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4” FLUMP SERIAL #16010 SRS RENTAL
INTRODUCTION WARRANTY GENERAL LAYOUT DRAWING PUMP CURVE HYDRAULIC SCHEMATIC FLUMP ELECTRICAL SCHEMATIC
SLUDGE REMOVAL SYSTEM In our continuing effort to provide excellence in low maintenance, easy to operate Sludge Removal Systems, we have assembled this Operations and Maintenance Man-ual. Contained in this manual is the information necessary to properly install, operate and maintain the Crisafulli Sludge Removal System. SRS Crisafulli Inc., Sludge Removal Systems are effectively handling sludge for a vari-ety of operations, which vary in size and handling requirements. Because of different requirements, the operator of each system must develop additional operational and safety guidelines, which will cover the specific site hazards of the individual operations. We are dedicated to providing excellence in Sludge Removal Systems and after sale service. If you should have any questions or comments concerning your Sludge Re-moval System, please call us at 1-800-442-7867. We would appreciate hearing from you. Sincerely, The Employees of SRS CRISAFULLI, INC.
INITIAL INSPECTION INITIAL ASSEMBLY PROPER ROTATION TESTING SLUDGE PUMP MOTOR SPECIFICATIONS POWER UNIT MOTOR SPECIFICATIONS BALDOR MOTOR O&M SEW EURODRIVE SPECIFICATIONS LAUNCHING INSTRUCTIONS TRAVERSE SYSTEM SET UP DISCHARGE PIPE & ELECTRICAL CORD INSTALLATION INSTRUCTIONS
The Flump was shipped in good condition but must be inspected for any damage that may have occurred during shipping and handling. Note and advise the factory of any damage immediately at the following address:
TRAVERSE MOTOR The traverse motor is installed on the Flump in a shipping only configuration. This electric winch motor and pulley assembly is attached to the Flump structure using four 1/2” bolts at the base of the traverse winch-mounting bracket. There is also an electri-cal cord clamp for the traverse winch cord. The assembly must be rotated one-half turn before the traverse cable can be attached. There is no need to disconnect the electrical cord during this set-up operation; however caution must be exercised to prevent cord damage during the following procedure. POSITIONING INSTRUCTIONS 1. The electric cord must be temporarily positioned to prevent unintentional damage during the assembly’s rotation to the operating position. 2. Remove the four 1/2” attaching bolts at the base of the traverse winch mount. 3. Rotate the traverse winch assembly so that the winch motor is to the outside of the flump and the cable sheaves are to the inside of the flump. 4. Align the four holes in the winch base with the four holes on the flump platform, re-install the four 1/2” attaching bolts and torque to 75 Ft ⋅Lb. 5. Reattach the electrical cord and clamp.
Refer to General Layout Drawing The Flump was tested at the factory prior to shipping to ensure proper rotation of all electric motors. In order to ensure that the control panel has been wired correctly on site, the rotation of one or more electric motors should be checked. 1. Press the Hoist winch “Lower” button. 2. Observe the direction that the pump column is moving. If the pump is moving in same direction that the panel button indicates , then the motor is rotating correctly. 3. If the motor is not rotating in the proper direction, push the opposite button Hoist winch “Raise” to return the pump column to its original position. 4. Disconnect main power from source and unhook power cable. 5. Change wiring to control panel and recheck motor for proper rotation by repeating steps 1-3. 6. Once the motor is rotating in the proper direction, it may be shut down until it is needed for operation. If the depth winch electric motor is rotating correctly, then all of the electric motors on the Flump are correct.
