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OPERATION MAINTENANCE MANUAL

WESTECHANEMPLOYEE-OWNEDCOMPANYOPERATION& MAINTENANCEMANUALEQUIPMENT:TWO(2)100'DIA METERCOPCLARIFIERMECHANISMSWESTECHMODELC OPC2 FOR:NOVATOWASTEWATERFACILITYUPGRADENOVAT O,CAFURNISHEDBY:WESTECHENGINEERING, ,UTAHWESTECHJOBNUMBER20253 AJANUARY2009 TITLEPAGEWESTEC H'-".AN.>..:E=MP,-=LO",-, :..-"-O,-,,-, ,NE=D-=CO=M,-,-, :.:..;:N,-,-Y_OPERATIONANDMAINTENANCEMAN UALTWO(2)100'DIAMETERCOPCLARIFIERMECHANI SMSWESTECHMODELCOPC2 FOR:NOVATOWASTEWATERFACILITYUPGRADENOVAT O,CAENGtNEER:RMCWATER&ENVIRONMENTWALNUTC REEK,CACONTRACTOR:MONTEREYMECHANICAL8275 SANLEANDROSTREETOAKLAND,CA94621 CONTACT:CARLREYNOLDS, :510-632-3173 FAX:510-632-3314 WESTECHAGENT:JBIWATER&WASTEWATEREQT., ,CA95762 CONTACT:JAMESZAISERPHONE:916-933-5500 FAX:916-933-5573 MANUFACTURER:WESTECHENGINEERING, ,UTAH84115 PHONE:(801)265-1000 FAX:(801)265-108024 HOUREMERGENCYASSISTANCE(801)263-4093 WESTECHJOBNUMBER20253 AJANUARY2009 TABLE OF CONTENTS AN EMPLOYEE-OWNED COMPANY OPERATION AND MAINTENANCE MANUAL COVER PAGE TITLE PAGE TABLE OF CONTENTS INTRODUCTION PRODUCT LINE CARDS SECTION 1: EQUIPMENT INFORMATION WARRANTY GENERAL DESCRIPTION GENERAL PRECAUTIONS SHORTAGES, DISCREPANCIES, AND FIELD CHARGES STRUCTURAL LIFTING PRECAUTIONS PROCEDURE FOR ORDERING SPARE AND REPLACEMENT PARTS RECOMMENDED SPARE parts list EXPLANATION OF parts list AND PARTS NUMBER SECTION 2: INSTALLATION INSTRUCTIONS SUGGESTED ERECTION SEQUENCE SUGGESTED TORQUE RATINGS ANCHOR BOLTS AND BENCH MARKS CENTER COLUMN C

table of contents an employee-owned company operation and maintenance manual piping and electrical installation mechanism parts list section 3: start-up and operation

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Transcription of OPERATION MAINTENANCE MANUAL

1 WESTECHANEMPLOYEE-OWNEDCOMPANYOPERATION& MAINTENANCEMANUALEQUIPMENT:TWO(2)100'DIA METERCOPCLARIFIERMECHANISMSWESTECHMODELC OPC2 FOR:NOVATOWASTEWATERFACILITYUPGRADENOVAT O,CAFURNISHEDBY:WESTECHENGINEERING, ,UTAHWESTECHJOBNUMBER20253 AJANUARY2009 TITLEPAGEWESTEC H'-".AN.>..:E=MP,-=LO",-, :..-"-O,-,,-, ,NE=D-=CO=M,-,-, :.:..;:N,-,-Y_OPERATIONANDMAINTENANCEMAN UALTWO(2)100'DIAMETERCOPCLARIFIERMECHANI SMSWESTECHMODELCOPC2 FOR:NOVATOWASTEWATERFACILITYUPGRADENOVAT O,CAENGtNEER:RMCWATER&ENVIRONMENTWALNUTC REEK,CACONTRACTOR:MONTEREYMECHANICAL8275 SANLEANDROSTREETOAKLAND,CA94621 CONTACT:CARLREYNOLDS, :510-632-3173 FAX:510-632-3314 WESTECHAGENT:JBIWATER&WASTEWATEREQT., ,CA95762 CONTACT:JAMESZAISERPHONE:916-933-5500 FAX:916-933-5573 MANUFACTURER:WESTECHENGINEERING, ,UTAH84115 PHONE:(801)265-1000 FAX:(801)265-108024 HOUREMERGENCYASSISTANCE(801)263-4093 WESTECHJOBNUMBER20253 AJANUARY2009 TABLE OF CONTENTS AN EMPLOYEE-OWNED COMPANY OPERATION AND MAINTENANCE MANUAL COVER PAGE TITLE PAGE TABLE OF CONTENTS INTRODUCTION PRODUCT LINE CARDS SECTION 1: EQUIPMENT INFORMATION WARRANTY GENERAL DESCRIPTION GENERAL PRECAUTIONS SHORTAGES, DISCREPANCIES, AND FIELD CHARGES STRUCTURAL LIFTING PRECAUTIONS PROCEDURE FOR ORDERING SPARE AND REPLACEMENT PARTS RECOMMENDED SPARE parts list EXPLANATION OF parts list AND PARTS NUMBER SECTION 2.

