installation #3

39000002

GENERAL SECTION 1



39000003

SECTION 1 GENERAL



39000004

GENERAL SECTION 1



FILTER

ELECTRIC MOTOR/PUMP ASSY.

DIRECTIONAL VALVE

PUSH FRAME/SLIDE GATE CYLINDER

PRESSURE SWITCH

39000237

SECTION 1 GENERAL


1.2.2 Sludge Pump With Poppet Valves

The sludge pump is designated with a "KSP" prefix and a size designation of 5, 10, 12, 17, 25, 40, 45, 50, 80, 140 or 220. It is a hydraulically driven, positive displacement, twin-cylinder reciprocating piston pump. The material cylinders are in line with the differential hydraulic cylinders that power the material piston head (ram) in suction and pressure strokes.Separating the material cylinders from the differential cylinders is a fluid filled chamber called the Water Box". The fluid cools and lubricates the material ram as it moves in the material cylinder. The fluid also rinses and cools the differential cylinder rod as it passes through the water box. The chamber also provides access for checking pump wear and for changing the material piston head (ram).

Figure 1.7 - Sludge Pump With Poppet Valves

In operation the two cylinders move in opposite directions so that one cylinder is charged with material from the feed system while the other cylinder is pushing material into the pipeline.

Flow of the material into and out of the cylinders is controlled by four (4) hydraulically actuated poppet valves, one discharge and one intake valve for each cylinder. They are activated in the following sequence:

1. The pumping pistons come to the end of their stroke, that is, one fully extend-ed and one fully retracted. The hydraulic valve drive is activated and the open discharge poppet closes, and suction poppets change state respectively.

2. Both discharge poppets are now closed. Hydraulic pressure increases and the pistons start to operate in the opposite directions, one charging and one discharging. As the discharging piston moves forward, the sludge is com-pressed in the delivery cylinder.

3. At the moment when the compressed sludge in the discharging cylinder equals the pressure of the compressed sludge in the delivery line, the dis-charge poppet opens and material flows into the pipeline.

Since the poppet valve for the discharging cylinder opens only when the cylinder contents are at the same pressure as the pipeline, no material can flow back into the pump. This minimizes shocks in the pipeline.

MATERIAL PISTON (RAM) MATERIAL CYLINDER

WATER BOX

DIFFERENTIAL HYDRAULIC CYLINDERS

POPPET VALVE CONTROL HOUSING

INTAKE PORT

DISCHARGE PORT

39000007

GENERAL SECTION 1


Figure 1.8 - Sludge Pump With Poppet Valve Cut-A-Way

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SECTION 1 GENERAL


1.2.3 Sludge Flow Measuring System (SFMS) - Poppet Valve KSP

Schwing Biosets Sludge Flow Measuring System, installed on a Poppet Valve Sludge Pump, monitors the pumping cycle time and calculates pump output. It compensates for pumping (filling) efficiency and relays the flow rate to control equipment or system monitors.

The Sludge Flow Measuring System consists of two magnetic proximity sensors, two ring magnets mounted on the pressure poppet valve pistons, and special programming within the PLC that controls the Sludge Pump. The sensors are mounted on the sides of the valve cylinders to sense the closed position of the poppet valves. The poppet is closed when the piston is at the limit of its extended travel. See Fig. 1.10 below.

Figure 1.9 - Pressure Poppet With SFMS Sensor

Schwing Biosets Sludge Pumps are designed such that at the end of each stroke both pressure poppet valves are closed. During the next stroke one of the poppets stays closed and one of the poppets opens to allow flow to the pipeline (discharge). Opening of this poppet is delayed until the material is compressed and the pumping cylinder pressure is the same as that of the pipeline. The end of the stroke is signaled when both poppets are again closed.

By timing the full stroke and the compression phase of the stroke, the PLC is able to determine pumping efficiency, flow (in gallons per stroke, gallons per hour, etc.) and limited totalizing.

EXTENDRETRACT

MAGNETICPROXIMITY

SENSOR

POPPET VALVE(Closed Position)

RINGMAGNET

PRESSURE POPPETVALVE HOUSING

PISTON

VALVECYLINDER

39000009

GENERAL SECTION 1


PLC Calculation

Referring to the table below, the Cycle Time for one stroke is T1. The Compression Phase is the time between both poppets closed and one of the poppets opening.

Pumping Time T2 is equal to T1 minus the compression time.

Pump Efficiency is Pumping Time divided by Cycle Time.

Flow Rate is Material Cylinder Volume times Efficiency divided by Cycle Time.

Figure 1.10 - Cycle Time Table (SFMS)

See Appendix A for parts (Pressure Poppet Valve), and section 5.4 for adjustment procedure.

T2 = T1 - COMPRESSION

EFF T2T1

=

FLOW VOLUME X EFFT1

= F ( )

T2Compression

T1

Time

BOTHPOPPETSCLOSED

BOTHPOPPETSCLOSED

DISCHARGEPOPPETOPENS

Pumping Time

Cycle Time

39000010

SECTION 1 GENERAL


1.2.4 Screw Feeder

The Screw Feeder increases pump efficiency by pressurizing the material feed into the pump suction. It consists of a feed trough with twin rotating augers that receive material from a feed hopper and convey it through a transition housing to the intake of the Sludge Pump.

The augers (or screws), are driven by a gear box with a hydraulic motor driven by the Power Pack.

Figure 1.11 - Screw Feeder

Control Housing (Poppet Valve)

Discharge End

External Screw Auger Bearings for Hopper

Openings Greater Than 35 in (900 mm) Screw Feeder Intake

Opening

Double Screw Feeder

Augers

HydraulicMotor

Control Block w/Forward-Reverse

Lever Operated Valve

Water Box

39000011

GENERAL SECTION 1


1.2.5 Hydraulic Power Pack

The Hydraulic Power Pack drives the Sludge Pump and its hydraulic control systems and auxiliary equipment such as a Screw Feeder or the Agitator Hopper augers. The power pack consists of an oil reservoir and steel frame with lifting eyes. The electric motor, hydraulic pump, flow control valves, and electric control enclosures are mounted on the power pack.

Additional equipment and configurations vary with each installation and may include oil coolers, auxiliary hydraulic pumps, special valves or control instruments, sound covers, etc. Please see your O&M manual for details on the unit installed for this project.