Brand Name: Baldor Electric Company Catalog number: EM4115T Description: 50 Hp, 1775 RPM, 3 Ph, TEFC, 326T NEMA Ship Weight: 750 lbs. Features: •Ball bearings •Suitable for mounting any position •Heavy cast iron frame Performance Data: Rating – Nominals Characteristics: Rated Output 50 Hp Volts 230/460 Full Load Amps 116/58 Speed 1775 Hertz 60 Phase 3NEMA Design Code ALR KVA Code HEfficiency 95 Power Factor 86 Service Factor 1.15 Rating – Duty 40C AMB-CONT Full Load Torque 148 lb-ft Break Down Torque 508 lb-ft 343% of F.L. Torque Locked-Rotor Torque 294.1 lb-ft Starting Current (Amps) 425 No-Load Current (Amps) 21.4
Brand Name: Baldor Electric Company Catalog number: VEM3770T Description: 7.5 Hp, 1770 RPM, 3 Ph, TEFC, 213TC NEMA Ship Weight: 170 lbs. Features: •Ball bearings •Locked drive end bearing •Heavy gauge steel frame Performance Data: Rating – Nominal Characteristics: Rated Output 7.5 Hp Volts 230/460 Full Load Amps 19/9.5 Speed 1770 Hertz 60 Phase 3NEMA Design Code ALR KVA Code JEfficiency 91.7 Power Factor 81 Service Factor 1.15 Rating – Duty 40C AMB-CONT Full Load Torque 22.1 lb-ft Break Down Torque 69.8 lb-ft 315.8% of F.L. Torque Locked-Rotor Torque 42.2 lb-ft Starting Current (Amps) 68 No-Load Current (Amps) 4.18 Line-line Resistance @ 25 ° C 1.43 Temperature Rise, C @ FL (in deg) 42
Refer to Drawing # 03206 The inspection, initial assembly and proper rotation testing procedures should be com-pleted prior to launching the Flump. A crane is required to remove the Flump from the shipping platform. The Flump weighs approximately 4000 pounds. Attach four lifting slings of equal length, at least 15 feet in length, to the four Flump lifting eyes using a clevis at each eye. Attach each of the four lifting slings to the lifting ring of the crane or the hoist. Carefully raise the Flump and position the unit over a suitable launch site with at least 18 inches of freestanding water to float the Flump. Slowly lower the Flump into the water and temporarily secure the Flump to a minimum of two anchor stakes at an accessible location in the dredging area.
Refer to Drawing # 20390 1. Locate four anchor rod base plates (1), twelve anchor rods (3), five Griphoist cable tensioners (2), four lateral cables with hooks (6), two tension triangles (5), one trav-erse cable with hook (4), one tensioning cable (7), one 3/8” cable hook, two 3/8” cable thimbles, and six 5/16” cable clamps provided. 2. Position the four-anchor rod base plates (1) at each corner of the rectangular area to be dredged. Position each anchor rod base plate in the same configuration as shown in Figure 1. 3. Drive one anchor rod (3) through each small hole in each of the four base plates (1) until the D-ring is within one inch of the anchor rod base plate. 4. Attach one of the Griphoist cable tensioners (2) to the D-ring on the anchor rod (3) at each of the four base plate (1) locations using the anchor pin in the Griphoist base (see Figure 2). 5. Release the Griphoist (2) by first depressing the small yellow latch on the side of the Griphoist frame and move the large yellow handle down and toward the anchor pin end until it latches in place. 6. Unroll one of the lateral cables (6). Feed the tapered free end of the cable through the small Griphoist (2) frame hole in the end opposite the anchor pin. Continue to feed cable through the Griphoist until at least 18 inches of cable are exposed. Re-peat this procedure at the other three corner locations. 7. Connect the hooks on the lateral cables (6) to their respective tension triangles (5) for each end. NOTE: Lateral cables are long enough to reach from one anchor location to the other anchor location on the same end of the dredging area. Tension triangles are located on the ends of the dredging area. Ca-ble attached to a tension triangle should originate at the anchor lo-cations on the same end of the dredging area. 8. Position the tension triangles (5), one at each end of the dredging area, so that a line from one triangle to the other triangle is as close as possible to the centerline of the Flump in its secured location. 9. Pull any excess cable through the Griphoist (2) and coil loosely on the ground. 10. Latch all four Griphoists (2) by pushing straight down on the large yellow handle. 11. Attach the 3/8” cable hook to one end of the traversing cable (4) and make a small loop in the other end of the traversing cable. 12. Feed the tapered end of the tensioning cable (7) through the remaining Griphoist. Attach the loop end of the traversing cable (4) to the other end of the Griphoist. The tensioning Griphoist may be placed at either end of the pond. 13. Route the traverse cable (4) through the traverse winch on-board the Flump by re-moving the nylon rollers, positioning the cable on the sheaves and reinstalling the nylon rollers (see Drawing # 20352). 14. Attach the hook on the tensioning cable (7) to one tension triangle (5) and attach the hook on the traversing cable (4) to the other tension triangle. 15. Adjust the tension in the traverse cable (4) with the Griphoist (2) that is attached to the tensioning cable until the traverse cable remains 6 to 8 inches above the water surface.
