Doha North Sewerage Treatment & Associated Works

Doha North Sewerage Treatment & Associated
Works
Doha North Sewage Treatment Works

Civil Project 682/1
Project Code DTC0091 Contract No. C2007/68
Installation, Operation & Maintenance Manual
[K654_834_02_600_0]
Document No. K654_834_02_600_0 Page 1

REVISION HISTORY
Rev Date Prepared By Description Chk. & Rev. By Appr. By

Appr. By KSES KSES
Contractor
0 13.06.12 SPIRAC Draft Issue for Comments / NN CA GEK

Approval

Contents
1 INTRODUCTION ................................................................................................................................... 6
1.1 GENERAL ............................................................................................................................................ 6
1.2 PRODUCT IDENTIFICATION ................................................................................................................ 6
1.3 PRODUCT DESCRIPTION - CONVEYORS .............................................................................................. 7
1.4 PRODUCT DESCRIPTION – SLIDING FRAMES ...................................................................................... 8
2 INSTALLATION ..................................................................................................................................... 9
2.1 CONVEYORS ....................................................................................................................................... 9
2.1.1 GENERAL .................................................................................................................................... 9
2.1.2 ASSEMBLING THE TROUGH ........................................................................................................ 9
2.1.3 CONNECTION OF SPIRALS ........................................................................................................ 10
2.1.4 MOUNTING THE DRIVE ASSEMBLY .......................................................................................... 10
2.1.5 CONNECTION TO SUPPORT STRUCTURE.................................................................................. 12
2.1.6 ELECTRICAL .............................................................................................................................. 12
2.1.7 WELDING ................................................................................................................................. 13
2.2 SLIDING FRAMES .............................................................................................................................. 14
2.2.1 GENERAL .................................................................................................................................. 14
2.2.2 DELIVERY TO SITE ..................................................................................................................... 14
2.2.3 INSTALLATION PROCEDURE ..................................................................................................... 15
2.2.4 ELECTRICAL .............................................................................................................................. 16
2.2.5 WELDING ................................................................................................................................. 17
3 OPERATION ....................................................................................................................................... 18
3.1 CONVEYORS ..................................................................................................................................... 18
3.1.1 PRE-START CHECKS .................................................................................................................. 18
3.1.2 OPERATIONAL CHECK-LIST ....................................................................................................... 19
3.1.3 EXTENDED SHUT-DOWN .......................................................................................................... 19
3.2 SLIDING FRAMES .............................................................................................................................. 19
3.2.1 PRE-START CHECKS .................................................................................................................. 19
3.2.2 RINSING THE HYDRAULIC PIPING AND TUBES ......................................................................... 20
3.2.3 INSTRUMENTS TESTING ........................................................................................................... 20
3.2.4 ROTATION TEST ....................................................................................................................... 20
3.2.5 OPERATING DATA .................................................................................................................... 20
3.3 SLUDGE RECEPTION AND CONVEYING SYSTEMS ............................................................................. 21
3.3.1 SUMMARY ................................................................................................................................ 21
3.3.2 NORMAL OPERATION .............................................................................................................. 22
3.3.3 ABNORMAL/EMERGENCY OPERATION .................................................................................... 28
3.3.4 CONTROLS ................................................................................................................................ 29
3.3.5 OPERATOR REQUIREMENTS .................................................................................................... 31
3.3.6 TROUBLESHOOTING................................................................................................................. 32
4 Maintenance ..................................................................................................................................... 33
4.1 CONVEYORS ..................................................................................................................................... 33
4.1.1 GENERAL .................................................................................................................................. 33
4.1.2 PACKING GLAND ADJUSTMENT ............................................................................................... 33
4.1.3 LUBRICATION ........................................................................................................................... 34
4.1.4 SURFACE COATING................................................................................................................... 34
4.1.5 MAINTENANCE TIME TABLE .................................................................................................... 35
4.2 SLIDING FRAMES .............................................................................................................................. 36
4.2.1 GENERAL .................................................................................................................................. 36
4.2.2 LUBRICATION ........................................................................................................................... 36
4.2.3 CYLINDER AND HYDRAULIC POWER PACK ............................................................................... 37
4.2.4 MAINTENANCE TIME TABLE .................................................................................................... 37
4.2.5 REPLACING THE GLAND PACKING ............................................................................................ 38
4.2.6 REPLACING THE D-ROD WIPER SEAL AND THE POWER SLIDES ............................................... 38
5 Service .............................................................................................................................................. 40
5.1 CONVEYORS ..................................................................................................................................... 40
5.1.1 REPLACING THE GLAND PACKING ............................................................................................ 40
5.1.2 REPLACING THE LINERS............................................................................................................ 40
5.1.3 REPLACING THE SPIRAL ............................................................................................................ 42
5.1.4 REPLACING THE DRIVE SHAFT .................................................................................................. 42
5.2 SLIDING FRAMES .............................................................................................................................. 44
6 TROUBLESHOOTING .......................................................................................................................... 45
6.1 CONVEYORS ..................................................................................................................................... 45
6.1.1 GENERAL .................................................................................................................................. 45
6.1.2 TROUBLESHOOTING CHART ..................................................................................................... 45
6.2 SLIDING FRAMES .............................................................................................................................. 46
6.2.1 GENERAL .................................................................................................................................. 46
6.2.2 TROUBLESHOOTING CHART ..................................................................................................... 47
7 SAFETY .............................................................................................................................................. 48
7.1 CONVEYORS ..................................................................................................................................... 48
7.1.1 GENERAL .................................................................................................................................. 48
7.1.2 NOISE ....................................................................................................................................... 49
7.2 SLIDING FRAMES .............................................................................................................................. 49
7.2.1 GENERAL .................................................................................................................................. 49
7.2.2 NOISE ....................................................................................................................................... 50
8 SPARE PARTS..................................................................................................................................... 51
8.1 CONVEYORS ..................................................................................................................................... 51
8.1.1 CONVEYOR PARTS DESCRIPTION ............................................................................................. 51
8.1.2 RECOMMENDED SPARE PARTS ................................................................................................ 52
8.2 SLIDING FRAMES .............................................................................................................................. 52
8.2.1 SLIDING FRAME SPARE PARTS ................................................................................................. 52
8.2.2 RECOMMENDED SPARE PARTS ................................................................................................ 53
9 SUPPLIER CONTACT ........................................................................................................................... 53

APPENDIX
Reference Contents
A CONVEYOR DATA SHEETS
B LUBRICATION CHECK SHEETS
C GENERAL ARRANGEMENT DRAWINGS
D MOTOR DATA SHEETS
E SPIRAC SLIDEGATE IOM MANUAL
F WELDING
G INSTRUMENTATION DATA SHEETS
H GEARBOX MANUAL
I MOTOR MANUAL
J HYDRAULIC PUMP MANUAL
K IMPORT HOPPER INSTALL INSTRUCTION MANUAL
L INSTRUMENTATION – INSTALLATION AND OPERATION MANUALS
- PROXIMITY SWITCH FOR HOPPER LID & SLIDING FRAME RAM
- MOTION SENSOR FOR CONVEYOR MOTOR
M LCS INSTALLATION AND OPERATION DETAILS

1 INTRODUCTION
1.1 GENERAL
We welcome you as a user of SPIRAC equipment. Your conveyors and sliding frames are products of
careful engineering and skilled workmanship. We believe you have the best equipment possible for
the service intended. With reasonable care and preventive maintenance it will give you long, efficient,
trouble-free service.
Refer to Safety Sheet in section 7.SAFETY.
This manual is furnished to acquaint you with some of the practical ways to install, operate and
maintain this equipment. Read it completely before doing any work on your unit and keep it handy for
future reference.
All SPIRAC conveyors and sliding frames are built to convey different types of materials that may be
wet, half fluid, sludgy, uneven or hygienically demanding etc. However every conveyor/sliding frame is
custom built to give maximum efficiency for the specified material being conveyed. It is not acceptable
to convey any product other than that noted in the Specification Sheets.
Any modification, change or rebuilding of the equipment must be approved in writing by SPIRAC so
that machine damage and personal injury are avoided and that documentation is relevant.
Only trained or instructed staff with clearly defined responsibilities for the operation, set up,
maintenance or repair on the conveyers or sliding frames should be used.
In the event of any queries please contact your nearest SPIRAC representative.
1.2 PRODUCT IDENTIFICATION
There is one identification plate (ID) on each conveyor/sliding frame. Figure 1.2a shows an example of
a typical ID plate.
SPIRAC CONVEYOR
U320-SPX/SS - 15m³/hr
FA77 - DV100M4 - 13RPM
415V/50Hz/3P IP56 2.2kW
CV-01
4775-01 09/05
Figure 1.2a

Permanent records for the conveyors/sliding frames are kept by Serial Number and it must, therefore,
be used with all correspondence and spare parts orders. The last sequence of numbers is specific to
that equipment and is utilised on orders of more than one conveyor/sliding frame. This sequence of
numbers is also the end users equipment tag numbers.
1.3 PRODUCT DESCRIPTION - CONVEYORS
The conveyors’ parts can vary in appearance due to the fact that all SPIRAC conveyors are custom
built. The figure below (Figure 1.3a) shows the principal parts of the conveyor. Drawings of each
particular conveyor can be found in Appendix ‘General Arrangement Drawings’.
Protective cover
Outlet
Spiral
Inlet
Support
Motor Gearbox
Figure 1.3a - Principal Parts of the Conveyor
The material is fed in/out via one or more inlets/outlets. These can be fitted with covers or slide gates
if so required. The inlets/outlets can be mounted to face any direction.
The conveyor moves the material with a rotating steel spiral. The spiral’s inclination and diameter are
relevant to the material being conveyed. The steel spiral has only one bearing, at the drive end. The
spiral is a helix without a centre shaft. This gives the conveyor more space for and less sensitivity to
the material being conveyed.
The drive unit can either be pushing or pulling. A pushing drive enables the conveyor to work with
materials that tend to snag.
Because the spiral has no centre shaft it is always in contact with the trough when it rotates. A
replaceable liner therefore protects the trough. The liners are available in several different materials

(plastic, steel, etc.) depending on the material being conveyed. To reduce wear the conveyor should
be driven as full as possible.
1.4 PRODUCT DESCRIPTION – SLIDING FRAMES
The sliding frame parts for the various models are similar in appearance as shown in the figure below.
The overall configurations are different due to the fact that SPIRAC sliding frames are custom built.
The figure below (Figure 1.4a) shows the principal parts of the sliding frame. Drawings of each
particular sliding frame can be found in Appendix ‘General Arrangement Drawings(K654-834-02-0006).
Figure 1.4a - Principal Parts of the sliding frame
The silo is filled with material from the top until is full. Once power to hydraulic power pack is switched
on, the cylinder rod connected to the sliding frame will reciprocate linearly at the silo flat bottom floor.
By this to-and fro movement on the part of the sliding frame, material is drawn into the metering
device(s) as shown in figure 1.4a above. The metering device(s) could be either U-Trough conveyors
or pump(s) depending on the material being conveyed.
The stuffing box acts as a seal around the cylinder rod preventing the content of the silo from
escaping.