2 INSTALLATION INSTRUCTIONS SUGGESTED ERECTION SEQUENCE SUGGESTED TORQUE RATINGS ANCHOR BOLTS AND BENCH MARKS CENTER COLUMN CENTER CAGE FEEDWELL AND SUPPORTS RAKE ARMS SCUM BOX SKIMMING MECHANISM AND SUPPORTS FINAL CHECK FOR LEVEL TORQUE TEST PROCEDURES T-1 TORQUE TEST DIAGRAM TANK GROUTING PROCEDURES SURFACE TREATMENT TABLE OF CONTENTS AN EMPLOYEE-OWNED COMPANY OPERATION AND MAINTENANCE MANUAL PIPING AND ELECTRICAL INSTALLATION MECHANISM parts list SECTION 3: START-UP AND OPERATION FIELD SERVICE REQUEST SAFETY INSTRUCTIONS STARTUP AND OPERATING PROCEDURES COLD WEATHER OPERATION STORAGE AND SHUTDOWN PRECAUTIONS EMERGENCY PROCEDURES AND TROUBLESHOOTING SECTION 4: DRIVE GENERAL INTRODUCTION RECEIVING AND INSPECTION FIELD CHARGES AND MODIFICATIONS STORAGE AND PAINT DURABILITY SANDBLASTING WARNING LUBRICATION WARNING TORQUE CONTROL SETTING WARNING MAINTENANCE AND OPERATION WARNING INSTALLATION LIFTING THE DRIVE UNIT DRIVE UNIT INSTALLATION WELDING WARNING STARTUP MAINTENANCE DRIVE DISASSEMBLY/ASSEMBLY DRIVE LUBRICATION YEARLY DRIVE MAINTENANCE WEEKLY DRIVE MAINTENANCE TABLE OF CONTENTS AN EMPLOYEE-OWNED COMPANY OPERATION AND MAINTENANCE MANUAL DRIVE TORQUE OVERLOAD CONTROL DEVICE LUBRICATION LUBRICATION OF ACCESSORY EQUIPMENT OPERATION OPERATION INSTRUCTIONS DRIVE UNIT DRIVE UNIT TROUBLESHOOTING CYCLOIDAL SPEED REDUCER INFORMATION DRIVE MOTOR TORQUE CONTROL INFORMATION DRIVE parts list SECTION 5: ELECTRICAL ELECTRICAL parts list SOLID STATE TIMING RELAYS SECTION 6.