Refer to Drawing # 20400 DISCHARGE PIPING NOTE: Installation of the discharge piping should be accomplished after the Flump has been set into the pond. The integral discharge system consists of flexible hose (1) and rigid pipe (2) sections. These sections are coupled together with ringlock clamps (3). When assembling the discharge piping, a flexible section MUST be attached at the Flump discharge (4) and at the shore discharge location (5). The discharge piping should be assembled with alternating rigid and flexible sections. NOTE: It may be necessary to couple two pipe sections or two flexible sec-tions together in order to accommodate the use of flexible sections attached at the Flump and shore connections. Procedure for assembling the discharge piping. 1. Attach one flexible section (1) to the Flump discharge (4). 2. Attach the electrical cords to their respective terminals on the Flump junction box (6)(see Electrical Cord section on the following page). CAUTION: Before working with electrical equipment, ensure that the power source is locked out. 3. Secure the electrical cord to the Flump via the strain reliefs (8). There is an eyebolt provided on the Flump, near the discharge (4), for attaching the strain reliefs. DISCHARGE PIPING CONT. 4. Adjust the strain reliefs (8) so that there is a minimal amount of slack between the strain reliefs and the junction box (6). 5. Assemble alternating sections of discharge pipe as described above on the edge of the shoreline. 6. Secure the electrical cord to the discharge piping with the elastic straps (see Draw-ing # 20378). The electrical cord should be attached to the rigid pipe (2) only. 7. After the electrical cord has been attached to the entire length of discharge piping, couple the end of the discharge piping to the shore discharge station (5). 8. Connect the electrical cord to its terminal in the control panel (7)(see Electrical Cord section below). NOTE: Coil any excess electrical cord on the shore beside the control panel. 9. The entire discharge piping and electrical cord assembly can now be placed into the lagoon. ELECTRICAL CORD One electrical cord supplies power to all the Flump components. Cord : 2 gauge – 4 conductor; this cord is used to power the control panel and thereby the entire flump. The Cord runs from the shore power source to the control panel on the dredge. The female connector attaches to the male plug on the control panel.
FLUMP SAFETY GUIDELINES DAILY START UP OPERATIONAL TIPS OPERATING INSTRUCTIONS LATERAL POSITIONING INSTRUCTIONS FLUMP LUBRICATION INSTRUCTIONS WINCH MOUNTING CODE DESIGNATION WINCH LUBE POINTS RECOMMENDED LUBRICATION & MAINTENANCE SCHEDULE TRAVERSE CABLE INSPECTION TROUBLESHOOTING PUMP TROUBLESHOOTING
GENERAL Review complete manual before operating this Sludge Handling System. The installation, operation, and maintenance of the SRS Crisafulli Flump require practices & procedures that ensure personal safety and the safety of others. This equipment is to be installed, operated, and maintained only by qualified persons in accordance with this manual and all applicable codes. Information presented in this manual pertains to equipment design, installation, operation, and maintenance, which should be read, understood, and practiced for safe operation of the Flump. The warning signs attached to Flump MUST be observed and practiced at all times. Replace any Warning stickers that are illegible or missing. Inquire at your local Crisafulli dealer or call SRS Crisafulli Incorporated at 1-800-442-7867. SAFETY ALERT NOTICES The following safety alert signal words are used throughout this manual to call attention to and identify different levels of hazards and special instruction. These safety alert signal words, Warning and Caution, call attention to the safety statements. Warning - Statements identify procedures or practices, which must be fol-lowed to avoid serious personal injury or loss of life. Caution - Statements identify procedures or practices, which must be fol-lowed to avoid, personal injury or damage to equipment. Important- Statements identify special instructions necessary for the most ef-ficient operation of this equipment.