2 INSTALLATION
2.1 CONVEYORS
2.1.1 GENERAL
These instructions must be carried out in the order stated to prevent machine damage and personal
injury.
Check conveyor for shortages and damage immediately upon arrival (an absolute must !). Prompt
reporting to the carriers agent, with notations on the freight bill, will expedite satisfactory adjustment by
the carrier.
Conveyors are normally shipped from the factory within open sided crates. Gearboxes may either be
completely assembled or packed separately for shipping. When the gearbox has been sent separately,
fixing bolts will be packaged in a separate container and shipped with the conveyor or attached to the
gearbox. Recommended torque settings for the spiral coupling disc and the drive shaft are as follows:
Torque Settings for the Coupling Disc
A4/70 M12x55 62Nm (oiled thread)

Torque Settings for the Drive Shaft

Before the conveyor is installed its dimensions must be checked against the dimensions on the
installation drawing.
Make sure the inlets/outlets to the conveyor are angled to suit the conveyors inlets/outlets.
The foundation must be substantial enough to absorb vibration (recommendations of the foundation to
weigh at least 5 times the weight of the conveyor). The foundation must form a permanent and rigid
base for the conveyor supports. This is important in maintaining the alignment of the conveyor trough.
Check to make sure that there are drains if these are required.
2.1.2 ASSEMBLING THE TROUGH

If the conveyor is so long that the trough has been delivered in several sections these should be
assembled first. If the trough is already assembled then continue to Sect. 2.3.

1. Lay out the trough sections in a straight line on a flat surface.
2. Check that the trough-sections are positioned in the correct order. The trough-ends are marked
with letters to show the order in which they should be assembled.
3. Make sure that the sealing strip or gasket is placed between the trough-sections.
4. Fix the trough-sections together with the bolts, nuts and washers provided (see Figure 2.1.2a)
Figure 2.1.2a - Assembling the trough
2.1.3 CONNECTION OF SPIRALS

This procedure requires welding, see Section 2.7 “Welding” before commencing to weld. Sometimes
the spirals are delivered longer than required and must therefore be cut to the length specified in the
drawing. The spiral should be cut at right angles to its axis. After this the edges should be ground and
angles cut where needed (see Appendix ‘Welding Procedure’ if applicable).
If the spiral is delivered in several sections it must be welded together. If the spiral does not need
welding go onto Sect. 2.4.
1. Centre the spiral sections in the trough using heavy wooden blocks or steel profiles. Check e.g.
with a tri-square that the spiral sections are in line before they are welded together.
2. Weld alternately on both sides of the join.
3. Grind the weld carefully to remove sharp edges and uneven-ness.
4. Prime coat (steel spiral) or passivate (if SS spiral) weld area as detailed in Sect. 4.4.
5. Replace the trough’s protective cover.
2.1.4 MOUNTING THE DRIVE ASSEMBLY

Occasionally the drive assembly is delivered not attached to the conveyor. If your conveyor has the
drive assembly sent separately, it is delivered ready to be attached. If the conveyor is to work in a
raised position it is better to mount the drive unit with the conveyor on the ground.
1. Remove the transport lock from the spirals’ drive shaft.

2. Remove the tape holding the key to the drive shaft.
3. If the drive shaft is not stainless steel it is treated with rust inhibitor. Use degreaser to remove
this.
4. Remove the cover from the motors cooling fan so that the drive shaft can be turned using the
fan.
5. Turn the drive shaft so that the key-way comes to the right position for the spirals’ drive shaft
and then push the gearbox onto the drive shaft.
6. Bolt the gearbox to the bell housing flange with the bolts, nuts and washers provided (see
Figure 2.1.4a).
Figure 2.1.4a - Mounting the Drive Assembly

7. Fasten the locking bolt, spring washer and stepped spacer to the spirals drive shaft in order to
fasten this in the gearboxes drive bore (see Fig 2.1.4b). When the spiral’s drive shaft is firmly
positioned in the drive bore the locking bolt should be tightened to the torque specified (refer
Sect. 2.1.1).
NOTE - The spiral must be pushed back towards the drive so that the locking bolt can
be threaded into the drive shaft.

Pressure Screws
Vent Plug
Figure 2.1.4b - Fastening the Motor Figure 2.1.4c-Tightening the Pressure Screws
8. Tighten the pressure screws until the gap between the packing box and the gland is only about
7mm wide. Tighten the screws alternately and check the gap is even after the screws are
tightened (see Fig 2.1.4c).
9. Fill the packing box with grease (see Sect. 4.3).
10. Replace the cooling fan cover to the motor.
11. Remove the screw on the top of the gearbox and attach the vent plug that is provided. (If not
already done so.)
12. Check level of oil in the gearbox (see Appendix ‘Lubrication Check Sheet’ for position of filler
plug).
2.1.5 CONNECTION TO SUPPORT STRUCTURE

All conveyors are fitted with support brackets welded to each side of the conveyor trough. These
brackets are pre-slotted and positioned in the factory prior to shipment.
If supports are supplied with the conveyor –
1. Make sure no one is standing beneath the trough while it is being lifted or mounted.
2. Lift the conveyor so that it assumes its operating position.
3. Fasten the supports to the support brackets (numbered for identification) utilising the bolts, nuts
and washers provided.
4. Make sure the conveyor is sufficiently anchored to the floor to withstand any working loads.
NOTE - If the conveyor is supplied with slide gates they should be attached before
the conveyor is raised. If the conveyor is at working height it is possible to attach the
slidegate after the supports are attached.
2.1.6 ELECTRICAL
Conveyor component manufacturers generally do not provide electrical equipment to control the
conveyors. In selecting electrical control equipment to be used with any conveyor installation, the
purchaser must use equipment conforming to the local electrical regulations. Consideration should be
given to some or all of the following devices and to others that may be appropriate.
• Overload Protection - Devices such as electronic shear pins, torque limiters and so forth are
used to shut off power whenever operation of the conveyor is stopped as a result of excessive
material, foreign objects, excessively large lumps and so on.
• No-Speed Protection - Devices such as zero speed switches to shut off the power in the event
of any incident that might cause the conveyor to stop operating.
• Safety shut off switch with power lock-out provision at conveyor drive.
• Emergency stop switches readily accessible whenever required.
• Electrical inter-locking to shut down feeding conveyors whenever a receiving conveyor stops.
• Signal devices to warn personnel of imminent start-up of conveyor, especially if started from a
remote location.
• Special enclosures for motors and controls for hazardous atmospheric conditions.
2.1.7 WELDING
Steel is affected by heat take care to avoid overheating when welding. If welding stainless steel,
ensure that the consumable material is as resistant to corrosion as the parent metal. The consumable
should therefore contain as much alloy as the parent metal. Welding together two dissimilar materials
should be avoided due to the risks for hair-line fractures, reduced weld strength and a greater
propensity to corrode due to electrolytic action.
The weld surfaces should be degreased with acetone (or an equivalent solvent) immediately prior to
welding. The material should be degreased at least 60mm from the weld surface.
The following electrodes should be used for arc welding;
ELECTRODE TYPES
OK 4800 For spirals of special steel (the electrode dimension
should be at least 2mm to avoid overheating).
OK 4800 For mild steel or HTMAS.
OK 6130 For stainless steel.
OK 6330 For acid resistant stainless steel to mild steel (or to
HTMAS).
OK 6333 For stainless to mild steel (or to HTMAS).
Suitable electrode sizes are 2.0 to 3.25mm depending on where the weld is placed.
If your conveyor is delivered in sections, it will be necessary to weld the spiral. Refer to instructions in
2.3 and Appendix ‘Welding Procedure’ for the correct procedure.
For weights of conveyors see Appendix ’General Arrangement Drawings’. Weights are shown under
Notes on each Drawing.

2.2 SLIDING FRAMES
2.2.1 GENERAL
These instructions must be carried out in the order stated to prevent machine damage and personal
injury.
Check sliding frame package for shortages and damage immediately upon arrival (an absolute must!).
Prompt reporting to the courier’s agent, with notations on the freight bill, will expedite satisfactory
adjustment by the courier.
Sliding frame packages are normally shipped from the factory within open sided crates. The hydraulic
power pack is always completely assembled prior to shipping but without oil.
Before the sliding frame is installed its dimensions must be checked against the dimensions on the
installation drawing.
Ensure that the sliding frame is assembled on the silo floor, fastened to cylinder and restrained with
the guide bridge as per the general arrangement drawings.
Ensure that the installation manual for both the hydraulic cylinder and the hydraulic power pack are
read prior to their installation.
Ensure that the hydraulic cylinder is suitable for the installation area.
Ensure that the all hydraulic piping are dimensioned according to the maximum pressure and flow rate
required.
Ensure that hydraulic piping surfaces are cleaned from dirt prior to mounting
Ensure that cylinder connections are sealed before adding pressure to the system
Make sure not to exchange the pipe ports when connecting the hydraulic cylinders
2.2.2 DELIVERY TO SITE
The hydraulic cylinder, stuffing box, cylinder clevis and a pin are usually shipped as one piece from
the workshop.
Figure 2.2.1 below is a sample exploded view showing the main components parts of the sliding frame.
This view also shows a conveyor layout for metering purposes although pumps can be used
depending on particular project specification.
Before commencing installation, inspect all parts to ensure that they are complete for your particular
project and in good condition. A manual and technical data is always included in the delivery of new
equipment.

Fig 2.2.1 Exploded view of the SLF-AUS-0001 model sliding frame
2.2.3 INSTALLATION PROCEDURE
The sequence of installation is as follows;
1. Metering screw conveyor

2. Sliding frame
3. Cylinder with stuffing box
4. Hydraulic power unit.
The installation procedure for the sliding frame assembly including the hydraulic cylinder is as detailed
below. Refer to Fig 2.2.1 and drawing K654-834-02-0006-0 for further details

1. Install the metering screw conveyor following instructions in the conveyor manual.
2. Lift and transport the sliding frame to the silo floor.
3. Ensure that the sliding frame is laid out on the silo floor as shown in the general arrangement
drawing.
4. Fasten main sliding frame beams and the side frame beams to the silo floor using the guide
clamps as per the general arrangement drawing.
5. Unscrew the cylinder clevis end (that is if it was delivered screwed to the cylinder)
6. Using the clevis pin supplied, mount the cylinder end clevis in-between the actuator brace on
the sliding frame. The vertical slot in the actuator brace shall allow for vertical adjustment for
proper alignment with the hydraulic cylinder rod.
7. Bolt the stuffing box to the silo and ensure that it is level.
8. Screw the cylinder into the end clevis.
9. Check the clevis pin and ensure that it is securely fastened to the actuator brace.
10. Attach and bolt the cylinder mounting brackets to the cylinder. Ensure that the cylinder aligns
with the stuffing box and both are level in a straight line. The maximum angular deviation
between stuffing box and the cylinder rod is 0.25 degrees.
11. Ensure that the cylinder is securely and firmly supported at the trunnion mount position.
12. Mount the sensor target bracket on the cylinder rod. The mounting location on the cylinder rod
shall allow the target bracket to reciprocate only between the two sensors positions during the
cylinder’s normal operation.
13. Mount the locating sensor bracket and attach the proximity sensors. Proximity sensors shall
be the same distance apart as the stroke length of the hydraulic cylinder. They shall locate the
target bracket on the cylinder rod’s positions when the cylinder is fully retracted and fully
extended during normal operation. Ensure proper alignment of bracket and sensors.
14. Cover the stuffing box and finger tighten the nuts against the spring washers so that the
glands are evenly adjusted.
15. Lubricate the packing by injecting grease through the nipple on the stuffing box.
16. When packing is new, frequent minor adjustments during the first few hours (if material being
conveyed is very fluid) of operation are recommended in order to compress and seal the
packing.
17. Connect the cylinder to the hydraulic power unit.
18. Connect the proximity sensors to the hydraulic power unit.
19. Using the cylinder and the proximity sensor cover, cover the exposed part of the cylinder rod
and the proximity sensors.
20. The sliding frame and hydraulic cylinder assembly is ready for operation once the above
procedure has been completed and the hydraulic power unit is connected to the power mains.
2.2.4 ELECTRICAL
Sliding frames component manufacturers generally do not provide electrical equipment to control the
sliding frames. In selecting electrical control equipment to be used with any sliding frame installation,
the purchaser must use equipment conforming to the local electrical regulations. Consideration should
be given to some or all of the following instrumentation devices and to others that may be appropriate.