3 ENCLOSURES B100 GENERAL NOTES D101 COP CLARIFIER GENERAL ARRANGEMENT TANK CUTAWAY VIEW D102 COP CLARIFIER GENERAL ARRANGEMENT ELEVATION VIEW D103 COP CLARIFIER GENERAL ARRANGEMENT PLAN VIEW D104 COP CLARIFIER GENERAL ARRANGEMENT CONCRETE TANK D105 COP CLARIFIER GENERAL ARRANGEMENT DETAILS C106 SCUM SKIMMER ASSEMBLY D110 COP CLARIFIER ERECTION TANK CUTAWAY VIEW D111 COP CLARIFIER ERECTION PLAN VIEW D112 MISCELLANEOUS ERECTION DETAILS D113 RAKE ARM ERECTION DETAILS D350G830 CAGE DRIVE ASSEMBLY - ELEVATION D350G831 CAGE DRIVE ASSEMBLY PLAN ASMDIAG ASSEMBLY DIAGRAM LUBETAG LUBRICATION TAGS DRV103 DRIVE ASSEMBLY PROCEDURES TABLE OF CONTENTS AN EMPLOYEE-OWNED COMPANY OPERATION AND MAINTENANCE MANUAL 900-611D DRIVE SHIMMING PROCEDURE E10D PANEL LAYOUT E11D ELECTRICAL SCHEMATIC ,EsTE C HANEMPLOYEE-OWNEDCOMPANYiOPERATIONANDMAI NTENANCEMANUALINTRODUCTIONT oensurecompliancewiththewarranty, thefrontof ,includingstandard"Buyout"items,mustbema intainedaccordingtoeachrespectivemanufac turer'soperationandmaintenanceprocedures enclosedwithinthismanualtoensurecoverage ofpossible failureswhiletheunitisstillunderwarranty ,alongwithensuringtrouble-freeoperationf orthelifeof , ,distribution, ' -AerotorTMTricklingFilters(RotaryDistrib utors)MotorDrivenBioDoc HydroDoc ClarifierSpiralBladesConventionalScraper BladesFlocculatingRimDriveSolidsContactS uctionHeaderSuctionPipeDissolvedAirFlota tionClarifiers&ThickenersRectangular&Cir cularDrivesReplacementDrivesforThickener sandClarifiersFiltersContinuousBackwashG ranularMediaGravityFiltersMulti-MediaPre ssureFiltersMembraneFilters(seeWATER listing)FilterPressesElectricalControlsU LListedPanels(UL508 NCSA)

4 PLCB asedControlsFlocculatorsHorizontalPaddle VerticalPaddle&MixerAxialFlowGritRemoval EquipmentAeratedGritChambersGritClassifi ersRakeCollectorsVortexGritSeparatorsIns tallationandErectionServicesLaboratoryan dPilotPlantTestEquipmentBenchScaleTestin gPilotPlantTestingPlantProcessAuditsMixi ngMixTecMixersExtremeDutyMixersOillWater SeparatorsAPIS eparatorDNFC larifiersParts&ServiceSupportDriveCompon entsFilterClothsSkimmerPartsWearPartsRec tangularBasinSkimmingRotatingScumPipesHe licalScumSkimmersScreensChannelMittShaft lessFineScreensCleanFlo ContinuousSelf-CleaningBeltScrewWashPres sesSludgeBlendersTankageSupplyandErectio nThickenersCenterFeedorSideFeedRakeLifti ngDevicesVacuumFiltersHorizontalBeltFilt erPrecoatDrumFilterDrumFiltersandDiscFil terswithScraperDischarge,RollDischarge,B eltDischargeAerationlDegasifiersESECHPRO DUCTLINECARDWATERG ranularMediaFiltrationForcedDraftInduced DraftCascadeDissolvedAirFlotationElectri calControlsULListedPanels(UL508 AJCSA)PLCB asedControlsFlocculatorsHorizontalandVer ticalPaddleFlocculatorsAxialFlowIntakeSc reensCleanFloTMIonExchangeMIEX OrganicRemovalSystemZeoliteSoftenersMixi ngMixTecMixersSedimentationBackwashClari fiersDecantClarifiersFlocculatingClarifi ersInclinedPlateSettlersRawWaterClarifie rsSolidsContactClarifiersMembranesWesTec hUltrafiltrationSystemsfeaturingthePolym em ModulesVerticalPressureFiltersHorizontal PressureFiltersMulti-CellGreenleafFilter sClari-Cell TwoStageFiltersCircularSteelFiltersSelfS toredBackwashGravityFiltersTechnasand ContinuousBackwashFiltersConcreteGravity FilterComponentsPyramed MediaRetentionUnderdrainModTecClusterFil tersIron& ManganeseRemovalUnitsGravityThickeningLi meSludgeThickeningClarifierUnderflowThic keningRakeLiftingDevicesPackagePlantsBuo yantandNon-buoyantMediaSludgeDewateringL imeMudFiltersRotaryDrumVacuumFiltersPlat eandFrameFilterPressesServicesLabandPilo tPlantTestingReplacementClarifier&