Keep the following in mind during normal daily operation: 1. Ensure that discharge piping and electrical cords are properly secured. 2. Maintain and follow lubrication schedules. 3. Check for hydraulic leaks. Possible leakage areas : Fittings, hoses, shaft seals and hydraulic reser-voir. 4. Check hydraulic oil level every day and check temperature periodically during operation. 5. If a leak is found, wipe area clean of oil and dirt so leak can be located. Tighten fittings or replace. During warm up period check for leaks at hoses and fittings. If leaks are de-tected; shut power unit off immediately and determine cause of leak. Repair as necessary.
These tips are provided to aid the operator in maximizing the performance and effi-ciency of the equipment. All applications are different, these tips are only suggestions and guidelines as to how this equipment should be run. Should any questions arise as to how the equipment should be performing, please consult the factory. CUTTERHEAD DEPTH For most applications, the cutterhead should be placed into approximately 12 inches of material. Depending on the viscosity of the material, this value may vary. As the op-erator becomes familiar with the material being pumped, he/she will be able to adjust the cutting depth according to the desired performance. TRAVERSING When traversing forward, tension must be maintained on the hoist winch cable at all times. When the cutterhead is adjusted properly it will be cutting a swath through the material that is parallel to the basin floor. If the tension is too loose, the cutterhead may start to dig into the material thereby burying itself and creating the potential for damage to the Flump. If the tension is too much, the cutterhead may be only skimming the material. While dredging, the Flump should be slightly higher on the front end than on the rear. After the desired cutterhead depth has been achieved, the traverse speed should be adjusted to achieve the desired slurry concentration. DISCHARGE LINE Observing the discharge line is one of the more accurate means of determining if your slurry concentration is adequate. During normal dredging operations the discharge line should be about 25% – 33% submerged. If the discharge line begins to sink, the slurry concentration is too high. To remedy this, either the cutterhead can be raised up or the traverse speed can be decreased.
NOTE: Before operating the Flump, make sure all daily start up procedures has been performed. NOTE: The panel can be used with either the radio remote or the panel, not both. When the panel is set to radio, all functions on the remote are locked out at the panel. The panel cannot be switched between panel and remote while the Flump is running. Radio Remote Operating Instructions The radio remote has all the main dredge functions onboard. To use the radio remote, turn the Control Selector Switch to “ Radio ”. Turn on the power of the remote using the Transmitter Off/On switch. The Sludge Pump and Power Unit can be activated by moving their respective toggle switches toward the “ ON ” position. Once the motor has started, release the toggle switch. The motor will stay engaged until the toggle switch is moved to the off position. To engage the Traverse , depress the switch in the desired direction and then release. The traverse will continue to move after the button has been released. To stop the traverse, move the toggle switch in the current direc-tion of travel. NOTE: Always place the traverse in the stop position before reversing di-rection. The Traverse Slow/Fast and Hoist Winch are momentary switches and need to be held until the desired result has been achieved. There is an E-stop on the top of the remote. Activate it by depressing the button. To clear the E-stop, cycle the remote power by using the transmitter Off/On switch. NOTE: The remote power can be turned off during a long traverse without interrupting unit function. Turning the remote off when not in use can significantly extend battery life. WARNING: The Emergency Stop switch on the remote will not function if the remote control is turned “OFF”. If remote does not work or works intermittently, try replacing the remote battery to re-store function. Dredge Startup Instructions 1. Turn Main Switch disconnect to the “ON” position. 2. With the Radio/Panel switch in the Radio position, lower cutterhead to desired depth by using the Hoist Winch “Lower” button. 