• Overload Protection - Devices such as electronic shear pins or current overload relay to shut off
power whenever operation of the sliding frame is stopped as a result of excessive material, foreign
objects, excessively large lumps and so on.
• Safety shut off switch with power lock-out provision at hydraulic power drive.
• Emergency stop switches readily accessible whenever required.
• Special enclosures for motors and controls for hazardous atmospheric conditions.
2.2.5 WELDING
When welding it should be noted that the steel is affected by heat. Overheating should therefore be
avoided. If welding stainless steel ensure that the consumable material is as resistant to corrosion as
the parent metal. The consumable should therefore contain as much alloy as the parent metal.
Welding together two dissimilar materials should be avoided due to the risks for hair-line fractures,
reduced weld strength and a greater propensity to corrode due to electrolytic action.
The weld surfaces should be degreased with acetone (or an equivalent solvent) immediately prior to
welding. The material should be degreased at least 60mm from the weld surface.
The following electrodes should be used for arc welding;
ELECTRODE TYPES
OK 4800 For mild steel.
OK 6130 For stainless steel.
OK 6330 For acid resistant stainless steel to mild steel (or to
HTMAS).
OK 6333 For stainless to mild steel (or to HTMAS).
Suitable electrode sizes are 2.0 to 3.25mm depending on where the weld is placed.

3 OPERATION
3.1 CONVEYORS
3.1.1 PRE-START CHECKS

Only persons completely familiar with the safety aspects (as detailed in Sect. 7.0) should be permitted
to operate the conveyor. The operator should thoroughly understand these instructions before
attempting to use the conveyor. Failure to follow these precautions may result in serious personal
injury or damage to equipment.
Before the initial start-up of the conveyor, make the following inspections;
1. Check to make sure the gearbox is securely fastened to the conveyor drive plate.
2. Check all connections to the motor and starting device with the wiring diagram. Check the
voltage, phase and frequency on motor nameplate.
Left Hand Spiral.
Right Hand Spiral
Figure 3.1.1a - Direction of Rotation
Remove motor cooling fan cowling and rotate spiral via fan to ensure that it rotates freely. At the same
time check spiral rotation and that material will flow towards outlet.
3. Check gland packing box adjustment, lubrication and piping (if supplied).
4. Check gearbox lubrication level.
5. Make sure all covers, guards and safety equipment are properly installed.
6. Check installation of speed sensors to see if they are properly installed as per IOM.

3.1.2 OPERATIONAL CHECK-LIST
The following should be used upon initial start-up and after extended shut-down periods.
1. Operate conveyor empty for 0-30mins (with addition of water), making a continuous check for
heating of gearbox bearings and noisy operation.
2. Check that the discharge of the conveyor is clear before feeding any material.
3. Increase feed rate gradually until rated capacity is attained.
4. Stop and start conveyor several times, and allow to operate for several hours.
5. Shut off conveyor and lock out power supply. Remove covers and check coupling bolts for
tightness.
6. Replace covers.
7. Ensure material is “flowing” in the correct direction.
8. Make certain that the conveyor controls (e.g. motion sensor, slide gates) are interlocked
correctly and functional.
3.1.3 EXTENDED SHUT-DOWN

If the conveyor is to be inoperative for a long period of time, it is advisable to permit it to operate for a
period of time after the feed has been cut-off in order to discharge as much material as possible from
the trough. The trough should be cleaned completely after the conveyor is shut down and the power
locked out.
Conveyors that are shut down during freezing conditions should be protected by one of the following
methods;
• Empty the trough completely.
• Insulate the conveyor to prevent the material from freezing.
3.2 SLIDING FRAMES
3.2.1 PRE-START CHECKS

Only persons completely familiar with the safety aspects (as detailed in Section 7.0) should be
permitted to operate the sliding frame. The operator should thoroughly understand these instructions
before attempting to use the sliding frame. Failure to follow these precautions may result in serious
personal injury or damage to equipment.
Before the initial start-up of the sliding frame, make the following inspections;
1. Check to make sure the motor is securely fastened to the cover of the oil reservior.
2. Inspect to ensure that the power supply voltage correspond with the voltage on the drive motors,
valves and instruments.
3. Check all connections to the motor and starting device with the wiring diagram. Check the
voltage, phase and frequency on motor nameplate.
4. Remove motor cooling fan cowling and rotate paddle assembly via fan to ensure that it rotates
freely and in the direction of rotation as marked on the motor.
5. Check oil reservoir oil level.

6. Make sure all valves, fittings, guards and safety equipment are properly installed.
7. Check and ensure accumulator is securely fastened, if one is installed.
8. Ensure the proximity sensors are correctly located and secured aligned with the target.
9. Ensure that the cylinder is firmly mounted and securely connected to the sliding frame.
10. Ensure that the guide bridges over the Frame members are securely fastened.
3.2.2 RINSING THE HYDRAULIC PIPING AND TUBES

Before rinsing the hydraulic piping and tubes it is advisable to remove the return filter of the hydraulic
unit.
During the start up the oil level will sink due to the filling of tubes, pipes and cylinder(s).
Use only hydraulic oil which is recommended by the manufacturer of the hydraulic unit.
3.2.3 INSTRUMENTS TESTING

a) Limit switches of the sliding frame
Test the function of the limit switches by holding a metal steel plate in front of the switch and
inspect if the cylinder moves in the other direction.
b) Pressure relief valve
The pressure relief valve is adjusted at the maximum pressure of the hydraulic system.
Do not adjust the value of this relief valve.
3.2.4 ROTATION TEST

Test the direction of rotation of the discharge conveyor.
Test the direction of rotation of the hydraulic pump motor.
3.2.5 OPERATING DATA

Note and complete the data in the table 3.5 below. These values can be used as directory by
maintenance.

3.3 SLUDGE RECEPTION AND CONVEYING SYSTEMS
3.3.1 SUMMARY
Particular Hazards Rotating Machinery - Physical damage, injury
Odour - Nuisance
P&ID Drawing(s) K654_503_02_2501 Sheet 1 of 3
K654_503_02_2501 Sheet 2 of 3
Civil Drawing(s) K654_101_02_2301 to K654_101_02_2413
Mechanical Drawing (s) K654_402_02_2302
K654_402_02_2303
K654_402_02_2304
K654_402_02_2305
K654_402_02_2306
Major Equipment Equipment Tag Model Supplier Manual
SB-HP-0n02(n=1,2,3) SPL-IH-40 K654_834_600_0
SB-HY-0n05(n=1,2,3) HPP-AUS-0001 K654_834_600_0
SB-J-0n06(n=1,2,3) OK320-SPX/SS K654_834_600_0
SB-J-0107A+0108A U420-SPX/SS K654_834_600_0
Import Hopper Conveyor System SB-J-0107B+0108B OK420-SPX/SS K654_834_600_0
SB-J-0109A/B OK420-SPX/SS K654_834_600_0
SB-J-0110A/B OK420-SPX/SS K654_834_600_0
SB-J-0111A/B OK420-SPX/SS K654_834_600_0
SB-J-0112A/B OK420-SPX/SS K654_834_600_0
SB-AV-0103A/B SGP-U320-SS K654_834_600_0 (App. E)

Slidegate Valve of Import Hopper Conveyor
System
SB-J-0118 U500-SPX/SS K654_834_600_0
SB-J-0119 U500-SPX/SS K654_834_600_0
SB-J-0207 U500-SPX/SS K654_834_600_0

Silo Distribution Conveyor System
SB-J-0208 U500-SPX/SS K654_834_600_0
SB-J-0307 U500-SPX/SS K654_834_600_0
SB-J-0308 U500-SPX/SS K654_834_600_0

SB-AV-0109 SGP-U500-SS K654_834_600_0 (App. E)

Slidegate valve of Silo Distribution Conveyor
System
SB-J-0113A/B OK500-SPX/SS K654_834_600_0
SB-J-0114A/B OK500-SPX/SS K654_834_600_0

Centrifuge Conveyor System
SB-J-0115A/B U500-SPX/SS K654_834_600_0
SB-J-0116A/B U500-SPX/SS K654_834_600_0
SB-J-0117 U500-SPX/SS K654_834_600_0
SB-AV-0105A/B TBD TBD

Slidegate valve of Centrifuge Conveyor
System
3.3.2 NORMAL OPERATION

In normal operation, the sludge fed to the drying trains comes from two primary sources. The first is
dewatered sludge from the dewatering centrifuges while the other is imported sludge cakes
(anticipated to be 18-32% dried solids content) from various STWs.
Imported sludge cakes are stored in cake import storage bins and transported to the sludge reception
cake import hoppers. Through the sludge cake import hopper conveyor system, sludge is delivered
from these import hoppers to the sludge cake silo distribution system which deposits the sludge into
the sludge silos. Sludge from the dewatering centrifuges is similarly transported by the centrifuge
conveying system to the same silo distribution system for storage.