5 ThickenerDrivesPlantProcessAuditsRentalE quipmentTankageSupplyandErectionESECHPRO DUCTLINECARDMININGANDMETALLURGICALEQUIPM ENTB atemanFlotationCellsCarbonRetentionScree nsIn-tankNKMS creensClarifiersPinBedSolidsContactIncli nedPlateSettlersVerticalPressureFiltersH orizontalPressureFiltersFilterPressesAut omaticRecessedChamberSemi-automaticReces sedChamberLinearScreensMixingMixTecMixer sPermrollMagneticSeparatorsServicesLaban dPilotPlantTestingReplacementClarifier&T hickenerDrivesPlantProcessAuditsRentalEq uipmentTankageSupplyandErectionAnchorCha nnelTanksElevatedTanksSteelBottom atGradeThickenersTailingsConcentrateHiFl oHighRiseRateThickenerUltraSepUltraHighR ateThickenerCenterFeedorSideFeedRakeLift ingDevicesReplacementDrivesSludgeDewater ingPicketsPasteThickenersVacuumFiltersHo rizontalBeltFilterPrecoatDrumFilterDrumF iltersandDiscFilterswithScraperDischarge ,RollDischarge, :PrimaryClarifierIs it a @ Number: :1 year(seeattached)StartDate:ExpirationDat e:Prorated:**ENDOFSECTION**SCHEDULEW astewaterFacilityUpgradeProject049-007- NovatoSanitaryDistrictOperationandMainte nanceDataPage01730-4 JaALDO:A~~'~~3$J&I-~i:ProductQuickSearch I!

6 QNM35:'!~~.._ ( '~,~---l:lOverviewACMotorsIInverterDutyI Specifications:IDNM3542l:lSpecifications !ZlPerformanceData!ZlPartsListLJDrawings j}jProductLiteratureMoreInformation----. ~1f,..-----!ZlWhereToBuy!ZlBaldorSalesOf ficesIIReturntoListCatalogNumber:Specifi cationNumber:Horsepower:Voltage:Hertz:Ph ase:FullLoadAmps:Usableat208 Volts:RPM:FrameSize:ServiceFactor:Rating :LockedRotorCode:NEMAD esignCode:InsulationClass:FullLoadEffici ency:PowerFactor:Enclosure:BaldorType:DE Bearing:ODEB earing:ElectricalSpecificationNumber:Mec hanicalSpecificationNumber:Base: ~--*Forcertifiedinformation, !Jct!! !J!Vs/EventsIAboutBaldorIInvestorRelatio nsI! !doLEJectrif.;C:OillPi:lDyLsanel:jui:lJo ppot"tunityemp! :CO:R~ \i($,; RELJANGEI1 ProductQuickSearch,1!~~35~~",.JII! !ctOverview.!ctSpecificationsACMotorsIIn verterDutyIPerformanceData:IDNM3542.!ctP erformanceDataI11 PartsList(Note:Pleasedisableanybrowserpo pupblockers.).IilDrawingsIIIP roductLiteratureMoreInformation'--~--" ,IReturntoList(Typicalperformance-Notgua ranteedvalues)GeneralCharactersticsat460 V,60Hz, @25 CPull-UpTorque5 !))