Figure 1.12 - Hydraulic Power Pack (A2 Hydraulic Pumps)

HYDRAULIC PUMPFOR SLUDGE PUMP

HYDRAULIC PUMPFOR SCREW FEEDER

RETURN LINE FILTER WITH INDICATOR SWITCH

MOTOR COUPLING ANDV-BELT DRIVE FOR AUX. PUMP

VALVE FORLEVER OPERATED SCREW FEEDER

W/ FORWARD-REVERSE VALVEW/ ADJUSTABLE RELIEF VALVE

ELECTRICMOTOR

VALVE FOR SLUDGE PUMPW/ ADJUSTABLE RELIEF VALVE

& SOLENOID FOR LEVER CONTROLLED BYPASS VALVE.

PRESSUREGAUGES

CLEAN-OUTCOVER

LIFTINGEYES

OIL TANKDRAIN

OIL LEVELSWITCH

FILLER CAP

HIGHPRESSURE

SWITCH

HIGHTEMPERATURE

SWITCH

ELECTRIC CONTROLS,LOCAL OR REMOTE LOCATED

39000013

SECTION 1 GENERAL


Figure 1.13 - Hydraulic Power Pack (A10V Hydraulic Pumps)

HYDRAULIC PUMPFOR SLUDGE PUMP

HYDRAULIC PUMPFOR SCREW FEEDER

LEVER OPERATEDW/ FORWARD-REVERSE VALVEW/ ADJUSTABLE RELIEF VALVE

ELECTRICMOTOR

PRESSUREGAUGES

CLEAN-OUTCOVER LIFTING

EYES

OIL LEVELAND TEMPERATURE

SWITCH

FILLER CAP

OIL COOLER

SOLENOID OPERATEDLOAD BY-PASS VALVE

FOR SLUDGE PUMPW/ ADJUSTABLE RELIEF VALVE

HIGHPRESSURE

SWITCH

HIGHTEMPERATURE

SWITCH

RETURN LINEFILTER WITH

INDICATOR SWITCH

CIRCULATIONLOOPFILTER

HYDRAULIC PUMPFOR CIRCULATION LOOP

OIL TANKDRAIN

ELECTRIC CONTROLS,LOCAL OR REMOTE LOCATED

39000014

GENERAL SECTION 1


Figure 1.14 - Electric Power Pack, Side View (A2 Hydraulic Pumps)

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39000015

SECTION 1 GENERAL


Figure 1.15 - Electric Power Pack, Top View (A2 Hydraulic Pumps)

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39000016

GENERAL SECTION 1


Figure 1.16 - Electric Power Pack, Side View (A10VO Hydraulic Pumps)

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ETER

RETU

RN FI

LTER

FOR H

YDRA

ULIC

OIL

ELEC

TRIC

AL C

ONTR

OLPA

NEL

SCRE

W C

ONVE

YOR

PRES

SURE

RELIE

F VAL

VE

ELEC

TRIC

MOT

OR

SCRE

W C

ONVE

YOR

CONT

ROL V

ALVE

(FORW

ARD,

NEUT

RAL,

REVE

RSE)CO

NDITI

ONIN

GLO

OP FI

LTER

HIGH

OIL

PRES

SURE

SLUD

GE PU

MP

SLUD

GE P

UMP

PRES

SURE

GAUG

E

SCRE

W C

ONVE

YOR

PRES

SURE

GAU

GE

39000240

SECTION 1 GENERAL


Figure 1.17 - Electric Power Pack, Top View (A10VO Hydraulic Pumps)

SCRE

W C

ONVE

YOR

HYDR

AULIC

PUM

P AA1

0VSO

28EL

COND

ITION

ING

LOOP

PUM

P

FORW

ARD/

REVE

RSE V

ALVE

FOR S

CREW

FEED

ER H

AND

LEVE

R CO

NTRO

LLED

W/ A

DJ.

RELIE

F VAL

VEBY

PASS

/LOA

D VA

LVE

FOR S

LUDG

E PUM

PSO

LENO

ID C

ONTR

OLLE

DW

/ ADJ

. REL

IEF V

ALVE

BALL

VAL

VE 1

"NPT

COOL

ER W

ATER

DRA

INBA

LL V

ALVE

1"N

PTCO

OLER

WAT

ER SU

PPLY

WAT

ER-O

IL CO

OLERHY

DRAU

LIC PU

MP A

A10V

SO FO

R SLU

DGE P

UMP

MILL

TRON

ICS U

NIT

39000241

GENERAL SECTION 1


Figure 1.18 - Electric Power Pack, Side View (A11VO Hydraulic Pumps)

LIFTI

NG EY

ES(FO

R LIFT

ING DE

-VI

CES P

ROVI

DED)

LOW

OIL

LEVE

LSW

ITCH

CLEA

N OU

TCO

VER &

FILL

ER C

AP HYD

RAUL

IC RE

SERV

IOR

SIGHT

GAU

GE A

NDTH

ERM

OMET

ER

RETU

RN FI

LTER

FOR H

YDRA

ULIC

OIL

DIRT

Y OI

LFI

LTER

SWITC

H

SCRE

W C

ONVE

YOR

PRES

SURE

RELIE

F VAL

VERO

TEX

COUP

LING

DRAI

NSC

REW

CON

VEYO

RCO

NTRO

L VAL

VE(FO

RWAR

D, NE

UTRA

L,RE

VERS

E)PRES

SURE

GAUG

E SHU

T-OF

FVA

LVE

SLUD

GE P

UMP

PRES

SURE

GAUG

E

SCRE

W C

ONVE

YOR

PRES

SURE

GAU

GE

COND

ITION

ING

LOOP

FILT

ER

HIGH

OIL

PRES

SURE

SLUD

GE PU

MP

ELEC

TRIC

AL C

ONTR

OLPA

NEL

ELEC

TRIC

MOT

OR

39000238

SECTION 1 GENERAL


Figure 1.19 - Electric Power Pack, Top View (A11VO Hydraulic Pumps)

HYDR

AULIC

PUM

PA1

1VO1

30EP

2DHY

DRAU

LIC PU

MP

A11V

O60E

P2D

HYDR

AULIC

PUM

PV2

0101

F8

HYDR

AULIC

CON

TROL

BLOC

K W/L

EVER

BYPA

SS V

ALVE

BALL

VAL

VE 1

"NPT

COOL

ER W

ATER

DRA

INBA

LL V

ALVE

1"N

PTCO

OLER

WAT

ER SU

PPLY

WAT

ER-O

IL CO

OLER

39000239

GENERAL SECTION 1


1.2.6 Material Pipeline

The pipeline used to convey the sludge from the pump to its destination may be supplied by Schwing Bioset or others. Generally it is pressure-tight steel pipe with bolted couplings. See Sludge Pump Installation drawing in your O&M manual for size and configuration of the discharge pipeline. Pump connection to the material pipeline must allow for safe disconnection from the pipeline to allow service of internal pump parts.