Normal Operation is described by three subsystems - Import Hopper Conveyor System, Distribution
Conveyor System, and Centrifuge Conveyor System separately below.
3.3.2.1 IMPORT HOPPER CONVEYOR SYSTEM:

There are three SCADA modes of operation for the Import Hopper Conveyor System:
• AUTO-RUN: In this mode, the operator selected Import Hopper system is operated in
AUTO as required. When SCADA is AUTO-RUN mode, plant operator select the duty import
hopper, and turn Hydraulic Power Pack control panel control selector to “AUTO” and depress
“START” button to inform SCADA to run the power pack. This is a safety function which
requires the operator to physically turn the power pack on at field site to ensure no-one is
close to the edge of the import hopper when the lid is open. Same procedure is required to
shut down the import hopper system. All AVAILABLE equipment in the subsystem must be
configured to this mode for effective operation of the subsystem in AUTO-RUN. The AUTO-
RUN of SCADA for Import Hopper is only controlling the motors (hydraulic motor and
hydraulic oil cooling fan motor). The sliding frame and hopper lid are only controlled through
hydraulic valves at LCP.
• MANUAL: In this mode the Import Hopper Conveyor subsystem is operated in
MANUAL, requiring manual selection of conveyors to operate through the SCADA or at the
LCS. The same start-up sequence for equipment for the system described in auto-run should
be followed, or the equipment start-up will be subject to the interlock conditions described
below. MANUAL operation of Import Hopper are to be carried out through LCS.
• UNAVAILABLE: In this mode the Import Hopper Conveyor System is shutdown automatically
according to procedures detailed below. This occurs when there is no dewatered sludge
available to convey to the Silos. This mode also applies to maintenance. The UNAVAILABLE
details can be read on Alarm list and Warning list.
The Import Hopper Conveyor System consists of three import hoppers (SB-HP-0n02) and two sets of
shaftless conveyors. During normal operations, imported sludge cake is deposited into the duty import
hoppers via the hopper’s retractable lid. Each hopper is equipped with two sliding frames which are
actuated by a hydraulic power pack (SB-HY-0n05). The sliding frames extend and retract along the
base of the hopper to direct the sludge into the screw conveyors (SB-J0-n06) directly beneath the
import hoppers. The system is designed such that all three Import Hopper (SB-HP-0102, SB-HP-0202
or SB-HP-0203) can be selected for duty. The Import Hopper Conveyor System is only providing
power to the Hydraulic Power Pack, the control of HPU is at LCP through the hydraulic directional
valves located at the HPU skid.
Depending on the duty train (Train A or B) selected, the corresponding slide gate valve (SB-AV-
0n03A/B) at the outlet of the import hopper will open to release sludge to the import conveyors SB-
J0107A/B and SB-J0108A/B.
NOTE: Train A is defined as Conveyors SB-J0107A and SB-J0108A while Train B is defined as
Conveyors SB-J0107B and SB-J0108B.
Sludge is then transported to another train of conveyors (Train A1 or B1). The duty train (A1 or B1) is
determined by which silo distribution conveyor is on duty. This will be elaborated in the later section.

NOTE: Train A1 is defined as Conveyors SB-J0109A, SB-J0110A, SB-J0111A and SB-J0112A while
Train B is defined as Conveyors SB-J0109B, SB-J0110B, SB-J0111 B and SB-J0112B.
In the automatic mode, the individual conveyors and slidegates are controlled automatically from a
sequencer commanding the start-up in the correct order. The Start-up sequence of the Import Hopper
System is as follows(assuming the Silo Distribution
Conveyor System is in operation and the relevant slidegate/silo open):
Assuming Import Hopper Train A(SB-J-0107A & SB-J-0108A) is the duty train and Train A1 is on duty
according to the duty silo distribution conveyor for the import hopper system.
Step 1 Select Duty Import Hopper from SCADA screen. Assuming Import Hopper SB-
HP0102 is selected as Duty unit and SB-HP0202, SB-HP0302 are selected as
Standby from SCADA, And below auto sequence is initiated.
a) Start cooling fan of SB-HP0102
b) Start hydraulic motor of SB-HP0102
c) Send “Enable” to LCP-HY0105
NOTE: All three import hopper can be in different combinations and can be in operation at same
time.
Step 2 Duty Vertical Conveyor SB-J0112A is on.

Step 3 Duty Feeder Conveyor SB-J0111A is on.
Step 4 Duty Vertical Conveyor SB-J0110A is on.
Step 5 Duty Feeder Conveyor SB-J0109A is on.
Step 6 Duty Slidegate SB-AV0104A is open
Step 7 Duty Conveyor SB-J107A/ SB-J108A is on.
Step 8 Duty Slidegate SB-AV0103A and/or SB-AV0203A and/or SB-AV0303A are opened,
depending on Step 1 Duty hopper selection, AV0103A will be opened.
Step 9 Duty Conveyor SB-J0306 is on.
Step 10 Operator at local, after verifying “Enable” status(Light Power Pack Running is on) on the
LCS, will turn the import hopper’s hydraulic power pack’s LCS control selector to “AUTO” and
press the “START” button, then sliding frames at the bottom of the Import hopper starts
moving back and forth, Import Hopper lids for SB-HP0102 open.
When the Import Hopper Conveyor subsystem is running and a fault occurs upstream or
downstream of the system, the system will shut down immediately upstream of the fault and
sequence shutdown downstream of the fault. The operator will have to investigate and put the line
back into automatic mode when it is ready.
When the Import Hopper Conveyor subsystem is running and a fault occurs upstream or downstream
of the system, the system will shut down immediately upstream of the fault and downstream will
continue to empty the sludge until the operator stops it. The operator will have to investigate and put
the line back into automatic mode when it is ready.

An Import Hopper will be made UNAVAILABLE in any of the following circumstances:
FAILED condition of hopper lid not opening
FAILED condition of the hydraulic pump
FAILED condition hydraulic oil temperature high
FAILED condition of the sliding frame actuator
FAILED condition of the oil pressure being too low
FAILED condition of the Duty Conveyor slidegate not opening.
FAILED condition of the Duty Conveyor SB-J0106/206/306
When the Import Hoppers are empty, the Import Hopper Conveyor line will shut down progressively,
one by one. The Shut-down sequence of the System is as follows:
Step 1: Assume SB-HP0102 is the Duty Import Hopper system, the operator press the Stop
button at LCP, Import Hopper Cover for SB-HP0102 is closed. “Disable” signal is sent to SCADA and
below SCADA shut-down sequence is activated.
a) hydraulic motor of SB-HP0102 is off
b) cooling fan of SB-HP0102 is off
Step 2 Duty Sliding Frame SB-HY0105 is off.
Step 3 Duty Conveyor SB-J0106is off.
Step 4 Duty Slidegate SB-AV0103Ais closed.
Step 5 Duty Conveyor SB-J107A/108A is off.
Step 6 Duty Slidegate SB-AV0104A is closed.
Step 7 Duty Feeder Conveyor SB-J0109A is off.
Step 8 Duty Vertical Conveyor SB-J0110A is off.
The sequence will make sure that all conveyors which are shut down complete the shut-down
sequence. In the event that there is a power failure, when the power is on again, there will be a queue
sequence to ensure that the conveyors are shut down one by one. The SCADA will also remind
operators to finish the shut-down sequence if it is not done.
3.3.2.2 DISTRIBUTION CONVEYOR SYSTEM:

There are three SCADA modes of operation for the Silo Distribution Conveyor System:
• AUTO-RUN: In this mode, the operator selected Silo Distribution Conveyor system is
operated in AUTO as required. All AVAILABLE equipment in the subsystem must be
configured to this mode for effective operation of the subsystem in AUTO-RUN.
• MANUAL: In this mode the Silo Distribution Conveyor subsystem is operated in MANUAL,
requiring manual selection of conveyors to operate through the SCADA or at the LCS.
• UNAVAILABLE: In this mode the Silo Distribution Conveyor System is shutdown
automatically according to procedures detailed below. This occurs when there is no
dewatered sludge available for conveying to the Silos.

The Storage Silo is selected by the operator taking into consideration which Dryers are on duty and
the status of radar level probe (SB-LIT-0n61) of Sludge Silo from main SCADA pop-up window. In the
automatic mode, the individual conveyors and slidegates are controlled automatically from below
sequencer commanding the start-up in the correct order.
During normal Automatic operation, Distribution Conveyors SB-J0118 & SB-J0119 or SB-J0207 & SB-
J0208 or SB-J0307 & SB-J0308 can be selected as the duty train for Centrifuge Conveyor System
Similarly for Distribution Conveyors SB-J0307 and SB-J0308 or J0207 and J0208 will the starting duty
train for Import Hopper Conveyor System. But it should be noted that the import hopper conveyor
system and centrifuge conveyor system cannot share the same set of duty distribution conveyors at
any point of time.
Starting sequence for sludge delivery from the Sludge Cake Import Hopper Conveyor Syste only.
(Assume Silo 1 is selected and Distribution Conveyor Train 3 is selected as duty train as normal Start-
up)
Step 1: Slidegate valve SB-AV0304 is open
Step 2: Distribution Conveyor Train 3 is on and sending sludge from West to East
Step 3: Vertical conveyor SB-J0112A is on
Step 4: Feeder conveyor SB-J0111A is on
Step 5: Vertical Conveyor SB-J0109A is on
Step 6: Follow Import Hopper Conveyor System Auto Start up sequence
Starting sequence for sludge delivery from the Centrifuge Conveyor System only. (Assume Silo 1 is
selected and Distribution Conveyor Train 1 is selected as duty train as normal Start-up)
Step 1: Slidegate valve SB-AV0304 is open
Step 2: Distribution Conveyor Train 1 is on and sending sludge from East to West
Step 3: Follow Centrifuge Conveyor System Auto Start-up
Starting sequence for sludge delivery by both the Centrifuge Conveyor System and Import Hopper
Conveyor System. (Assume Silo 1 is selected and Distribution Conveyor Train 1 is selected as duty
train for Centrifuge Conveyor System and Distribution conveyor Train 3 is selected as duty train for
Import Hopper Conveyor Systemas normal Start-up)
Step 1: SB-AV0109 is open
Step 2: SB-AV0304 is open
Step 3: Distribution Conveyor Train 1 is on and sending sludge from East to West. Distribution
Conveyor Train 3 is on and sending sludge from West to East.
Step 4: Follow Centrifuge Conveyor System Auto Start-up
Step 5: Follow Import Hopper Conveyor System Auto Start-up
When the Silo Distribution Conveyor subsystem is running and a fault occurs upstream or downstream
of the system, the system will shut down immediately up stream of the fault and the downstream will
continue to run until manually stopped by the operator. The operator will have to investigate and put
the line back into automatic mode when it is ready.
The Silo Distribution Conveyor System will be made UNAVAILABLE in any of the following
circumstances:
FAILED condition of the Duty and Standby Conveyor
FAILED condition of the Storage Silo
When the Storage Silos are full, the Import Hopper and Centrifuge Conveyor line will shut down
progressively, one by one. The Shut-down sequence of the System is as follows:
Step 1 Import Hopper/Centrifuge System Shutdown Sequence.
Step 2 Silo Distribution Duty Conveyor is off.
Step 3 Duty Slidegate is closed.
sequence. In the event that there is a power failure, there will be a queue sequence to ensure that the
conveyors are shut down one by one. The SCADA will also remind operators to finish the shut-down
sequence if it is not done.
3.3.2.3 CENTRIFUGE CONVEYOR SYSTEM:

There are three SCADA modes of operation for the Centrifuge Conveyor System:
• AUTO-RUN: In this mode, the operator selected Centrifuge Conveyor system is operated in
AUTO as required. All AVAILABLE equipment in the subsystem must be configured to this
mode for effective operation of the subsystem in AUTO-RUN.
• MANUAL: In this mode the Centrifuge Conveyor subsystem is operated in MANUAL, requiring
manual selection of conveyors to operate through the SCADA or at the LCS.
• UNAVAILABLE: In this mode the Centrifuge Conveyor System is shutdown automatically
according to procedures detailed below. This occurs when there is no dewatered sludge from
the dewatering system available for conveying to the Silos or when all the Silos are full.
The Storage Silo is selected. Distribution Conveyor Train 1 (J0118 & J0119 as starting duty train).
In the automatic mode, the individual conveyors and slidegates are controlled automatically from a
sequencer commanding the start-up in the correct order. The Start-up sequence of the Centrifuge
Conveyor System is as follows (it is assumed the Silo Distribution Conveyor System is in operation
and the relevant slidegate/silo open:
Assume SB-J0115A & SB-J0116A are duty conveyor train and the duty centrifuge conveyor is J0118
and J0119.
Step 1: Duty Slidegate AV0114A and AV0113A are closed.
Step 2: Emergency Bypass Slidegate AV0105 is closed.
Step 3: Duty Conveyor SB-J0116A is on.
Step 4: Duty Conveyor SB-J0115A is on.
Step 5: Duty Vertical Conveyor SB-J0114A is on.
Step 6: Duty Feeder Conveyor SB-J0113A is on.
Step 7: Dewatering System is producing cake.

