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Service Report

Inspection Report
Parts & Service
Revision : 01/2010

Customer : Tennamaram POM Service Engineer : Johairi Hussin


Location : Batang Berjuntai Job no : -
Contact : Mr. Mohd Nasir Date : 1 Dec 2010

Equipment:
PANX 934 S/n 5019073 R/H 01330/46

OBJECTIVE:

- To do inspection of decanter condition.


- To do inspection of pre-cleaner system (Westfalia, double stage system).

FINDING:

 Decanter

1. Checked machine vibration and bearing housing temperature

Sludge (after cleaning)


1. 14.2 mm/s Big - 66ºC
2. 15.8 mm/s
3. 14.5 mm/s Small - 59ºC
4. 14.3 mm/s

 Throughput 10 m³/h
 Main motor 55 A
 Damplate size 137/142

2. Decanter drum and conveyer


1. Remove all damplates and do manual cleaning.

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Service Report

Inspection Report
Parts & Service
Revision : 01/2010

2. Drum and scroll can turn smoothly.


3. No abnormal condition at drum.
4. All screws at hub, drum and housing still in good condition, no
replacement required.
5. Grease nipple still in good condition.

3. Inlet zone
1. Inlet tube in good condition.
2. Discharge bushing in good condition.

4. Gear box and back drive


1. Gear oil level and condition – OK.
2. GS Clutch ball bearing – OK.
3. Back drive ball bearing – OK.
4. Need new gear box cover.
5. No abnormal sound and vibration during operation.

5. Decanter frame
1. Decanter frame condition, clean.
2. Decanter cover need new gasket.
3. Liquid outlet funnel need new gasket
4. Vibration dampers still in good condition.
5. All screws still in good condition.

6. Belting (v-belt and tooth belt)


1. All belting tensioning – OK.
2. All belting still in good condition.

7. Flow meter and safety device


1. Flow meter still in good condition.
2. All safety device functioning (emergency, cover and overload switch).
3. Air supply 5 bar.
4. Manual flushing system.

8. Decanter panel
1. Panel in good condition. Need new tagging for all indicator lamp.
2. All indicator lamp and ammeter functioning.

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Inspection Report
Parts & Service
Revision : 01/2010

9. Oil loss result (from lab)

1. 26 Nov 2010 H/p 0.80 %


Cake 3.43 %

2. 27 Nov 2010 H/p 0.86 %


Cake 3.29 %

3. 29 Nov 2010 H/p 1.18 %


Cake 3.75 %

10. Sludge temp 90ºC

11. Underflow oil content

1. 26 Nov 2010 6.33 %


2. 29 Nov 2010 7.33 %
3. 30 Nov 2010 6.00 %

12. Recommendation
 To change new cover gasket to avoid oil leak during operation.
 To change new gasket for liquid outlet funnel.
 To change new gear box cover. The existing cover already in bad
condition
 To install new tagging at decanter panel.

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Inspection Report
Parts & Service
Revision : 01/2010

 To check due date for servicing (high vibration).

Maintenance for decanter (Recommendation).

1. Flushing
During start up when ampere reaches 50A, open hot water feed 5m³/h. EVERY 4
hours, we highly recommend mill to do MANUAL flushing, open hot water 10m³/h for
10 minutes.
During STOPPING, close sludge valve and open hot water 5m³/h until machine slow
down. Close water valve before motor stop to prevent water back pressure and pour
onto the electrical motor.

2. Greasing
Grease the main bearing every 150 hours. Qty 10 gram (10 strokes)
Grease the conveyor bearing every 300 hours. Qty 100 gram (67 strokes)
Type of grease SKF LGHF2

3. Check the motor V-belt (4 pcs) tension every 2000 hours (strongly recommended
to check every week). Please keep one set stock.

4. Check the 2.5 kNm gearbox flat belt tensioning every 2000 hours (strongly
recommended to check every week). Please keep one set stock.

5. Check the level of gear oil inside the 2.5 kNm gearbox every 3 month. We request the
mill 1 container (4 ltr) of gear oil in the store to top up.

6. Every 2 months, remove the grease from grease outlet at bearing housing. If you do
not remove this grease, your motor V-belt will snap and need replacement frequently.

7. Casing
Open the 10 screws on drum cover and check inside the casing for solid deposits
(every 300 hours). There is an opening at the big end side of casing that the liquid
can flow out into the light phase compartment. If this opening is block by solid

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Inspection Report
Parts & Service
Revision : 01/2010

deposits, the drum touches the liquid level and motor requires more power. The amp
will increase and motor might burn or V-belt snap.