Figure 1.20 - Recommended Pipeline Connection

Pipeline

ANSI Flange

In-line Fully PortedShut-off Valve

1/2" Dutchman

Spool Piece

2" Fully PortedBleed Valve SchwingTwo Bolt

Clamp SchwingSludge Pump

Discharge

39000017

SECTION 1 GENERAL


1.2.7 Sliding Frame Silos

The Sliding Frame is a bridge-breaker; when in operation it ensures mass movement of material through the silo and into the receiving conveyor or pump.

The Sliding Frame, which is inside the silo, is attached to the Extension Shafts which pass through the wall of the silo and attach to the cylinders which are on the outside. The silo wall openings are effectively sealed by means of the Stuffing Bpx seals on the Extension Shafts.

Figure 1.21 - Sliding Frame

39000243

GENERAL SECTION 1


1.2.8 Push Floor

The push floor system is designed to receive and temporarily store the large and periodic quantities of material. The push floor can take these uneven loads and provide a consistent discharge through the conveyors and pumps. The push floor moves the material to the inlet of the extraction screw conveyor. The screw conveyor will then move the material to the screw conveyor outlet. The push floor moves the material through the use of the moving frame sections. Hydraulic rams move a push bar down the length of the floor. The floor scrapers are designed to push material in one direction, while minimizing material movement on the return stroke. The floor sections are constantly moving, with the two outside sections moving in the opposite direction of the middle section for multiple scraper configuration.

Figure 1.22 - Push Floor

39000244

SECTION 1 GENERAL


1.2.9 Pipeline Lubrication System

The pipeline is used to convey the sludge from the pumps to either the sludge loading station or the post liming station. Due to the nature of the material being pumped, pipeline pressure may build up under certain conditions. Wet biosolids sludge tend to pump well and does not usually require lubrication. The higher the solids concentration of the biosolids, the more resistance to pumping and higher the resulting pipeline pressure. The pipeline lubrication systems are provided to inject a layer of water in the pipeline, reducing fiction along the pipe walls, and reducing the pipeline pressure. The lubrication pumps supply a small quantity of water to a lubricating ring. The ring installed in the pipe injects a constant flow, forming a thin film of water along the inside surface of the pipe. The pump can be set to automatically start whenever the pipeline pressure exceeds a given pressure for a sustained time period. Initial setting for pump start-up is 300 psi.

Figure 1.23 - Pipeline Lubrication System

39000259

GENERAL SECTION 1


1.2.10 Automatic Greaser System

The automatic greaser system serves to minimize the need for frequent lubrication maintenance by supplying periodic injections of grease to the equipment. The lubrication system provides grease to the push floor hydraulic cylinders, bearings on the metering screw conveyors and the seals on the twin screw augers. The system is a simple electric pump that runs on a timer. Grease is pumped to the equipment based on a programmed timing interval. The time can be independently programmed for each of the application points.

Figure 1.24 - Automatic Greaser System

30358024

SECTION 1 GENERAL


1.3 INSTALLED EQUIPMENT LISTPROJECT: Sample Only

1.3.1 General With Data Sheets

Equipment supplied:

Qty Model Description

1 -- Sliding Frame Recieving Bin - RBSF

2 -- Recieving Bin Conveyors - RBC-1, RBC-2

2 KSP140 (HD) XL Sludge Pump, vertical horizontal configuration, with poppet valves, rock valve - RP-1, RP-2

2 SD500 HD Screw Feeder with Outboard Bearings

HHH Agitator Hopper

2 200/150 HP Hydraulic Power Pack - RPPP

HHH Agitator Hopper

2 230/40 HP Hydraulic Power Pack - RBSFPP

2 Milroy C Pumps Pipeline Lubrication Pumps - PLP-1, PLP-2

1 Lincoln 1827 Automatic Greaser system

APPENDIX 'F' in the O&M manual contains data sheets with serial numbers, and other information, for the major components of the Sludge Pump System supplied.

1.3.2 Sliding Frame Receiving Bin

Refer to installation drawings (Section 6) in the O&M manual for the general arrangement and overall dimensions. See Section 9 for additional details. The hydraulic circuits for the sliding frame hydraulic rams are detailed in Section 7 in the O&M manual. Electrical details are included in Section 8 in the O&M manual.

1.3.3 Receiving Bin Conveyor

Refer to installation drawings (Section 6) and electrical drawings (Section 8) in the O&M manual. Detailed information on the conveyor is contained in Section 10 in the O&M manual.

GENERAL SECTION 1


1.3.4 Sludge Pump - KSP 140 (HD)XL

V Configuration:The Sludge Pump is configured with one cylinder above the other, that is, they are aligned in a vertical plane ("V"). The Installation Drawing in Section 6 in the O&M manual gives overall dimensions of the equipment. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual.

"H" configuration:The Sludge Pump is configured with one cylinder along side of the other, that is, they are aligned in a horizontal plane ("H"). The Installation Drawing in Section 6 in the O&M manualgives overall dimensions of the equipment. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual.See Appendix A for Sludge Pump assembly drawings and Bills of Material for replacement parts.Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information.

1.3.5 Screw Feeder - SD 500 HD

The installed Screw Feeder is configured as shown on the Assembly Drawing in Appendix B.The Installation Drawings in Section 6 give overall dimensions. The pressure settings are shown on the hydraulic schematic in Section 7 in the O&M manual.Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information.

1.3.6 Agitator Hopper - MODEL HHH

The installed Agitator Hopper is configured as shown on the Assembly Drawing in Appendix B. The installation drawing in Section 6 in the O&M manual gives overall dimensions. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual.

Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information.

1.3.7 Hydraulic Power Pack - MODEL 2000, 200/150 HP

The installed Hydraulic Power Pack is configured as shown on the Assembly Drawing. See Appendix C for Bills of Material and replacement parts.