When the Centrifuge Conveyor subsystem is running and a fault occurs upstream or downstream of
the system, the system will shut down immediately up stream of the fault and sequence shutdown
downstream of the fault. The operator will have to investigate and put the line back into automatic
mode when it is ready.
The Centrifuge Conveyor System will be made UNAVAILABLE in any of the following circumstances:
FAILED condition of the Duty and Standby Conveyor
FAILED condition of the Storage Silo
When the Storage Silos are full, the Centrifuge Conveyor line will shut down progressively, one by one.
The Shut-down sequence of the System is as follows:
Step 1 Dewatering System stops producing cake.
Step 4 Duty Conveyor SB-J0115A is off.
Step 6 Duty Slidegate AV0114A and AV0113A is closed.
sequence. In the event that there is a power failure, there will be a queue sequence to ensure that the
conveyors are shut down one by one. The SCADA will also remind operators to finish the shut-down
sequence if it is not done.
If it is determined by plant operators that the Centrifuges cannot be shut down even with the silos full,
then the emergency bypass conveyor will be brought on line. In this case the revised shut down
sequence will be as follows;
Step 1 Emergency Slidegate AV0106 is open.
Step 2 Emergency Conveyor SB-J0117 is on.
Step 3 Emergency Slidegate AV0105A is open.
Step 4 Duty Slidegate AV0113A and AV0114A are closed.
This sequence stays in place until the Storage Silos become available again.
3.3.3 ABNORMAL/EMERGENCY OPERATION

Maintenance – The operator is required to manually operate the conveyors through LCS after the
subsystem is put to UNAVAILABLE.
Emergency Operation–
• Silos are full however the sludge is being delivered from Dewatering Conveyor System. The
emergency bypass conveyor line will be activated, and the shut-down sequence is described
in the Centrifuge Conveyor System.

• The operator is required to manually operate the conveyors from the SCADA, or FIELD in
exceptional circumstances. If the conveyors become blocked and are not able to be cleaned
automatically, the operators will be required to perform manual cleaning. The conveyors are
isolated by selecting MANUAL from the SCADA. The conveyor drives can then be controlled
from the local control switch in the MANUAL.
• In the event of a mains power failure, only one Import Hopper is powered by the generators.
The operator has to select the Import Hopper to be operated during the power failure, and re-
set the status of the chosen line back to automatic mode. Before bringing all Import Hoppers
back to operation, the operator will initiate the shut-down sequence for the rest of the Import
Hoppers.
3.3.4 CONTROLS
The following alarms and disturbances can happen on the conveyor systems. When the subsystem is
running and a fault occurs upstream or downstream of the system, the system will shut down
immediately upstream of the fault and sequence shutdown downstream of the fault. The operator will
have to investigate and put the line back into automatic mode when it is ready.
All alarm messages will be displayed on SCADA and alarm lights will be displayed on LCS.
3.3.4.1 ALARMS
Possible
Tag Description
Alarms
Import Hopper System
SB-NZ1-0n03 Conveyor Motor Fail n(1,2,3) Critical
SB-SS-0n04 Conveyor Motion Sensor Trip n(1,2,3) Critical
SB-NZ1-01n A/B Conveyor Motor Fail n(06,08,11,13,15,17) Critical
SB-SS-01n A/B Conveyor Motion Sensor Trip n(07,09,12,14,16,19) Critical
SB-HY-0n05 Hydraulic Pump Motor Fail n(1,2,3) Critical
SB-HY-0n05 Hydraulic Oil Temp High n(1,2,3) Critical
SB-HY-0n05 Hydraulic Oil Level Low n(1,2,3) Critical
SB-HP-0n02 Import Hopper Door Not Open n(1,2,3) Non-Critical
SB-HP-0n02 Import Hopper Door Not Closed n(1,2,3) Non-Critical
Distribution Conveyor System
SB-NZ1-013n Conveyor Motor Fail n(4,6) Critical
SB-SS-013n Conveyor Motion Sensor Trip n(5,7) Critical
SB-NZ1-012n A/B Conveyor Motor Fail n(0,2,4,6) Critical
SB-SS-012n A/B Conveyor Motion Sensor Trip n(1,3,5,7) Critical
SB-SS-0130 Conveyor Motion Sensor Trip Critical
3.3.4.2 PROCESS INTERLOCKS (SOFT)

Downstream Interlock
Tag Description conditions
Import Hopper System
SB-HY0105 not running(refer to description of Failed
SB-HP0102 Cake Import Hopper 1 Condition in 3.56.4.2)
SB-HY0105 Hydraulic unit for sliding frame 1 SB-J0106 not running


SB-J0106 Import Hopper Conveyor 1 SB-AV0103A Close and SB-AV0103B Close

SB-AV0103A Slide Gate Valve SB-J0108A not running
SB-AV0103B Slide Gate Valve SB-J0108B not running


SB-J0107A and SB-J0108A Import Hopper Conveyor 4A and 5A SB-AV0104A closed and SB-J0109A not running
SB-J0107B and SB-J0108B Import Hopper Conveyor 4B and 5A SB-AV0104B closed and SB-J0109B not running

SB-AV0104B Slide Gate Valve SB-J0109A not running
SB-J0119A Import Hopper Conveyor 6A SB-J0110A not running
SB-J0119B Import Hopper Conveyor 6B SB-J0110B not running


SB-J0208 not running or
SB-J0112A Import Hopper Conveyor 9A SB-J0208 running in forward direction
SB-J0308 not running or
SB-J0112B Import Hopper Conveyor 9B SB-J0308 running in forward direction
Distribution Conveyor System

SB-AV0109 and SB-AV0110 closed and SB-J0119
SB-J0118 Silo distribution conveyor 1 (forward) not running
SB-J0119 Silo distribution conveyor 1 (forward) SB-AV0111 and SB-AV0112 closed

SB-J0207 Silo distribution conveyor 2(forward) not running or SB-J0208 is running reverse direction
SB-AV0204 and SB-AV0205 closed or SB-J0208 is
SB-J0207 Silo distribution conveyor 2(reverse) running forward direction
SB-J0208 Silo distribution conveyor 2(forward) running reverse direction
SB-J0208 Silo distribution conveyor 2(reverse) not running or SB-J0207 is running forward direction
SB-J0307 Silo distribution conveyor 3(forward) not running or SB-J0308 is running reverse direction

SB-J0307 Silo distribution conveyor 3(reverse) running forward direction
SB-AV0306 and SB-AV0307 all closed or SB-J0307
SB-J0308 Silo distribution conveyor 3(forward) is running reverse direction
SB-J0308 Silo distribution conveyor 3(reverse) not running or SB-J0307 running forward direction
SB-AV0109 Slide gate valve SB-LIT0106 high level





SB-J0113A Centrifuge Conveyors 1A SB-J0114A not running
SB-J0113B Centrifuge Conveyors 1B SB-J0114B not running
SB-J0114A Centrifuge Conveyors 2A SB-J0115A not running

SB-J0114B Centrifuge Conveyors 2B SB-J0115B not running
SB-J0115A Centrifuge Conveyors 3A SB-AV0105A closed and SB-J0116A not running
SB-J0115B Centrifuge Conveyors 3B SB-AV0105B closed and SB-J0116B not running

SB-AV0113A and SB-AV0114A closed and SB-
SB-J0116A Centrifuge Conveyors 4A J0118 not running
SB-AV0113B and SB-AV0114B closed and SB-
SB-J0116B Centrifuge Conveyors 4B J0118 not running
SB-AV0113B is open or SB-J0207 not running or SB-
SB-AV0113A Slide gate valve J0207 running reverse direction
SB-AV0114B is open or SB-J0307 not running or SB-
SB-AV0114A Slide gate valve J0307 is running reverse direction
SB-AV0113A is open and SB-J0207 not running or
SB-AV0113B Slide gate valve SB-J0207 is running reverse direction
SB-AV0114A is open and SB-J0307 not running or
SB-AV0114B Slide gate valve SB-J0307 is running reverse direction
SB-AV0105A Slide gate valve SB-J0117 not running

SB-AV0105B Slide gate valve SB-J0117 not running
SB-J0117 Truck Discharge Conveyor SB-AV0106, SB-AV0107 and SB-AV0108 all closed
3.3.5 OPERATOR REQUIREMENTS

The Conveyor systems are fully automatic. The SCADA system operator must be trained on how to
handle the systems first.

In the Auto-Run mode, the operator will select which Import Hopper/s to open and which Silos to
discharge to.
The Manual Mode on SCADA is prepared for service and maintenance; it allows to operate motors
and slidegate valves, import hoppers.
3.3.6 TROUBLESHOOTING
Refer to supplementary safety instructions and procedure for the trouble shooting in the equipment
documentations, as follows:
Component Doc. No.
Motor & Gearbox K654_834_600_0
Slidegate valve K654_834_600_0
Hydraulic power pack K654_834_600_0
Import hopper rams K654_834_600_0
Import hopper bin K654_834_600_0
Import Hopper Sliding Frame K654_834_600_0
Local Control Station K654_834_600_0
Proximity Sensor for Import Hopper Sliding Frame Ram K654_834_600_0
Proximity Sensor for Import Hopper Bin K654_834_600_0
Conveyor Motor Speed Sensor K654_834_600_0
Slidegate Valve Proximity Swtich K654_834_600_0

4 MAINTENANCE
4.1 CONVEYORS
4.1.1 GENERAL
Generally it is necessary to establish routine periodic inspections of the entire conveyor to ensure
continuous maximum operating performance. Practice good house keeping. Keep the area around the
conveyor and drive assembly clean and free of obstacles to provide easy access and to avoid
interference with the function of the conveyor or drive.
Always –
1. Follow the established local regulations and/or procedures for isolation of equipment.
Or-
2. Lock-out power to motor before doing any maintenance work preferably with a padlock on
control panel or isolator.
3. Do not remove padlock from control, nor operate conveyor, until covers and guards are
securely in place.
4.1.2 PACKING GLAND ADJUSTMENT

Packing gland bolts should be evenly adjusted so they are little more than finger tight. Over tightening
of the packing gland may result in premature packing failure and possible damage to the shaft and
gland.
When packing is new, frequent minor adjustments during the first few hours (if material being
conveyed is very fluid) of operation are recommended in order to compress and seal the packing.
Figure 4.2a - Packing Box Arrangement

4.1.3 LUBRICATION
Please refer to the Appendix ‘Lubrication Check Sheets’ for Grease and Oil types for your particular
conveyor.
4.1.4 SURFACE COATING