8. Feed tube
Take off the V-belt guard at motor side and dismantle the feed tube. Before pulling out
the feed tube, please mark the position so that when you assemble the feed tube It is
in the same position as before. If there are worn out marks, the same worn out marks
place in the same position to avoid further damage to other rotation which may result
feed tubes broken into two pieces.

9. Safety switches
During start up or decanter STOP due to safety switches being activated, DO NOT
start decanter before the causes investigated.

 Overload switch
Once the light lid up at overload switch at control panel, open the gear box
cover. Try to rotate the drum by hand. If the drum is difficult to rotate, open
decanter cover. Rotate drum by hand and at the same time open hot water to
cleanup the sludge inside the drum (strongly recommended to pull out all dam
plates). You have to get rid of the sludge inside the drum until the drum is able
to be rotated with one hand.
Then close the decanter cover (do not put the gearbox cover yet) and start up
the decanter. Once decanter reaches maximum speed, open the hot water
valve.
 Thermistor
Motor operating at high temperature thus motor need to cool down at least 1
hour before start up again. Else motor burn.
 Thermal trip
Motor operating over its allowable maximum current. Reset push button on
overload relay below delta connector inside control panel (K2).
 Cover open
Push pin inside the slot.
 Remote emergency switch
Release emergency stop by pulling out the knob.

10. Solid conveyor


Some control panel incorporates this safety feature onto the control panel. If you do
not have, please do your own interlocking system.

11. Vibration

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Parts & Service
Revision : 01/2010

If decanter vibration is too high or strange sound please inform mill in charge (max
vibration 18 mm/s).

12. Decanter jammed


Call Alfa Laval and inform which side of decanter
Small end side (main motor side)
Big end side (gear box side)

Tel No : 03 5191 2300


Fax No : 03 5191 7051

Pre-cleaner system

 1st and 2nd stage

 Top and bottom actuator can activate.


 All actuator valve installed at the correct position.
 No leakage discovered at sludge pump, pipe and pre-cleaner unit.
 Installed with digital and conversional pressure gauge.
 Both pressure gauge chocked and not working.

 Recommendation

 To check all pressure gauge condition and make sure inlet pressure 3 bar
and outlet 1 bar.

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Parts & Service
Revision : 01/2010

Note:
The pre-cleaner used for the removal of fine sand and particles from sludge.
It is normally installed before decanter or separator to provide pre-treatment
and protect the equipment against excessive wear. There will definitely be
considerable savings in maintenance cost as a result of lower wear and tear
on the equipment. The most important requirement for efficient sand removal
in any desanding system is the pressure drop.

The recommended pressure for the pre-cleaner is:

Inlet pressure: 3 bars


Outlet pressure: 1 bars

The maximum inlet pressure should not exceed 4.5 bars. The separating
efficiency does not increase proportionally with high inlet pressure.

The timers setting also one of the most important things to pre-cleaner
system. Pre-cleaner must run with correct timers (discharge sequence) to
make sure sand cannot go through to decanter feed tank when the dirt
receiver full. Pre-cleaner cannot run with too short or too long discharge
interval. The timers will be set according to sand built up inside the dirt
receiver (see sight glass).

The others thing we need to take care is the pre-cleaner pump. A good pre-
cleaner pump must meet the following criteria

 Inlet pressure to the pre-cleaner of at least 3 bar corresponding to the


capacity and pumping head
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Parts & Service
Revision : 01/2010

 Impeller rotating at low speed to avoid excessive agitation to the


process medium
 Casing with hard material to withstand the wear and tear of the
application.

Existing Sludge Piping

VC tank Sludge
Tank

1st stage
precleaner

1st stage
Sludge tank

2nd stage precleaner


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Inspection Report
Parts & Service
Revision : 01/2010

To Decanter feed tank

Appendix 1

Decanter panel, new tagging for indicator lamp Flow meter ingood condition
and push button.

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Parts & Service
Revision : 01/2010

Need new cover gasket Defected cover gasket

Appendix 2

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Revision : 01/2010

Discharge bushing still in good condition Liquid outlet funnel

Bearing housing condition

Gear box and back drive

Appendix 3

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Parts & Service
Revision : 01/2010

Liquid outlet funnel gasket-OK V-belt condition

Digital and normal pressure gauge No pressure reading (inlet/outlet)

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