The installation drawings in Section 6 in the O&M manual give overall dimensions. The pressure settings are given on the hydraulic schematics in Section 7 in the O&M manual.

SECTION 1 GENERAL



1.3.8 Agitator Hopper - MODEL HHH

The installed Agitator Hopper is configured as shown on the Assembly Drawing in Appendix B. The installation drawing in Section 6 in the O&M manual gives overall dimensions. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual.


1.3.9 Hydraulic Power Pack - MODEL 230, 40 HP

The installation drawings in Section 6 give overall dimensions. The pressure settings are given on the hydraulic schematics in Section 7 in the O&M manual.


1.3.10 Pipeline Lubrication System

Refer to installation drawings (Section 6) in the O&M manual for the general arrangement. Electrical controls are detailed in Section 8 in the O&M manual. See Appendix I in the O&M manual for detailed information on the lubrication system.

1.3.11 Automatic Greaser System

See Appendix G (Catalog Cuts) in the O&M manual for detailed information on the Lincoln Automatic Greaser System.

GENERAL SECTION 1


1.4 SAFETY REGULATIONS

When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following paragraphs contain some supplementary recommendations.

ANSI standards "ANSI 2244.1-1952" set down minimum safety requirements covering lockout or tagout of energy sources for personal safety. These should be reviewed before any maintenance or inspection.

WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.

WARNING! DANGER OF AMPUTATION! Keep hands out of the screw feeder and agitator hopper.

WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the dis-charge valve housing (rock valve or poppet valves).

Operation and maintenance of this equipment shall be performed only by trained, capable, and authorized personnel.

Only Certified Licensed Electricians shall be allowed to work on electrical systems.

WARNING! DANGER OF ELECTROCUTION! Before working on electrical sys-tems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency.

Keep unauthorized personnel away from the work area during maintenance.

Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Good Preventative Maintenance programs are essential for a good Safety Program.

Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation.

Other sections of this manual contain specific safety recommendations for INSTALLATION, STARTUP, ADJUSTMENTS & CHECKS, AND MAINTENANCE. See the Table of Contents and study and review these sections also.

!

!

!

!

SECTION 1 GENERAL


SAFETY REGULATIONS SECTION 2



2.1 SAFETY REGULATIONS

When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, Facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following paragraphs contain some supplementary recommendations.

OSHA standards 1910.147 (subpart J) set down minimum safety requirements covering lockout or tagout of energy sources for personal safety. These should be reviewed before any maintenance or inspection.

Operation and maintenance of this equipment shall be performed only by trained, capable, and authorized personnel.


WARNING! DANGER OF ELECTROCUTION! Before working on electrical sys-tems, be sure that the main circuit breakers are TURNED OFF and SECURED, machines might have multiple sources. Check for voltage before touching any electrical point. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned gov-erning agency.

Figure 2.1 - Warning Decal (P/N 30333417)

!

39000018

WARNING

Multiple power sources. Check for voltage before touching any point.

30333417 A



Whenever doing any maintenance on the inside of the pump, i.e. replacing poppet valves or piston heads, the pump discharge must be disconnected from the pipeline prior to starting work on the pump.

WARNING! DANGER - CONFINED SPACE! When entering a silo to perform any work, follow the guidelines below. Serious injury or death may occur if proper guidelines are not followed.

ALWAYS -Establish a confined space entry program. Perform a confined space hazard analysis and follow local regulations dealing with confined space entry.ALWAYS -Clean the silo of material to prevent hazardous gases or collapse of bulk materials.ALWAYS -Wear personal protective equipment required (hard hat, boots, respirator, hearing protection, etc.).ALWAYS -Have a rescue plan established BEFORE a person enters a confined space. Safety lines attached to the person working in the confined space, and a means to pull them to safety, can prevent a rescuer from being exposed to the same hazard encountered by the worker.ALWAYS -Provide adequate ventilation of fresh air. Natural ventilation alone may not be sufficient to maintain breathable quality air.ALWAYS -Have air quality tested by a qualified person BEFORE entering a confined space, and continually monitor until the work is completed.ALWAYS -Have at least two (2) persons present when performing work in confined spaces; one (1) person must stay outside of confined space as an observer in case of emergency.


Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel.


Other sections of the O&M manual contain specific safety recommendations for INSTALLATION, STARTUP, ADJUSTMENTS & CHECKS, AND MAINTENANCE. See the Table of Contents and study and review these sections also.

2.2 SAFETY DURING INSTALLATION

Supplementary recommendations:

Read and review the O & M Manual and relevant contract drawings for installation information.

Lifting equipment, cables, chains, etc. are to be connected only at the lifting points provided.

!



Keep unauthorized personnel away from the work area during positioning of equipment or installation.

Installation work should only be done by qualified, authorized personnel.



Do not install or repair damaged pipes, fittings, or hoses. Replace damaged hydraulic hoses immediately

2.3 SAFETY PRECAUTIONS - STARTUP

Before start-up the operator shall perform all necessary pre-start-up checks as described in Section 2.4, Page 2 - 4 if this is a testing start-up, first time start-up, restart after maintenance, or restart after Long Term Shutdown

At start-up observe the following safety precautions:

Keep area clear of unauthorized personnel.

Be observant for leaks or unusual noises.

DOUBLE CHECK THAT ALL HAND VALVES ARE IN NEUTRAL POSITION and/or BYPASS SWITCH IS IN "BYPASS" (NOTE INDICATOR LIGHT) BEFORE STARTING.

Review the "Sequence of Operation" that is included on the Electrical Schematic in Section 8 to understand what happens at start-up of system.


WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the screw feeder and agitator hopper.


All covers, guards and safety decals must be in place before start-up.

!

!

!

!



2.4 SAFETY INSTRUCTIONS - ADJUSTMENTS AND CHECKS

Only trained and authorized personnel shall perform adjustments to the sludge pump and related equipment.

Read and study all of the adjustment procedures before making any adjustment. One adjustment may have an effect on another.

Covers for rotating parts must be in place during adjustments and checks.

All personnel shall know the location and operation of EMERGENCY CONTROLS. See the sequence of operation and control layout drawings on the electrical schematic in your O&M manual.