This section describes how the conveyors surfaces should be treated, if made of stainless steel or not.
The materials of construction for your particular conveyor are specified in the Appendix ‘Conveyor
Data Sheets’.
Operation in sewage treatment plant or damp environments exposes the conveyor to air that may
contain chemically or biologically corrosive particles. In these cases painted, galvanised and stainless
steel surfaces can be damaged. It is therefore important that personnel follow the operating
instructions and remedy any corrosion or damage to coatings as soon as they occur.
Standard Procedure for Surface Repair
• Painted
In the standard manufacturing procedure the conveyors trough and protective cover are
sandblasted to Class 2-½ as per AS1627.4 and then prime coated with a two component red
oxide zinc phosphate epoxy polyamide to give a dry film thickness (DFT) of no less than 75µm.
The final coat shall be a two component epoxy polyamide to give a DFT of no less than 175µm.
The coating shall be sufficiently cured for re-coating within 24 hours at 25°C.
Final colour to be Blue Grey N53 (or as specified by client) as shown in AS2700.
To ensure long equipment life it is important that the coated surfaces are maintained to prevent
rust that can cause serious damage in a short space of time.
Rust may be ground back to bare metal and the surface carefully cleaned before it is covered
by the above or an equivalent rust protective coating.
• Hot Dip Galvanised.
The conveyor trough and protective cover have been Hot Dip Galvanised to AS1650 and
AS1214.
Rust may be ground back to bare metal and the surface carefully cleaned before application of
a suitable “Cold Galvanising” agent.
• Stainless Steel.
The materials used are 304 or 316SS (refer to Appendix ‘Conveyor Data Sheets’). These
materials do not need any special treatment but the following should be observed.
Grinding or welding in close vicinity of the conveyor must be avoided. Showering sparks onto
the stainless steel can cause a rust brown discolouration.
All stainless steel surfaces must be handled so that the corrosive resistance is not impaired. As
a minimum the stainless steel should not come into contact with steel of other qualities during
transportation or assembly. Wood, cloth or plastic should be used to pad the stainless steel
when lifting or transporting the conveyor.
The heat input during welding leads to the formation of chromium oxides on the steel surface.
The underlying material is depleted of chromium, increasing the risk for corrosion. Passivating
removes the oxides, scale and slag. The surface is cleaned to bare metal and a thin protective
layer, or “passive” layer, is built up. This restores optimal corrosion resistance and ensures that
the weld will have the longest possible life.

4.1.5 MAINTENANCE TIME TABLE
The following checks outlined below are recommendations only. They can be adjusted to suit the
operation time of the conveyor or incorporated into existing site maintenance procedures. It is
important, particularly with all new equipment that it be monitored for performance / potential hazards
and as a result specific procedures developed. Specific procedures for use on site need to be
developed by the client which capture OHS and site access requirements. These should also be
developed according to frequency of use and adapted to individual site process requirements.
PREVENTIVE MAINTENANCE
PERIOD ACTIVITY
Check bell housing packing box temperature with a thermometer, not by
Weekly hand. If over 60°C it may be due to lack of grease.
Check for any unusual vibration or noise. Locate and rectify.
Clean the conveyor inside and outside (if necessary). This is usual if the
conveyor has been standing idle for long periods.
Check the liner for wear. If yellow backing is showing through replace
damaged section.
Monthly Check gland packing box for leaks (if very moist materials).
Re-tighten if necessary.
Check the spiral for any excessive wear or unusual damage. A
maximum of 20% of the spirals original sectional dimension can be worn
away before it requires replacement. If the spiral is extremely long
(>15m) it should be replaced before this level is reached.
Check all fasteners (supports, trough connections etc.).
Check all trough welds.
Half
Yearly Check the oil level in the gearbox and its colour. If the oil is heavily
emulsified (cream-like) there is water in the oil. Rectify and replace.
Check the control system, i.e. emergency stops, sequential control etc.

4.2 SLIDING FRAMES
4.2.1 GENERAL
Generally it is necessary to establish routine periodic inspections of the entire unit to ensure
continuous maximum operating performance. Practice good house-keeping. Keep the area around the
unit and hydraulic power pack clean and free of obstacles to provide easy access and to avoid
interference with the function of the sliding frame.
Always –
1. Follow the established local regulations and/or procedures for isolation of equipment.
Or-
2. Lock-out power to motor before doing any maintenance work preferably with a padlock on
control panel or isolator.
3. Do not remove padlock from control, nor operate frame, until covers and guards are securely in
place.
4. Follow the cylinder and hydraulic power pack manufacturer’s maintenance requirements.
5. Any planned maintenance and repair of both cylinder and hydraulic power pack must be
performed by the manufacturer, accredited representative of authorised personnel.
4.2.2 LUBRICATION
Please refer to the Appendix ‘Lubrication Check Sheets’ for Grease and Oil types for your particular
installation. Table 4.2.2 below shows some of the most common grease and hydraulic oil type.
GREASE VISCOSITY
TYPE AND ISO ARAL BP ESSO MOBIL OIL SHELL TEXACO
MAKE DIN 51519
HYDRAULIC ENERGOL
HLP 46 HLP 46 HLP 46 HLP 46 HLP 46 HLP 46
UNIT HLP-HM 46
GEARED BG 150 ENERGOL SPARTAN MOBILGEAR OMALA 2 MIROPA

VG 150
MOTORS BMB 150 GR 150-XP EP 150 628 150 150
BEARINGS GREASE ENERGREASE BEACHON MOBILUX ALVANIA MULTIFAK

(WHERE GREASE
APPLICABLE) HL 3 LS 3 3 2 2 2
GREASE ENERGREASE BEACHON MOBILUX ALVANIA MULTIFAK

STUFFING GREASE
HL 3 LS 3 3 2 2 2
BOXES
Table 4.2.2

4.2.3 CYLINDER AND HYDRAULIC POWER PACK
Refer to the individual manufacturer’s maintenance manual. However, as a minimum maintenance
requirement, please refer to section 4.4.
4.2.4 MAINTENANCE TIME TABLE

The following checks outlined below are recommendations only. They can be adjusted to suit the
operation time of the Frame or incorporated into existing site maintenance procedures.
PREVENTIVE MAINTENANCE
PERIOD ACTIVITY
Recordings of operational parameters

System (running) pressure
Return pressures
Pump case pressures
Cylinder speeds and check proximity sensor positions.
All operational temperatures
Monthly
Check oil levels and replenish reservoir as required
Check oil leaks
Inspect the stuffing box cover area for possible leaks and tighten as required
Ensure good house-keeping and repair minor leaks.
Check the grease canister and replace if required
Inspect drive systems for noises.
Check all fasteners and fittings for tightness.

Half Yearly
Replace air breather elements
Filter Service
Replace all return and drain filter elements
Replace air breather elements
Take oil sample from sample points
Change hydraulic fluid, if deemed necessary.
Annual Service
Check Accumulator pre-charge pressures
Inspect coolers or heaters, as the case may be, if installed.
Inspect and test Directional Control Valves for correct operation
Check for oil leaks and repair where possible
Efficiency test / data log hydraulic systems, if deemed necessary.

Inspect filter indicators
Inspect all hoses for corrosion and damage
Carry out extensive visual and external inspection of all components.
Ensure all operational functions are working correctly.
Preventative
Maintenance Take oil sample from sample point, if deemed necessary.
For highly abrasive materials, periodic inspection of the stuffing box for possible leakage is recommended.
Due to the nature of such materials, wear on the seal wiper and power-slide seals may occur. The
replacement of these components may be scheduled as part of the routine plant maintenance
requirements.
4.2.5 REPLACING THE GLAND PACKING

a) Ensure that the silo is empty of material.
b) Loosen the nuts and the washers on the gland cover studs and slide the cover back along the
hydraulic cylinder rod length.
c) Remove the packing and the lantern ring and clean the packing box seats.
d) Cut the new packing with an angle (45 degrees). Put a tape around the packing before cutting
to prevent the ends fraying.
e) Push the new packing into the stuffing box seat with the cut ends first.
f) Repeat this process for the other packs. Check that each is in place before the next is put in.
The packs should be rotated at 90o to each other so that the joins are in different places.
g) Replace the gland cover and finger tighten the nuts so that the packing is evenly adjusted in the
stuffing box seats.
h) Ensure that the lantern ring aligns with the grease nipple.
i) Lubricate the packing by injecting grease through the grease nipple on the stuffing box.
j) Test run the cylinder with material to make sure the stuffing box does not leak.
k) When packing is new, frequent minor adjustments during the first few hours (if material being
conveyed is very fluid) of operation are recommended in order to compress and seal the
packing.
4.2.6 REPLACING THE D-ROD WIPER SEAL AND THE POWER SLIDES
a) Ensure that there is no material in the silo and the cylinder is disconnected from the HPU.
b) Using a lifting device to hold the cylinder in place, unbolt and remove the cylinder mounting
brackets.
c) Unscrew the cylinder from the end clevis.
d) Unbolt the stuffing box from the silo.
e) Remove and lift the cylinder and the stuffing box assembly to a convenient working location and
slide the stuffing box off the cylinder rod.
f) Remove the D-Rod wiper seal and the two power slides.
g) Replace the power slides and the D-Rod wiper seal

h) Slide the stuffing box back unto the cylinder rod.
i) Replace the gland packing and fill the stuffing box with grease.
j) Lift and move the cylinder stuffing box assembly back to the silo.
k) Bolt the stuffing box to the silo and ensure that it is level.
l) Screw the cylinder into the end clevis.
m) Attach and bolt the cylinder mounting bracket. Ensure that the cylinder aligns with the stuffing
box and it is level.
n) Check the clevis pin and ensure that it is securely fastened
o) Mount the cylinder at the trunnion end securely bolt the mounting brackets into a firm support.
p) Ensure that proximity sensors align with the target bracket on the cylinder rod.