3. Engage cutterhead rotation using Cutterhead “Start” button, allow cutterhead to run 3-5 minutes to warm the hydraulic system. Warning: The water lubricated bearing on the cutterhead must be submerged to function properly. The cutterhead should be AT LEAST 12 INCHES below the water surface before starting the auger. If it is necessary to start the auger at a shallower depth, caution must be taken in order to prevent the floatline from becoming entangled in the auger. 4. Engage dredge pump using Dredge Pump “Start” button. 5. Set desired dredge depth by using the Hoist Winch “Raise” or “Lower” but ton. 6. Begin forward travel using the Traverse Winch “Forward” button. 7. When the desired forward travel has been completed, stop the Flump with the Traverse Winch “Stop” button. 8. Raise the cutterhead to about 12 inches below the water surface by using the Hoist Winch “Raise” button. 9. Stop the cutterhead with the Cutterhead “Stop” button. 10. Allow the dredge pump to run for 30-60 seconds in order to flush out the dis charge piping system. Stop dredge pump by using the Dredge Pump “Stop” button. NOTE: The Flump will continue to pump light material in the reverse direc-tion. If light material is being pumped, steps 8-10 may be skipped. 11. Reverse travel with the Traverse Winch Reverse button. 12. When the desired travel has been achieved, stop reverse movement with the Traverse Winch “Stop” button. 13. If the dredge pump is still running at this point, follow steps 8-10. 14. If a lateral move is desired, refer to the Lateral Positioning Instructions. NOTE: The Flump should NEVER be moved laterally with the cutterhead in the down position. 15. When lateral movement is complete, repeat above steps. NOTE: The cutterhead depth and traverse speed are adjustable while using the auto-mode sequence. The operator is encouraged to fine-tune the flump perform-ance by using the Hoist Winch Raise/Lower or Traverse Speed Fast/Slow while the Flump is in motion.
Refer to Drawing # 20390 Moving the Flump laterally requires the adjustment of all four Griphoist cable tension-ers. To move the Flump laterally, the two Griphoists on one side must be loosened, while the two Griphoists on the other side are tightened. The following is an example for moving the Flump 8 feet down according to the layout in Drawing # 20390. 1. Release 8 feet of cable from Griphoist A. 2. Release 8 feet of cable from Griphoist C. 3. Pull in 8 feet of cable at Griphoist B. 4. Pull in 8 feet of cable at Griphoist D. The Griphoists are infinitely adjustable and can be used to move the Flump any dis-tance in either direction. The Griphoists should be moved evenly in order to maintain the correct amount of tension in the traverse system and to prevent the Flump from skewing. NOTE: If desired, the Griphoists can be adjusted so that the Flump will dredge diagonally.
LUBE POINT DESCRIPTION FREQUENCY LUBRICATION TYPE Quantity 1 Traverse System Guide Roller Daily Shell Alvania #1 Grease or Equal Single pump on each of 4 rollers 2 Traverse Winch Idler Sheaves Daily Shell Alvania #1 Grease or Equal Single pump on each sheave 3 Sludge Pump Shaft Thrust Bearing Weekly Shell Alvania #1 Grease or Equal Single pump 4 Sludge Pump Electric Motor Every 6 Months Shell Alvania #1 Grease or Equal Single pump 5 Power Unit Electric Motor Every 6 Months Shell Alvania #1 Grease or Equal Single pump A Hoist Winch Monthly Mobilgear 630 Oil or Equal Gearbox Half Full (See Attached) B Traverse Winch Monthly Mobilgear 630 Oil or Equal Gearbox Half Full (See Attached) C Bearing Frame Site Bottles Daily Exxon Nuto 46 Oil or Equal Each Bottle Half Full D Hydraulic Reservoir Daily Exxon Nuto 46 Oil or Equal Half Full on Site Glass
Check winch oil level at least every month. It is recommended that the oil be changed every 10,000 hours or every two years, whichever comes first. Below is the winch des-ignation, mounting location, lubricant volume. Please refer to the mounting position sheets for location of breather valve, oil level plug, and oil drain plug. For additional information, see the attached lubrication schedule for SEW-Eurodrive gear units. All gear reducers are of type R. Winch Mounting Location Lubricant Amount Gallons/Liter Traverse Winch M1 0.63 / 2.4 Hoist Winch M1 0.29 / 1.1 Lateral Traverse Winch M4 2.03 / 7.70 Recommended Lubricant - Mobilgear 630