2.5 SAFETY DURING MAINTENANCE

When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, Facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following are some supplementary recommendations:

Read and review this O & M Manual and relevant contract drawings for maintenance information.


Maintenance work should only be done by qualified, authorized personnel.

Whenever doing any maintenance on the inside of the pump, i.e. replacing poppet valves or piston heads, the pump discharge must be disconnected from the pipeline prior to starting work on the pump.


WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the screw feeder and agitator hopper.




Before working on hydraulic systems, depressurize the whole system and secure the electrical and hydraulic controls in OFF or NEUTRAL position.

!

!

!

!



WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE THE PRESSURE on the line by selecting the reverse position of the pump for several strokes.

Sludge discharge lines are operating under high pressure. Extreme caution and proper safety practices should be followed whenever the flanges are being loosened or the clamps removed from the sludge discharge line.

To relieve the pressure in a sludge discharge line, follow these steps:

1. Place the screw conveyor or conical hopper in the reverse position.

2. Tighten down the throttle valves until they are completely closed, then open them 1/2 turn. (Located on the control block)

NOTE: If your pump is equipped with the SFMS (Sludge Flow Measuring System) you must fully open the throttle check valves located on the discharge poppet hydrau-lic cylinders.

3. On manually operated control blocks (older models) place the S-1 spool in the reverse position and let the pump kit stroke in reverse for a short period of time.

4. Observe the hydraulic cylinder rods for the discharge poppets to verify that they are moving. (If they are not moving assume that the line is still pressur-ized.)

5. Observe the hopper to see if any sludge is coming from the pump into the hop-per. Also observe the discharge line pressure gauge to see if it is dropping (if so equipped).

6. Open the pressure bleed off valve to release any residual pressure remaining (if so equipped).

7. Shut the pumping unit off and disconnect all power sources. Remove the flanges and clamps, using the proper safety procedures.

Do not install or repair damaged pipes, fittings or hoses. Replace damaged hydraulic hoses immediately.

Lifting equipment, cables, chains, etc., are to be connected only at the lifting points provided.

Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Good Preventative Maintenance programs are essential for a good Safety Program.

!




Figure 2.2 - Recommended Pipeline Connection

WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE THE PRESSURE on the line by selecting the reverse position of the pump for several strokes.

39000017

Pipeline

ANSI Flange

In-line Fully PortedShut-off Valve

1/2" Dutchman

Spool Piece

2" Fully PortedBleed Valve SchwingTwo Bolt

Clamp SchwingSludge Pump

Discharge

!



Figure 2.3 - Typical Decal Location - KSP

Deca

l Loc

atio

n Dw

g.-1

of 5

KSP w

/Pow

er P

ack

KSPp

umpk

it(Ty

pica

l)Dr

awn

By

Date

Appr

oved

REV.

3035

8014

RE08

/23/

01

n/a

REV.

CHAN

GE /

E.C.O

#NA

ME

DAT

E30

3580

14Jo

b Nu

mbe

r:

Job

Nam

e:

Labe

l Ass

ign

men

t by:

Assig

nm

ents

:

1. B

yp

ass

: Use

#

Wri

te in

num

ber

Wri

te in

num

ber

3112

11

(Choose

betw

een:

322670

338672)

2. M

oto

r ra

ting

:

Date

:

3. R

ev/F

wd

: Use

#

4. P

ress

ure

lab

els

:

Slu

dg

e p

um

p:

Scr

ew

feed

er:

Acc

um

ula

tor:

Slid

e g

ate

:

Slid

e fra

me:

Push

flo

or:

Hyd

raulic:

3031

4576

3031

1258

3031

1257

3035

55x6

3035

55x7

3035

55x8

3035

55x9

(Use

3112

63 fo

r tab

le 1,

3, 5,

7;

Use

311

262

for t

able

2, 4,

6, 8)

460V

316189

oth

er

575V

317932

WAR

NING

: Byp

ass-L

oad

does

not

stop

scre

w fe

ed - 3

0311

211

WAR

NING

: Byp

ass-L

oad

stops

bot

hsc

rew

feed

er an

d slu

dge p

ump

- 303

2267

0or

or

WAR

NING

: Scr

ew fe

eder

and

sludg

epu

mp

have

sep

arat

e By

pass

-Loa

dsw

itche

s - 3

0338

672

WAR

NING

: Do

not p

utha

nds i

n w

ater

box

3031

9872

WAR

NING

: Do

not p

utha

nds i

n ho

pper

3031

9869

(Both

sides

of ma

terial

cylin

ders)

WAR

NING

: Sta

rtsau

tom

atica

lly30

3370

69 WAR

NING

: Saf

ety

Guar

d is

miss

ing

3033

7004

(in th

e wate

rbox

,u

nde

r the

gua

rd)

Fwd/

Rev -

311

262

Lift h

ere

3031

7940

Main

ID ta

g30

3017

33

Main

ID ta

g30

3017

33

or Re

v/Fw

d - 3

1126

3

Lette

ring

per

hydr

aulic

sche

mat

ic

3611

29

26

14

15

4

8

27

1 6

9



Figure 2.4 - Typical Decal Location - Power Pak

Deca

l Loc

atio

n Dw

g. - 2

of 5

KSP w

/Po

wer

Pac

kDr

awn

By

Date

Appr

oved

REV.

3035

8014

RE08

0901

A

POW

ER PA

CK

(Typi

cal)

REV.

CHAN

GE /

E.C.O

.NA

ME

DATE

3035

8014

Texa

co H

D 46

(get #

from

dec

al)

ATTE

NTIO

N: C

hang

efi

lter -

303

1405

0W

ARNI

NG:Th

is Eq

uip.

star

ts Au

tom

atica

lly30

3370

69 (b

oth Sid

es)W

ARNI

NG: H

yd.