7 !.N'-'=E""'MP!..!=L""-Oy'-'= :EO=W=N!.!=.!ED~C=O!!.!.!MP"""'--'AU-!Ny _OPERATIONANDMAINTENANCEMANUALRECOMMENDE DGREASEIGEARSANDDRIVEBEARINGSAMBIENT5 F to140 FTEMPERATURE(-15 Cto60 C) # # # # #2 CHEVRONDura-LithGreaseEP# #2 PENNZOILPen2 LubeRECOMMENDEDFOODGRADEGREASEIGEARS& DRIVEBEARINGSAMBIENT5 F to140 FTEMPERATURE(-15 Cto60 C) !.N.!..J,E:!.!!.M!!..!PL~O:..L!yE==E~O:. !!..!W.!.:!JNE==D~C~O!.!!!JMP!..!:A!.!.: !.Ny.!.. lightsprayoillikeWD-4 Oor F to 41 F32 F to95 F32 F to140 FTEMPERATURE(-10 C to5 C)(0 C to35 C)(0 C to60 C) Fto140 FTEMPERATURE(-10 Cto60 C) ' :it separatesmoreeasilyfromwater,hasa strongerboundarylayerresultinginbetterlu brication,andgenerallyhasa (aftertheinitial500hourrun-inperiod) HA'-"N"'-'E=M'-'-P=LO<..!-Y=EE=-:O=W.:.. :..;N=ED=-C=O=M'-'-PA'-"N-'-' (Fortorquevaluesofthefasteners,refertoth e'DriveAssemblyProcedures'drawing).Oilsa mplesshallbesenttoa (oilandgrease) oilisnoticeablydiscolored,it shouldbedrainedandfilteredthrougha (WD-40orequal) freezingoccursinsidethetorquebox, ,checkdailyforicebuild-uponandaroundthed rive/torquebox ,refertodrawing7-8222B1.

8 "\MAINTENANCEWESTEC H!l! !E=.!.!MC!.!:.PJ:l,LO:!..!.YE!EE=..\O !..W.!!.!.:N!.!:!ED!LC~O~MC!.!:.P!l!AN:! ..!Y-c----=-=---=--_OPERATIONANDMAINTENA NCEMANUALLUBRICATIONOFACCESSORYEQUIPMENT R educer(GreaseLubricated):All greaselubricatedreducersarepre-lubricate datthereducermanufacturer' ' 'LubricationTags' C HQ!AN.:!..!E=!.!!M.!LP~LO~Y.!=!EE=--lO~ !!=E-"!..D~CO~M~P~ANL!..!Y'------'-_OPER ATIONANDMAINTENANCEMANUALBREAK-INMAINTEN ANCEREQUIREMENTSINTERVALINITIALSDATED rainandFillOilCavity/Cavities(Beforeohou rsOperatinq)DrainandReplaceOil500hoursIP REVENTIVEMAINTENANCEIREQUIREMENTSG reaseCycloReducerMGreaseUpperBearingMGre aseMainBearingWOilMainGear/LowerBearingW DrainandReplaceMainGear/ ANNUALLY,S SEMIANNUALLY,M MONTHLY,W WEEKLY,D minimum, :896711310250T181N11410250TC7N11510250TC 9N142 FNQ-R-5146700-HR52TA17201 RPM32F7205 RPM22F7209 RPM12F7222E50AR1223E50KL220 PartsListNo:8989101103104105113RR-0002A1 14MS-0194A115MS-0289A1168R-0053A117RR-00 27A121121G112 COO123123G0278051248R-0001A127RR-0018A12 8RR-0003A415MS-0066A416MS-0182A441GA-000 5A445VA-OOOBA447445-116803-8450445-23080 5-8 LAMPFORPILOTLIGHT,120 VGLASSLENS,REDGLASSLENS,AM8 ERTIMEDELAYFUSE,5 AMPTIMINGRELAY,PINSTYLERELAY,3 POLE,PLUGIN,120 VACRELAY,2 POLE,PLUGIN,120 VACRELAY,SINGLEPOLE,PLUGIN,120 VACLIMITSWITCH,SPDTLIMITSWITCHACTUATORTO RQUECONTROLDEVICESPEEDREDUCER(INTERMEDIA TE)SPEEDREDUCER(PRIMARY)RAKEDRIVEMOTORRE TAININGRING33/4"EXTLOWERSEALUPPERSEALUPP ER8 EARINGRETAININGRING23/4"EXTPINIONSHAFTPI NIONGEAR,15 TPINIONGEAR(15T)PINION8 EARINGRETAININGRING53/4"INTRETAININGRING 31/2"EXTO-RINGSEAL(3/16 DIAMETERx 13'-0"LENGTH)DUSTSHIELD(1/4x1-1/2x13'-0" )(FOR406)OILLEVELSITEGAUGEDRAINVALVEPINI ONPORTCOVERGASKETINSPECTIONPORTCOVER/OIL FILLGASKETP leasecall, 'sreputationasa qualitymanufacturer,andbymanyyearsofexpe riencein ,Inc.