5 SERVICE
5.1 CONVEYORS
5.1.1 REPLACING THE GLAND PACKING
Figure 5.1.1a - Gland Cover Screws Figure 5.1.1b - Packing Box Assembly
1. Empty conveyor of all material. Unscrew the gland cover screws and slide the cover back along
the drive shaft.
2. Remove the packing and clean the packing box seats.
3. Cut the new packing with an angle (45 Degrees). Put tape around the packing before it is cut to
prevent the ends from fraying.
4. Push the new packing into the packing box seat cut ends first.
5. Repeat this process for the other packs. Check that each is in place before the next is put in.
The packs should be rotated by 90° to each other so that the joins are in different places.
6. Replace the gland cover and tighten the screws so that the packing is properly formed in the
packing box seats.
7. Lubricate as per the Appendix ‘Lubrication Check Sheets’.
8. Test run the conveyor with material to make sure the packing box does not leak.
5.1.2 REPLACING THE LINERS

Depending on what is to be conveyed the conveyor can be lined with different materials. There are
three different types of liners -

• Plastic or UHMW Polyethylene
• Steel Bar
• Steel Plate
Technical data concerning the liners steel and plastic qualities is specified on the drawings.
Liners can often be replaced without the spiral being totally removed. However servicing is easier
without the spiral in the trough.
5.1.2.1 REPLACING THE PLASTIC LINER

The new plastic liners are either delivered ready shaped or flat. The shaped liners should not be
removed from their packaging until immediately before they are to be fitted. Once the liner has been
removed from its packaging it takes only one hour for it to become flat and needs reshaping.
Refer to Figure 5.1.2.1 for details.
1. Empty the conveyor of material. Unfasten the lid and remove or push it back from the trough
2. Unfasten the nuts on the coupling disc bolts holding the spiral to the coupling disc.
3. Remove the spiral from the trough or lift it to increase accessibility.
4. Insert a heavy duty screw driver or lever down between the trough and the plastic liner so that it
releases from its steel block retainers.
5. Take hold of the liner and pull it out.
6. Push the new liner under the spiral, making sure the wear indicator strip is at the bottom. It is
important to secure the liner under the retainer blocks on each side of the trough.
7. Replace the bolts holding the spiral to the coupling disc.
8. Replace the lid to the trough.
Figure 5.1.2.1

5.1.3 REPLACING THE SPIRAL
There should be no welded joints in the spiral closer than 4 spiral-turns to the spirals coupling disc.
1. Undo the bolts holding the protective cover and remove it from the trough.
2. Check the new spiral has the dimensions given on the drawing and check against the existing
spiral.
3. Un-bolt the spirals coupling disc from the drive shafts coupling disc.
Figure 5.1.3a - Removing the Spiral
4. Lift the spiral from the trough. Depending on the local facilities the spiral can be removed in
several ways. The spiral can be either lifted, pushed out through the troughs opening or cut
into sections etc.
5. Place the new spiral in the trough.
6. Fasten the coupling discs together (use new locking nuts each time).
7. Replace the protective cover to the trough.
5.1.4 REPLACING THE DRIVE SHAFT

1. Undo the bolts holding the protective cover and remove it from the trough.
2. Un-bolt the spirals coupling disc from the drive shafts coupling disc.
3. Remove the spiral from the trough or move it forward enough so that the drive shaft can be
removed via the trough.
4. Unscrew the locking bolt, spring washer and stepped spacer from the drive shaft, located at the
rear of the gearbox (see fig. 5.1.4a).
5. Remove the gland cover screws from the packing box (see Fig 5.1.4b).
6. Use an extractor tool to push the drive shaft into the trough. Remove the key from the gearbox
keyway before the drive shaft goes through the packing box. NOTE: The end of the drive
shaft must be protected so that the threads are not damaged. A screw can be threaded
into the end of the shaft before this is placed under pressure.
7. Remove the old drive shaft from the trough and lift in the new one.
8. Turn the gearbox hollow shaft so that the key way is in the correct position in relation to the
spirals drive shaft. Push the new drive shaft in so that it takes the place of the old shaft. Place
the key in the key way before the drive shaft goes into the gearboxes hollow shaft.
9. Screw the locking bolt, spring washer and stepped spacer into the new drive shaft. NOTE The
spiral must be pushed towards the drive end in order for the locking bolt to thread into
the drive shaft.
10. Tighten the gland cover screws so that only a 7mm (approx.) gap remains between the
packing box seat and the gland. Tighten the screws alternately and check the remaining gap
after each turn.
11. Fasten the coupling discs together (use locking nuts).
12. Replace the protective cover to the trough.
13. Lubricate packing box as per Appendix ‘Lubrication Check Sheets’.
14. Test run conveyor with material to make sure that the packing box does not leak. If there is
heavy leakages tighten the gland cover screws. NOTE: DO NOT OVERTIGHTEN.
Figure 5.1.4a - Remove the Locking Bolt, Spring Washer and Stepped Spacer
Figure 5.1.4b - Gland Cover Screws Figure 5.1.4c - Using an Extractor Tool

5.2 SLIDING FRAMES
REFER TO SECTION 4.2

6 TROUBLESHOOTING
6.1 CONVEYORS
6.1.1 GENERAL
Between regular maintenance inspections, be alert for signs of motor or Conveyor trouble. Common
symptoms are listed below.
Correct any trouble immediately and AVOID COSTLY REPAIR AND SHUTDOWN.
Troubleshooting shall be done with the power supply disconnected and locked off, except for those
checks which cannot be performed without voltage.
Always make sure there is no one near the conveyor when the power supply is turned on. Use the
following table as an aid to troubleshooting. It is assumed the conveyor and installation have formerly
functioned satisfactorily.
6.1.2 TROUBLESHOOTING CHART
PROBLEM CAUSE REMEDY
Blown Fuse Determine and correct cause of failure and

replace fuse
Motor protection device activated Reset protective device. Identify and correct
Conveyor Fails to cause for failure
Start
Motor protection device faulty or will not reset Check protection device for faults
Motor not connected for proper voltage Check connection diagram in conduit box
cover and correct the wiring.
Spiral jam from foreign object entering trough. Remove object and restart
Conveyor starts Gearbox seizure due to no oil Remove gearbox and service
but motor
protection device Settings on motor protection incorrect Check and re-set
trips immediately
Motor improperly connected Check connection diagram in conduit box
cover and correct the wiring
Loose drive station Check and re-tighten fixing bolts
Excessive
Unstable ground conditions Rectify
vibration
Loose support/trough connections Check and re-tighten
Worn spiral screw Replace spiral
Conveyor output Material being conveyed is not as originally Contact SPIRAC

is too low specified

Motor not connected for proper supply voltage Check connection diagram on conduit box
cover and correct wiring
Insufficient cooling air volume due to obstructed Provide clearance around fan area
Motor air flow
overheats Motor allowable duty cycle is exceeded. Too The problem may not be solved by a larger
many starts per hour unit. Review with manufacturer
Single phasing due to break or loose Repair supply line. Replace fuse
connection in supply line or blown fuse
Excess material causing spiral to rise and Reduce material inflow. Install anti-lift bars
interfering with lids/cross bars
Foreign object in conveyor Remove object
Spiral screw
jamming Liner has come loose and wedged itself inside Remove and replace liner
the spiral
Incorrect alignment of screw when welding Confirm and replace/re-weld
causing eccentric rotation
Conveyor runs in Electrical cable leads wired incorrectly Reconnect two phase wires.
wrong direction
6.2 SLIDING FRAMES
6.2.1 GENERAL
Between regular maintenance inspections, be alert for signs of any trouble. Common symptoms are
listed below. Correct any troubleshooting immediately and AVOID COSTLY REPAIR AND
SHUTDOWN.
Troubleshooting shall be done with the power supply disconnected and locked off, except for those
checks which cannot be performed without power.
Always make sure there is no one near the Frame when the power supply is turned on. Use the
following table as an aid to troubleshooting. It is assumed the sliding frame and installation have
previously functioned satisfactorily.

6.2.2 TROUBLESHOOTING CHART
Removed strainer for

inspection, cleaning and re-
install
Restriction at the suction end
Replace the strainer if there
is any mechanical damage.
Pump or Relief valve failure. If problem remains after cleaning or A significantly low oil flow
replacing strainer, check for pump failure by disconnecting the rate than rated during relief
circuit after the relief valve so that only the pump, relief valve and valve adjustment will
pressure gauge remain in the pump circuit. Cap or plug both ends suggest oil slippage inside
of the plumbing and start the pump. If full pressure can be the pump. Replace the
developed then the problem lies further downstream. Otherwise, pump.
disconnect the return line from the relief valve to the reservoir and
Increased attach a short length of hose to it. Start the pump and adjust the
pump noise, relief valve up and down.
loss of high A steady oil flow rate similar
pressure and or to rated value without any
speed appreciable increase in
gauge readings suggest
faulty relief valve. Replace
relief valve.
Defective cylinder seals and packing: After eliminating the strainer, Replace worn out or
pump and the relief valve as described above, have the cylinder defective cylinder packings
tested for worn out or defective packings and seals. and seals.
Defective Directional Control Valve(s): If the problem remains after Replace worn out DCV
all the above have been done, have the DCV checked for worn valve(s).
valve spool. Although this is extremely unlikely to occur, an
excessive worn out valve spool can slip enough oil to prevent build
up of maximum pressure. Symptoms include loss of cylinder speed
together with difficulty to build up to full pressure even with the relief
valve adjusted to a high setting.
Motor not connected to proper supply voltage Check connection diagram

on terminal box cover and
correct wiring
Hydraulic Motor
Insufficient cooling air volume due to obstructed air flow Provide clearance around
overheats
motor cowling area
Single phasing due to break or loose connection in supply line or Repair supply line.
blown fuse Replace fuse

7 SAFETY
7.1 CONVEYORS
7.1.1 GENERAL
The following instructions should always be observed when handling or working with the conveyor.
1. SPIRAC equipment is supplied conforming to AS 4024.1 - 2006 - Safeguarding of Machinery

and complies providing all guards remain locked in place with the bolts supplied. Any work
that necessitates removal of any guarding must be carried out in strict accordance with the
SPIRAC Operation and Maintenance manual supplied. However Local work practices and
regulations should be applied to the selection of any protective equipment or labelling that
may be required.
2. Ensure the conveyor is maintained in accordance with section 4. MAINTENANCE of this
manual.
3. Any person who will install, operate, service, repair or supervise the operation of this equipment
must be trained and informed in accordance with local regulations and legislation.
4. Where local regulations dictate that Work method statements, Safe working practice statements,
Job Safety Analysis, Pre-commencement Hazard checks and attendance to tool box meeting
be adhered to, it is the responsibility of the owner/operator of this equipment to ensure the
fore noted is actioned and recorded.
5. Always isolate the conveyor main power source and ensure that the conveyor cannot be started
before commencing any servicing work.
6. Ensure that all service equipment, such as but not restricted to, chain blocks, slings, staging is
well maintained and is in accordance with local regulation and legislation.
7. Never try to lift more than one item at a time i.e. protective covers (or lids).
8. Take care to avoid compression injuries when removing or replacing the spiral. Note that the
spiral can slide out of the trough when the conveyor is inclined.
9. Personnel operating or servicing the conveyor should be equipped with the correct protective
wear should a biological or mechanical hazard be present. Local work practices and
regulations should be applied to the selection of the protective equipment.
10. Personnel working frequently in these areas where conveyors have remote control or
automatic start/stop, must be informed of the operation.
11. On completion of any service work, please refer to this manuals section 3. OPERATION, for
the necessary instruction on re-starting.
12. Ensure that no one is working on the conveyor before it is started.
13. Never use the conveyor for other purposes other than which it is designed or above its given
capacity.
14. Personnel should never use the conveyor as a walkway to go to other areas.