Accu

mul

ator

- 30

3245

99(un

its w

ith ac

cum

ulat

ors)

Pow

er Pa

ckSe

rial N

umbe

rPl

ate

- 303

0431

4

Sludg

e Pu

mp

Pres

sure

- 30

3112

57Ac

cum

ulat

orPr

essu

re -

3031

4576

Scre

w Fe

eder

Pres

sure

- 30

3112

58Sli

de G

ate

Pres

sure

- 30

3555

66Sli

de Fr

ame

Pres

sure

- 30

3555

67Pu

sh Fl

oor

Pres

sure

- 30

3555

68Hy

drau

lic Pr

essu

re(ge

neric

) - 30

3555

69

Fwd

/ Rev

- 303

1126

2

Lette

ring

per h

ydra

ulic

sche

mat

ic

WAR

NING

:Stor

edHy

d. en

ergy

- 303

3497

6(un

its w

ith ac

cum

ulat

ors)

(Insid

e of E

lec.

pane

l) W

ARNI

NG: m

ultip

le po

wer

so

urce

s-30

3334

17

WAR

NING

: Sta

rts

Attn

: One

-W

ay

WAR

NING

: Do

not

oper

ate

with

out

train

ing

- 303

3701

3

Safe

ty In

stru

ctio

ns:

Safe

ty ru

les

3031

2298

Safe

ty In

stru

ctio

ns:

Ac

cum

ulat

or ru

les -

3031

411

5(un

its w

ith ac

cum

ulat

ors)(

locate

her

e an

d ne

ar ac

cum

ulat

or)

IMPO

RTAN

T:Re

orde

r inf

o30

3332

69

War

nin

g:

Haza

rdou

s vol

tage

WAR

NING

:Hyd

.

Accu

mul

ator

-303

2459

9(un

its w

ith

accu

mul

ator

s)(lo

cate

here

an

d

Safe

ty In

stru

ctio

ns:

Accu

mul

ator

rule

s - 3

0314

115

WAR

NING

:Bypa

ss-L

oad

does

not

stop

scre

w fe

ed - 3

0311

211

WAR

NING

:Bypa

ss-L

oad

stops

bot

hsc

rew

feed

er an

d slu

dge p

ump

- 303

2267

0

WAR

NING

:Scre

w fe

eder

and

sludg

epu

mp

have

sep

arat

e By

pass

-Loa

dsw

itche

s - 3

0338

672

or or

SCHW

ING

AB

C

One o

r mor

e of

thes

e,lo

cate

d un

der p

ress

ure

gaug

es

198

7 34 2

31

3311 29 36

30

14

21

58

2831 30

335



Figure 2.5 - Typical Decal Location - Screw Feeder

REV.

CHAN

GE /

E.C.O

. #

NAM

EDA

TE30

3580

14

Deca

l Loc

atio

n Dw

g. - 3 o

f 5KS

P w/

Pow

er P

ack

Draw

n B

yDa

teAp

prov

ed

REV

.

3035

8014

RE08

0901

n/a

Scre

wfe

eder

(Typi

cal)W

ARNI

NG: S

afet

yGu

ard

is M

issin

g30

3370

04(As

Req

'd)

WAR

NING

: Kee

p Ha

nds O

utOf

Ag

itato

r As

sy.-30

3122

97(If

Equi

pped

with

hop

per)

(Both

Sides)

WAR

NING

: Sta

rts Au

tom

atica

lly-3

0337

069

(Both

sides

of ho

using

, if

expo

sed)

WAR

NING

: Byp

ass-L

oad

does

not

stop

scre

w fe

ed - 3

0311

211

Lette

ring

per h

ydra

ulic

sche

mat

ic

or WAR

NING

: Byp

ass-L

oad

stops

bot

hsc

rew

feed

er an

d slu

dge p

ump

- 303

2267

0or W

ARNI

NG: S

crew

feed

er an

d slu

dge

pum

p ha

ve s

epar

ate

Bypa

ss-L

oad

switc

hes -

303

3867

2

WAR

NING

: Byp

ass-L

oad

does

not

stop

scre

w fe

ed - 3

0311

211

or WAR

NING

: Byp

ass-L

oad

stops

bot

hsc

rew

feed

er an

d slu

dge p

ump

- 303

2267

0or W

ARNI

NG: S

crew

feed

er an

d slu

dge

pum

p ha

ve s

epar

ate

Bypa

ss-L

oad

switc

hes -

303

3867

2

WAR

NING

: Kee

p Ha

nds O

utOf

Scre

w Fe

eder

-303

1126

4(Bo

th Sid

es)

Lift h

ere

3031

7940

918

8

11 29

11 29 36

16

4



Figure 2.6 - Typical Decal Location - Lube Pumps

REV.

CHAN

GE /

E.C.O

. #

NAM

EDA

TE30

3580

14

Deca

l Loc

atio

n Dw

g. - 4

of 5

KSP w

/Po

wer

Pac

k - Lu

be p

umps

Draw

n B

yDa

teAp

prov

ed

REV.

3035

8014

RE08

0901

n/a

LUBE

PU

MP

CON

TRO

L PA

NEL

IMPO

RTAN

T:Re

orde

r inf

o30

3370

13

WAR

NING

:M

ultip

le po

wer

sou

rces

3033

3417

WAR

NING

:Ha

rzar

dous

volta

ge in

side

3033

6368

WAR

NING

:M

achi

ne m

ay st

art

at a

ny ti

me

3033

7069

IMPO

RTAN

T:Do

cum

enta

tion

orde

ring

info

3033

3269

SAFE

TY IN

STRU

CTIO

NSSa

fety

ope

ratin

gin

stru

ctio

ns -

KSP

3031

2298

IMPO

RTAN

T:Do

cum

enta

tion

orde

ring

info

3033

3269

SAFE

TY IN

STRU

CTIO

NS:

Safe

ty o

pera

ting

inst

ruct

ions

- KS

P30

3122

98

WAR

NING

:M

achi

ne m

ay st

art

at a

ny ti

me

3033

7069

WAR

NING

:Do

not

ope

rate

with

out t

rain

ing

3033

7013

7

35 34 8 33

19 33

19

8 7



Figure 2.7 - Safety Reminder - Electrical Disconnections

Figure 2.8 - Safety Reminder - Guards And Shrouds

ELECTRICAL DISCONNECTS SHOULD HAVE PADLOCKSACCESSIBLE TO REPAIR PERSONNEL OR SET-UP MECHANICS.

39000022

SUITABLE GUARDS AND SHROUDS HELP PREVENTOPERATORS FROM INJURING THEMSELVES.

39000023



Figure 2.9 - Safety Reminder - Good Housekeeping

CONSTANT ATTENTION TO SAFETY AND GOOD HOUSEKEEPINGIS THE BEST WAY TO PREVENT COSTLY ACCIDENTS.