DAILY: WEEKLY: EVERY 100 HOURS: DESCRIPTION OF CHECK & MAINTENANCE REMARKS DESCRIPTION OF CHECK & MAINTENANCE REMARKS DESCRIPTION OF CHECK & MAINTENANCE REMARKS EVERY 400 HOURS: EVERY 600 HOURS: EVERY 1200 HOURS: DESCRIPTION OF CHECK & MAINTENANCE REMARKS Hydraulic reservoir Drain oil and refill, clean filler-breather (Exxon NUTO H46) Hydraulic return-line filters Replace element Main dredge pump Check and tighten mounting bolts in suction flange and base Electrical system Check indicator lights, fuses and switches Traverse winch drum & idler pulleys Check for wear Traverse cable Check for wear Lateral positioning cables Check for wear Lateral positioning winch drum Check for wear Safety decals Clean or replace as necessary DESCRIPTION OF CHECK & MAINTENANCE REMARKS Wiring and connection check Impeller Check for wear DESCRIPTION OF CHECK & MAINTENANCE REMARKS Hydraulic filters Replace
A cabling system is only as strong as the weakest point, be it a wire rope, hook, or con-nection. Timetables for replacement intervals of wire rope are not applicable. The proper way to determine if replacement is necessary is through a documented inspec-tion process. The following instructions will describe how, when, and what to look for during an inspection as well as the documentation needed. Any degradation of the wire rope severely reduces the load capacity. Abrasion, bending, and crushing are the ABC’s of rope inspection to discover early conditions that allow for safe replacement. Each inspection needs to be completed by a competent person. Periodic inspections need to be conducted and documented on a set schedule. The inspection duration depends on the amount of service the cabling system in enduring. The following intervals are a guide to use for inspection intervals. These intervals are only a guide and should be deemed as such; additional inspections should be con-ducted whenever appropriate. WIRE ROPE INSPECTION SCHEDULE HEAVY SERVICE (35+ HOURS/WEEK) ---- WEEKLY INTERMITENT SERVICE (10-35 HOURS/WEEK) ---- MONTHLY LIGHT SERVICE (LESS THAN 10 HOURS/WEEK)---- EACH USE INSPECTION GUIDELINES 1) Maintain inspection records in accordance with above schedule 2) Prior to each use a walk-around inspection needs to be conducted, addressing the following items. a) Check all equipment functions related to the traverse system b) Visual inspection for unsafe conditions, i.e., broken wires, kinking, twisting, or corrosion. Attention needs to be directed toward any new damage. c) Function and ease of cable movement should be verified. d) Inspect all end connections such as hooks, splices, and snatch blocks for excessive wear or distortion. 3) An annual inspection and report of all traverse related components needs to be conducted. 4) The utmost in care must be taken during inspection of all components. Safety is the number one priority and must be at the forefront of each person’s mind while on or around equipment. WIRE ROPE INSPECTION The following is a general list of inspection criteria; the main types of failure are cov-ered. If additional inspection data or procedures are desired contact the American Iron and Steel Institute. The listed criteria are to be used as a guide and not a substitute for a competent inspector. Occasionally a single wire will break after installation. If no other breaks occur at the same time, there is no need for concern. However, if other breakages occur, the cause should be carefully investigated. 1) ABRASION Wire rope (cable) abrades as it moves through abrasive mediums or over drums and sheaves. Most standards require removal from service if the outer wire diame-ter wear exceeds 1/3 of the original wire diameter. This is not easy to measure. Other listed inspections will provide evidence of abrasion also. 2) ROPE STRETCH All wire rope stretches as loads are applied. The amount of stretch and the rate at which that occurs can be used as a judge to determine replacement time. As rope degrades, continued application of a constant load will produce varying amounts of stretch. By recording and paying attention to the amount of tightening required, one may judge the condition of the rope. Stretch occurs in three phases: Phase 1 : Initial stretch, during beginning of service, caused by setup and ad-justments to operation. Phase 2 : Service life, after break-in a long period of minimal stretch will occur. The stretch results from normal wear and fatigue. Phase 3 : Warning period, an accelerated rate of stretch occurs during this pe-riod. The rope has reached the point of rapid degradation. The system should be removed from service and the rope should be replaced. 