9 ,oncepaidforinfull,isbackedbythefollowin gwarranty:Forthebenefitoftheoriginaluser ,WesTechwarrantsallnewequipmentmanufactu redbyWesTechEngineering, ,andwillreplaceorrepair, ,anypartorpartsreturnedtoitwhichWesTech' sexaminationshallshowtohavefailedunderno rmaluseandservicebytheoriginaluserwithin one(1)yearfollowinginitialstart-up,oreig hteen(18)monthsfromshipmenttothepurchase r, , ,likethat~ ~ ,withrespecttowhich,repairorreplacements hallbesubjecttoapro-ratacha rgebaseduponWesTech' 'sobligationunderthiswarrantyiscondition eduponitsreceivingpromptnoticeofclaimedd efects,whichshallinnoeventbelaterthanthi rty(30)daysfollowingexpirationofthewarra ntyperiod,andis ,INCLUDINGWARRANTIESOFMERCHANTABILITYAND FITNESSFORPARTICULARPURPOSE,WHETHERWRITT EN,ORAL,EXPRESS,IMPLIED, ,CORROSION,ORANYCONTINGENT,INCIDENTAL, WesTechfactory,ordamagedbyimproperinstal lation,application,ormaintenance,orSUbje ctedtomisuse,abuse,neglect,accident,orin complete adherencetoallmanufacturer'srequirements ,including,butnotlimitedto, operations &Ma intenanceManualguidelines& , , ,accessories, , ,SaltLakeCity,UT84115QF-00-032E(801)265: -100008/18/05 CONTRACTNO.

10 :EQUIPMENTDESCRIPTION:WESTECHEQUIPMENTFI ELDINSPECTIONCERTIFICATIONMANUFACTURER:W esTechEngineeringInc., ,SaitLakeCity,Utah84115 Phone(801)265-1080 PROJECTNAME:--!. :.;o""--'-y-l-PS~.."..-'-'\ :/),O?:fi8 AIf)()IVIA(t)tz(R;,{L.,tl' 'SNAME:/ (Ifnotinitialed,indicatereasonsundercomm ents.) :--!/L-Methodof storage,sitestorageconditions,andinstall ationhandlingoftheequipmenthasnotadverse lyaffected/""" ,rusting, }JI/ ' ~ion:---- -Theequipmentitem(s)namedabovehasbeenins pected,checked, ,alignedandisfree ""O",p,'i,rot,lio,'0th,p'ope,directioo,. /c'wDCCWIA,,,;ewe''remmolO,''"'0""',)___ Equipmentinstallationisnotcompleteat thistime.(Indicateundercommentsallitemso f workthatmustbecompletedbeforeinitialoper ation.) :; ' :~II/I /Y}OilMfr/Grade:bte,0/t2 :___0 TestingperSpecificationSection:_oAccepte dbyOwnersAgent:_____Date:-f-Th'op,,,,lio oofth,""pm,o'""'"""''",','''"D,ct,.,"odi lio",h"b"o0"'''''''"','0myopioioo,/J/.. #-Electrical,torquealarmandcut-outswitch esoperateproperly.,"(ManualTestI21"Torqu eTest/(AttachTestRecord)oIf checked, , (Documentattendanceseparately)___Operati onwasnotobserved.


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