39000024

HYDRAULICS SECTION 3



3.1 RULES OF HYDRAULICS1. Hydraulic pressure always takes path of least resistance.

2. Hydraulic pressure is created equal in all directions (Pascal's Law).

3. Liquids (oil) are relatively incompressible.

12

3

4

The bottle is filled with a liquid, which is not compressible

If the bottom has an area of 20 square inches and each square inch is pushed on by 10 pounds of force, the entire bottom recieves a 200 pound push.

A 10 pound force applied to a stopper with a surface area of one square inch......

Results in 10 pounds of force on every square inch (pressure) of the container wall

Pascal's Law

1000 lbs of Force

1000 lbs of Force

OIL

AIR

OIL

AIR



4. When hydraulic pressure and flow is not converted into work it is converted into heat.

5. When oil is heated it will expand (5% or more).

6. When oil is heated the viscosity of it changes.

Open relief (Heat)

Vacuum formed as

hydraulic oil cools

Atmospheric pressure

forces water past seals

Seals

Hydraulic Cylinder

Water Box

6 bar



7. In industrial applications the recommended maximum fluid velocity is 17 FPS (Feet Per Second).

8. GPM (Gallons Per Minute) only determine the speed at which the actuator (motor or cylinder) oper-ates.

9. P.S.I. (Pounds Per Square Inch) determine only the amount of force exerted upon the load by the actu-ator.

M35 psi P

0 GPM 10 GPM

1000 PSI

10 gallon maximum

capacity cylinder

10,000 LBS

LOAD

10 inch of area on

cylinder piston



10. The resistance created in a hydraulic circuit, whether by the amount of the load on the actuator and/or the pressure drop in a circuit, is what determines how much work is required.

F

P A

F = FORCE (in pounds) (lb)P = PRESSURE(in pounds per square inch) (P.S.I.)A = AREA (in square inches) (in 2 )F = P x A

P = F /AA = F/P

F = FORCE (in kilograms) (Kg)P = PRESSURE(in kilograms per square centimeter) (Kg/cm2 )A = AREA (in square centimeters) (cm2 )

U.S.

METRIC

Q = FLOW RATE(unit of volume per time period)P = PRESSURE(unit of force per unit of area)

GENERAL

POWER =CONSTANT

Q x P

HP = HORSEPOWERGPM = GALLONS PER MINUTEPSI = POUNDS PER SQUARE INCH

U.S.

1714 = KNOWN CONSTANT

HP =1714

GPM x PSI

KW = KILOWATTSLPM = LITERS PER MINUTEBAR = METRIC UNIT OF PRESSURE

METRIC

600 = KNOWN CONSTANT

KW =600

LPM x BAR



Mechanical Versus Hydraulic

Transfer of Energy

10 lb.(44.48 N)

100 lb.(444.82 N)

1. Ten pounds (44.48 N) here...

3. if this arm is 10 timesas long as...

4. this arm.

2. will balance 100 lb(444.82 N) here...

A. SIMPLE MECHANICAL LEVER

COMPARISON OF MECHANICAL FORCESVERSUS HYDRAULIC FORCES

10 lb.(44.48 N)

100 lb.(444.82 N)

1. An input force of10 lb.(44.48 N) on aone square inch(6.45 cm ) piston...

2. develops a pressure of10 pounds per square inch(psi)(.69 bar) (68.94 kilopascals)throughout the container.

3. This pressure willsupport a 100 lb.(444.82 N) weight ifthis is a 10 sq. in.(64.52 cm ) piston.2

INPUT OUTPUT4. The forces are proportionalto the piston areas.

10 lb. (44.48 N)1 sq. in (6.45 cm 2 ) =

100 lb. (444.82 N)10 sq. in (64.52 cm2 )

B. SIMPLE HYDRAULIC PRESS

2

10 sq. in.(64.51 cm 2 )

1 sq. in.(6.45 cm )2

10 lb.(44.48 N)

100 lb.(444.82 N)

1. Moving the small piston 10 in.0.25 m) displaces 10 cu. in.(163.87 cm3 ) of liquid.(1 sq. in. x 10 in. =10 cu. in.)(6.45 cm 2 x 25.40 cm = 163.87 cm 3 )

10 in(0.25 m)

1 in(0.02 m)

10 cu. in. (163.8 cm 3 ) of liquidwill move the larger piston only1 in. (2.54 cm)(10 sq. in. x 1 in. = 10 cu. in.)(64.52 cm x 2.54 cm = 163.87 cm )

2.

3. The energy transfer here equals10 lb. x 10 in. (44.48 N x 0.25 m)or 100 in. lb. (11.30 Nm)

4. The energy transfer here also is100 in. lb. (11.30 Nm)(1 in. x 100 lb. = 100 in. lb.)(.02 m x 444.82 N = 11.30 Nm)

10 sq. in.(64.51 cm2 )

1 sq. in.(6.45 cm 2 )

ENERGY CAN NEITHER BE CREATED NOR DESTROYED



Hydraulic Jack

Linear & Rotary Actuators

PISTON

HYDRAULIC

ROD

8"

PUMP

PUMP

MOTOR

ROTARYDRIVE SHAFT

LOAD

1.The pump pushes thehydraulic liquid into lines.

2. Lines carry the liquid toactuators which are pushedto cause a mechanical outputto move a load.

3. Some actuators operate ina straight line (linear actuators).They are called cylinders or rams.They are used to lift weight, exertforce, clamp, etc.

PISTON & ROD

TO RESERVOIR

ROTARY ACTUATORLINEAR ACTUATOR4. Rotary actuators or motors give the system rotating output.They can be connected to pulleys,gears,rack-and-pinions, conveyors, etc.



Basic Hydraulic Components

Check Valve

Throttle Valve

Throttle Check Valve

Switching Valve



3.2 HYDRAULIC PUMPSHydraulic pumps are used to create flow (GPM) in a hydraulic system.(Hydraulic pumps do not create pressure)

There are 4 basic designs of hydraulic pumps:

1 Piston Pumps:a. Radial Pistonb. Axial Piston

I. Bent AxisII. Swash Plate

STYLES: AVAILABLE CONTROLSFixed Displacement 1. ManualVariable Displacement 2. Horse-power regulated

3. Pressure Compensated4. Pressure cut-off

Piston pumps are rated in CC (Cubic Centimeters) or CID (Cubic Inch Displacement) perrevolution.