3) REDUCTION IN DIAMETER Any reduction in diameter indicates that some form of degradation has taken place. Some forms are: excessive external abrasion internal or external corrosion loosening or tightening of rope lay inner wire breakage rope stretch An evaluation of the rope diameter needs to be started immediately upon putting the cable into service. Readings will need to be taken in accordance with inspec-tion schedule, in the same spots and under similar loading each time the rope is measured. After initial loading the diameter of the rope should be measured and recorded. The diameter after initial reduction will soon stabilize and only a small decrease will occur during the life of the cable. If a sizable reduction in diameter is found, use should stop immediately. While a reduction in the diameter is one judge of cable strength it should not be used alone. A cable may not have had a sizable reduction in diameter but may be unsafe due to other existing conditions. The rope diameter is only one criterion for replacement and should be used with the other listed inspections in determining the replacement time for the wire rope. 4) CORROSION One of the most serious yet difficult to evaluate forms of degradation is corrosion. The usual cause for corrosion on wire ropes stems from a lack of lubrication. An oxidation inhibiting, alkali free, nonwater soluble, viscous lubricant with high film strength should be used. Corrosion will occur internally before there are any visual signs on the surface. Pitting on the surface is cause for immediate replacement. Severe rusting can lead to premature failure. SRS Crisafulli uses galvanized wire rope to deter corrosion. In cases where corrosion is still occurring a stainless steel rope may need to be used. 5) FATIGUE FAILURE Fatigue fractures are easy to identify, the ends of the broken wires are square frac-tures and the surface of the wire will show little or no wear. The fractures occur on the crown of the strands or in the valleys between strands where contact is made. Replacement of wire rope is based upon the number of breaks found in the cable. Replacement should occur when one strand has 3 or more breaks and/or one lay has 6 or more breaks. 6) VALLEY BREAKS Valley breaks can also occur as a result of a core failure. When one valley break is found in the attaching end of a rope, the rope should immediately be replaced. When two or more valley breaks are found elsewhere on the rope replacement should be immediate. 7) SHEAVE INSPECTION When inspecting the traverse cable it is also important to check the sheaves on the dredging unit. The sheaves need to be checked for proper alignment and to deter-mine if each sheaves turns freely. The groove and working surfaces of each sheave and drive need to be checked for proper diameter and to determine if corru-gations are forming.
SYMPTOM COMPONENT CHECK FOR Reduced Performance SLUDGE PUMP Pump speed Proper submergence Plugged suction Air pocket in suction Direction of impeller rotation Foreign material in cutterhead Viscosity of material Lack of flow Plugged cutterhead or discharge line Excessive wear on impeller Pump speed Proper submergence Drive Motor over loaded Specific gravity or viscosity Low voltage Total dynamic head too low Foreign material in cutterhead Misaligned or bent shaft Insufficient Discharge Pressure Air pocket in suction Pump speed too low Direction of rotation Total dynamic head too high Specific gravity or viscosity differ-ent from design Impeller damage Excessive Noise Impeller plugged Worn bearings Impeller retaining nut loose Cavitation Direction of rotation Proper Submergence Impeller damage Bent Shaft Misalignment of rotating parts Worn bearing seals Misalignment of rotating parts Contaminated bearings Insufficient lubrication Bent shaft Electric motor failure PRIME MOVER Power source characteristics Electrical connection Bearing failure Insufficient cooling Rapid wear on coupling cushion Misalignment or rotating parts Bent shaft No Cutterhead Rotation CUTTERHEAD Check oil level in power unit Check drive coupling (drive bolt & keyway) Check outboard bearing Check for foreign material in cutter-head Check rotation of electric motor on power unit Power Unit Inoperative POWER UNIT Power supply Power unit running, no hydraulic power being supplied Oil level in reservoir Drive coupling Suction screen Hydraulic pump Flump won’t traverse TRAVERSE WINCH Power supply Traverse cable tension Cutterhead won’t raise or lower HOIST WINCH Power supply Hoist winch cable