7.1.2 NOISE
The equivalent continual A-wave noise level during normal operation is <70dB.
In cases where the equivalent continual A-wave noise level exceeds 70 dB, ear protection must be
worn.
7.2 SLIDING FRAMES
7.2.1 GENERAL
The following instructions should always be observed when handling or working with the sliding
frames–
1. The operation instructions are part of the installation and should be available for operating and
maintenance personnel.
2. Make sure that the maximum working conditions of the cylinder are not exceeded.
3. Ensure to use hydraulic fluid compatible with the selected sealing system
4. As a minimum, ensure that the recommended installation procedure as detailed under section 2
INSTALLATION is followed.
5. The proximity sensors must never be removed while the cylinder is under pressure. The
connectors must never be plugged or unplugged when the power supply is switched-on.
6. SPIRAC equipment is supplied conforming to AS 4024.1 – 2006 and ISO 12100-1:2003 -
Safeguarding of Machinery and complies providing all guards remain locked in place with the
bolts supplied. Any work that necessitates removal of any guarding must be carried out in
strict accordance with the SPIRAC Operation and Maintenance manual supplied. However
Local work practices and regulations should be applied to the selection of any protective
equipment or labeling that may be required.
7. Ensure the sliding frame and accessories are maintained in accordance with section 4.
MAINTENANCE of this manual.
8. Any person who will install, operate, service, repair or supervise the operation of this equipment
must be trained and informed in accordance with local regulations and legislation.
9. Where local regulations dictate that Work method statements, Safe working practice statements,
Job Safety Analysis, Pre-commencement Hazard checks and attendance to tool box meeting
be adhered to, it is the responsibility of the owner/operator of this equipment to ensure the
fore noted is actioned and recorded.
10. Always isolate the hydraulic motor from the main power source and ensure that the Frame
cannot be started before commencing any servicing work.
11. Ensure that all service equipment, such as but not restricted to, chain blocks, slings, staging is
well maintained and is in accordance with local regulation and legislation.
12. Never attempt to independently pick up tools or other parts of the silo.
13. Take care to avoid compression injuries when removing or replacing equipment.

14. Personnel operating or servicing the sliding frame and accessories should be equipped with
the correct protective wear should a biological or mechanical hazard be present. Local work
practices and regulations should be applied to the selection of the protective equipment.
15. Personnel working frequently in these areas where the Frame has remote control or automatic
start/stop, must be informed of the operation.
16. On completion of any service work, please refer to this manuals section 3. OPERATION, for
the necessary instruction on re-starting.
17. Ensure that no one is working on the frame before it is started.
18. Never use the unit for other purposes other than which it is designed or above its given
capacity.
19. Personnel should never use the unit as a walkway to go to other areas. Never walk on the
cylinder(s)
20. Do not open the silo door so long as the silo is not completely empty.
21. Do not enter silo before aeration of the silo.
22. Do not enter the silo without watch guard.
23. Do not enter the silo without measurement of the presence of gases.
24. Do not stand under the silo or discharge screw whilst installation work is in progress.
25. Do not enter the silo during thunderstorm.
26. During inspection or maintenance keep a safety zone of 1 meter around the installation as a
safety area.
7.2.2 NOISE
The equivalent continual A-wave noise level during normal operation is <70dB.
In cases where the equivalent continual A-wave noise level exceeds 70 dB, ear protection must be
worn.

8 SPARE PARTS
8.1 CONVEYORS
8.1.1 CONVEYOR PARTS DESCRIPTION

The list of spare parts gives the correct names for the parts of the conveyor and therefore eases the
ordering of spare parts.
The dimensions and technical data for your conveyor are specified in Appendix ‘General Arrangement
Drawings’. Make sure you have the drawing available when ordering parts by telephone. Also refer to
Technical Specifications in Appendix ‘Conveyor Data Sheets’.
LID
Screen
Figure 8.1.1 Conveyor Parts
Conveyor Standard Parts Accessories

1 Motor and gearbox 8 Draining section with screen
2 Bell Housing 9 Slidegate (Knifetype)
3 Drive shaft and coupling disc 10 Electronic linear actuator /
pneumatic cylinder
4 Spiral and coupling disc 11 Longopac holder with adapter
5 Spiral
6 Trough
7 Liner

8.1.2 RECOMMENDED SPARE PARTS
SPIRAC have endeavoured to provide you with equipment that will give you continued and long
lasting service. However, we recommend that the following wear items be kept as a minimum to
ensure uninterrupted service:
Drive Station Gland Packing 1 Set

(for each size gearbox supplied)
Conveyor Liners – Duraflo (with coloured wear Depends on conveyor length and type of liner
backing) or Steel originally supplied - Refer to Drawing
Instrumentation Motion Sensing Probe 1 required (for each area)

(Where applicable)
For actual part numbers and descriptions, please refer to Technical Specifications in Appendix
‘Conveyor Data Sheets’ and the Appendix ‘General Arrangement Drawings’, also quoting the drawing
number.
8.2 SLIDING FRAMES
8.2.1 SLIDING FRAME SPARE PARTS

The list of spare parts gives the correct names for the parts of the Frame and therefore eases the
ordering of spare parts.
The dimensions and technical data for your Frame are specified in Appendix ‘General Arrangement
Drawings’. Make sure you have the drawing available when ordering parts by telephone. Also refer to
Technical Specifications in Appendix ‘Conveyor Data Sheets’.

8.2.2 RECOMMENDED SPARE PARTS
SPIRAC have endeavoured to provide you with equipment that will give you continued and long
lasting service. However, we recommend that the following wear and critical items be kept as a
minimum to ensure uninterrupted service:
16x16 PV30 Multipac gland packing I Set
Stuffing Box Powerslide Seal T 100G 15x2.5 mm NBR 2 off
Lubrication Canister 1 Set for the grease nipple
Telemechanique Inductive Proximity Sensor

Hydraulic Cylinder Type XS618B1NAL2
2 Sets
Gear Pump 1 off
Coupling Element 1 Set
Return Filter Element 1 Set
Hydraulic Power Breathers 2 off

Pack
24V DCV Coils 1 Set
Relief Valve Cartridge 1 Set
Accumulator Charging Kit / Spare Bladder Kit (if 1 Set

supplied)
For actual part numbers and descriptions, please refer to Technical Specifications in Appendix
‘Conveyor Data Sheets’ and the Appendix ‘General Arrangement Drawings’, also quoting the drawing
number.
9 SUPPLIER CONTACT
SPIRAC ENGINEERING has Sales Offices throughout the world. Manufacturing is undertaken in
Australia and Sweden. If you are unsure of your Agent, please make your initial contact to:
SPIRAC Engineering
PO Box 1216
BIBRA LAKE, DC WA 6965
Western Australia
Ph : +61 (08) 9434 0777
Fax : +61 (08) 9434 0778
Email: info@spirac.com.au

APPENDIX A
CONVEYOR DATA SHEETS
REFER TO K654_834_02_504_0
Document No. K654_834_02_0542_0

APPENDIX B
LUBRICATION CHECK SHEETS
Document No. K654_834_02_0542_0

LUBRICANT CHECK SHEET
CONVEYORS:
Part to be lubricated Gearbox

Recommended lubricant BP Energol GR-XP 220 (or equiv)
Change Frequency 6 - 12 months
Oil Volume Refer Gearbox Tag Plate
Part to be lubricated Bell Housing Gland Packing – Buraflon 5846 / 6.35

Recommendable lubricant Castrol Grease EPL2 Multi Purpose Extreme Pressure
Change Frequency Every 6 months
Filling method Grease Gun
(Refer to Appendix H & I for additional information)
SLIDING FRAMES
Recommended Cylinder Hydraulic Oil Ecoterra Hydraulic Fluid ISO VG 46 (or equiv)
Change Frequency Refer to Maintenance Schedule
Oil Volume Refer Tag Plate
Part to be lubricated Cylinder Stuffing Box

Recommendable lubricant Perma lube 12 month grease canister, Multi Purpose
Extreme Pressure
Change Frequency Refer to Maintenance Schedule
Filling method Replaceable Canister
(Refer to Appendix J & I for additional information)
Document No. K654_834_02_0542_0

APPENDIX C
GENERAL ARRANGEMENT DRAWINGS
REFER TO K654_834_02_0001 TO 0030

&
REFER TO K654_834_02_0040 TO 0043
&
REFER TO K654_834_02_0200 TO 0202
Document No. K654_834_02_0542_0

APPENDIX D
MOTOR DATA SHEETS
REFER TO K654_834_02_505_0
Document No. K654_834_02_0542_0

APPENDIX E
SPIRAC SLIDEGATE IOM MANUAL
Document No. K654_834_02_0542_0

APPENDIX F
WELDING
Document No. K654_834_02_0542_0

APPENDIX G
INSTRUMENTATION DATA SHEETS
REFER TO K654_834_02_400_0
REFER TO K654_834_02_401_0
REFER TO K654_834_02_403_0
Document No. K654_834_02_0542_0

APPENDIX H
GEARBOX MANUAL
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APPENDIX I
MOTOR MANUAL
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APPENDIX J
HYDRAULIC PUMP MANUAL
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APPENDIX K
IMPORT HOPPER INSTALL
INSTRUCTION MANUAL
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APPENDIX L
INSTRUMENTATION – INSTALLATION
AND OPERATION MANUALS
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APPENDIX M
LCS INSTALLATION AND OPERATION
DETAILS
REFER TO K654_834_02_0200_0
Document No. K654_834_02_0542_0

Doha North Sewerage Treatment & Associated Works

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Doha North Sewerage Treatment & Associated Works

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Doha North Sewerage Treatment & Associated

Doha North Sewage Treatment Works

Installation, Operation & Maintenance Manual

Document No. K654_834_02_600_0 Page 1

Rev Date Prepared By Description Chk. & Rev. By Appr. By

0 13.06.12 SPIRAC Draft Issue for Comments / NN CA GEK

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9 SUPPLIER CONTACT ........................................................................................................................... 53

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A CONVEYOR DATA SHEETS

B LUBRICATION CHECK SHEETS

C GENERAL ARRANGEMENT DRAWINGS

D MOTOR DATA SHEETS

E SPIRAC SLIDEGATE IOM MANUAL

G INSTRUMENTATION DATA SHEETS

J HYDRAULIC PUMP MANUAL

K IMPORT HOPPER INSTALL INSTRUCTION MANUAL

L INSTRUMENTATION – INSTALLATION AND OPERATION MANUALS

- PROXIMITY SWITCH FOR HOPPER LID & SLIDING FRAME RAM

- MOTION SENSOR FOR CONVEYOR MOTOR

M LCS INSTALLATION AND OPERATION DETAILS

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Refer to Safety Sheet in section 7.SAFETY.

1.2 PRODUCT IDENTIFICATION

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1.3 PRODUCT DESCRIPTION - CONVEYORS

Figure 1.3a - Principal Parts of the Conveyor

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1.4 PRODUCT DESCRIPTION – SLIDING FRAMES

Figure 1.4a - Principal Parts of the sliding frame

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Torque Settings for the Coupling Disc

A4/70 M12x55 62Nm (oiled thread)

A4/70 M12x60 20Nm (oiled thread)

2.1.2 ASSEMBLING THE TROUGH

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Figure 2.1.2a - Assembling the trough

2.1.3 CONNECTION OF SPIRALS

2.1.4 MOUNTING THE DRIVE ASSEMBLY

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Figure 2.1.4a - Mounting the Drive Assembly

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2.1.5 CONNECTION TO SUPPORT STRUCTURE

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2.2.2 DELIVERY TO SITE

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2.2.3 INSTALLATION PROCEDURE

The sequence of installation is as follows;

1. Metering screw conveyor

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3.1.1 PRE-START CHECKS

Left Hand Spiral.

Right Hand Spiral

Figure 3.1.1a - Direction of Rotation

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3.1.3 EXTENDED SHUT-DOWN

3.2 SLIDING FRAMES

3.2.1 PRE-START CHECKS

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3.2.2 RINSING THE HYDRAULIC PIPING AND TUBES

3.2.3 INSTRUMENTS TESTING

3.2.4 ROTATION TEST

3.2.5 OPERATING DATA

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