The efficiency of this pump design remains high throughout its pump life. The efficiencydrops off very quickly at the end of the pumps life.

They are designed for high pressure and high range of RPM.

2 Gear Pumps:a. External Gearb. Internal Gear

I. GerotorII. Crescent

Gear pumps have a nominal rating in GPM at 1000 PSI and 1200 RPM. They are gener-ally designed for medium range hydraulic pressure and RPM.

The efficiency of this pump design declines gradually throughout its pump life. It is sogradual that it is hardly noticeable until it has deteriorated considerably.

3 Vane Pumps:

Vane pumps have a nominal rating in GPM at 1000 PSI and 1200 RPM. they are gener-ally designed for medium range pressure and RPM.

The efficiency of this pump remains high throughout its pump life and drops quickly at theend of the pumps life.

4 Screw Pumps:

These pumps operate at various pressure ranges and RPM's. There design is mainlyused when a hydraulic system can't tolerate any hydraulic pulsations.



Figure 2.10 - Different Types of Pumps

Figure 2.11 - Different Types of Axial Piston Pumps

notsiPraeG

Screw Vane

Bent Axis Swash Plate



Figure 2.12 - Pumping Action In Bent-axis Pumps

Figure 2.13 - Increasing/Decreasing Piston Pump Output

to outlet

from inlet

Piston is withdrawingfrom bore at inlet

Rotating shaft causespistons to reciprocate

Universal link

Piston rod

Piston

Cylinder block

Oil forced to outlet as pistonis pushed back into cylinder

39000040

Maximum piston stroke Reduced stroke

No stroke

Maximum angle Less angle

No angle

39000041



Figure 2.14 - Internal and External Gear Pumps

Drive Gear

Outlet pressure against teeth causes heavy side-loading on shafts as indicated by arrows.

through this port.Oil entering here....

(4) OUTLET

INLET

Vacuum is created here as teeth unmesh. Oil enters from reservoir.

(1)

...and forced out of pressure port as teeth go back into mesh.

(3)

Oil is carried around housing in chambers formed between teeth, housing, & side plates...

(2)

External Gear Pump

(1)

by the constant withdrawal of teeth on this inner gear...

Cresent seal

from the spaces between the teeth of this inner gear...

(3)is carried in these spaces...

(4)

to this point, where constant meshing of two gears forces the oil...

(5)

(6)

Internal Gear Pump

(2)

39000042



3.3 VALVES

3.3.1 Control Valves

Control valves are designed to direct and control the flow of oil to or from the work in a hydraulic circuit.

These operating mechanisms of the valves are:

1 MANUAL OPERATED:a. Hand lever b. Push buttonc. Pedal operated

2 SOLENOID OPERATION:a. AC coilsb. DC coils

3 PILOT OPERATEDa. Hydraulic pilot b. Air pilot

3.3.2 Relief Valves

Relief valves are designed to regulate the maximum amount of pressure that can be built in a hydrauic circuit.

They are built in three designs:

1. Direct acting

2. Pilot operated

3. Solenoid operated.



Figure 2.15 - Different Types of Activation Devices

Figure 2.16 - Typical Spool-type 4 Way Valve

ManuallyActuated

Push Button

A

P

B

T

Hand Lever

A

P

B

T

Foot Pedal or Treadle

A

P

B

T

Mechanically Actuated Symbol

A

P

B

T

Hydraulic Pilot

A

P

B

T

Air Pilot

A

P

B

T

Solenoid

A

P

B

T 39000043

A B A B

T P P T

Pressure to "b" port, "a" port to tank Pressure to "a" port, "b" port to tank

A B

P T

39000044



3.3.3 The Basic Relief Valve

This is a direct acting non adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style pressure relief is not adjustable except by changing the internal spring.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring. When this direct acting design relieves it causes pulsations in the system.

Figure 2.17 - Direct Acting Non-adjustable Relief Valve

This is a direct acting adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style is adjustable though a external control which varies the spring tension on the relief poppet.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring.

Figure 2.18 - Direct Acting Adjustable Relief Valve

Tank

Pressure

39000045

39000046

Tank

Pressure

39000046



This is a pilot operated adjustable relief valve. The relief poppet has a small orifice in it that allows the hydraulic pressure to also be applied on the back side of the poppet. This internal chamber is hydraulically locked and it will hold the main poppet closed as long as it has equal pressure on the front side and the back side. There is also a much smaller pilot poppet, that is operator adjustable. This smaller poppet, with a smaller area, can have a smaller spring controling it. Once this pilot poppet opens we lose our hydrau-lic lock, the pressure is reduced on the back side and thus the main poppet can relieve the excess pressure to tank. With this design we are able to control large volumes of oil at high pressures with minimal sized springs.

Figure 2.19 - Pilot Operated Adjustable Relief Valve

Tank

Pressure Pressure

39000047



3.4 HYDRAULIC SYMBOLS

Figure 2.20 - American-German Symbol Comparison

A.N.S.I. D.I.N.

A.N.S.I.

D.I.N.

A.N.S.I. = AMERICAN NATIONAL STANDARDS INSTITUTEDIN = DEUTSCHE (GERMAN) INDUSTRIAL NORM



Figure 2.21 - Hydraulic Symbols - Sheet 1

LINES CROSSING

LINES JOINING FOUR WAY VALVE, TWO POSITIONMANUALLY OPERATED

LINE, WORKING (MAIN)FOUR WAY VALVE,THREE POSITION,LEVER OPERATED, W/ DETENT

LINE, PILOT (FOR CONTROL) OIL LEVEL SIGHT GLASSW/ THERMOMETER

PORTFOUR WAY VALVE, THREEPOSITION, SOLENOID AND PILOTOPERATED, SPRING RETURN

LINE W/ THROTTLE VALVE

CHECK VALVE W/ NO SPRING

CHECK VALVEW/SPRING RETURN FLOAT-TYPE SWITCH

TANK

FILTER

DOUBLE ACTING CYLINDER RODEND CYLINDER SHUT-OFF VALVE

PUMP,VARIABLEDISPLACEMENT,NON-COMPENSATEDUNIDIRECTIONAL

PRESSURE SWITCH

HYDRAULIC MOTOR,BI-DIRECTIONAL OIL COOLER

PRESSURE GAUGE

TL

M

PRESSURE RELIEF VALVE

TA

ksp poppet manual 2011

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