SYMPTOM COMPONENT CHECK FOR
SYMPTOMS CAUSES CORRECTIONS Failure to pump Pump not primed. Pump speed too low or head too high. Air leak. Plugged suction. Pump or suction pipe not completely filled with liquid. Air pocket in suction. Inlet of suction insufficiently submerged Prime pump. Consult SRS Crisafulli, Inc. Check and rework suction line. Remove obstacle. Check supply. Locate and correct. Increase suction pipe submergence. Reduced perform-ance Obstructed suction line or impeller. Insufficient submergence of the suction. Excessively worn impeller or wear ring. Direction of impeller rotation wrong. Speed too low or head too high. Viscosity of liquid different from design. Remove obstruction. Increase suction pipe submergence. Replace impeller and/or wear ring. Reverse rotation. See start-up instructions. Consult SRS Crisafulli, Inc. Consult SRS Crisafulli, Inc. Driver over loaded Speed higher than design. Liquid specific gravity too high. Too large an impeller diameter. Low voltage. Total head lower than design. Foreign material in impeller. Misalignment. Shaft bent. Reduce speed. Consult SRS Crisafulli, Inc. Consult SRS Crisafulli, Inc. Consult power company. Consult SRS Crisafulli, Inc. Remove foreign matter. Realign. Replace shaft. Insufficient pres-sure developed Excessive amount of air or gas in liquid. Speed too low. Direction of impeller rotation wrong. Head too high. Viscosity of liquid different from design. Impeller damaged. Check for suction leak. Check Electrical - Consult SRS Crisafulli, Inc. Reverse rotation. See start-up instructions. Consult SRS Crisafulli, Inc. Consult SRS Crisafulli, Inc. Replace impeller.
SYMPTOMS CAUSES CORRECTIONS Excessive noise Misalignment. Material lodged in impeller. Worn bearings. Impeller bolt loose or broken. Cavitation. Direction of impeller rotation wrong. Suction improperly submerged. Operation at very low capacity. Shaft bent. Impeller damaged. Align rotating parts. Remove Material. Replace bearings. Replace bolt. Raise cutterhead to dilute slurry. Reverse rotation. See start-up instructions. Submerge suction further. Consult SRS Crisafulli, Inc. Replace shaft. Replace impeller. Premature bearing failure Grease line plugged or pinched. Worn bearing protection seals. Misalignment. Bent shaft. Water or contaminates entering bearings. Inadequate bearing lubrication. Wrong type of lubrications. Repair or replace. Replace. Align all rotating parts. Replace shaft. Protect pump from environment. See lubrication schedule, Section 5. See lubrication schedule, Section 5. Electric motor fail-ure High or low voltage. Electric surge. Poor electric connection. Overloads. Bearing failure. Cooling vent plugged Water. Check voltage. Monitor voltage and consult power Company. Turn power off, clean and check connections. Check amperage. Do not exceed nameplate full load amperage. Change bearings in motor. Install proper screens. Protect pump from environment. Rapid wear on coupling cushion Misalignment. Bent shaft. Align. Replace shaft.
BEARING FRAME MECHANICAL SEALS IMPELLER VOLUTE UPPER SHAFT HOUSING FLEXIBLE SHAFT COUPLER CUTTERHEAD MOTOR & DRIVE COUPLER WATER LUBE BEARING POWER UNIT TORQUE SPECS
Refer to Drawing # B20380-A DISASSEMBLY Remove the cutterhead assembly. Remove the impeller retaining nut (15). Withdraw the impeller (19) from the pump volute case (20). Note: (2) 5/8-16 set screws may be removed from impeller base plate to allow use of bar type puller. Separate the pump volute case from the bearing frame. Remove the upper 1/2" pipe plug for access to facilitate removal of the two setscrews in the coupling. Remove the flange bolts be-tween the bearing frame and the upper chamber and separate these two components. Remove the snap ring (10a) and the outboard mechanical seal (13) (See Mechanical Seal Removal and Installation Instructions). Remove the setscrews (3) from the bear-ing frame housing (2). Remove the outboard stationary seal holder (12), the O-ring seal (7a) and the spacer ring (11). Remove the snap ring (10b) and the inboard me-chanical seal (9). Remove the inboard stationary seal holder (8)(See Mechanical Seal Removal and Installation Instructions) and the O-ring seal (7b). The entire shaft assembly will now slide out through the pump end of the bearing frame
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