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KSP Poppet Manual
2011
FACTORY TRAINING
Schwing BiosetParts and Service
(715) 247-3433
OR
Fax (715) 247-3438
Paul Katka - Parts/Service Manager
Dave Larson - Quality Control Specialist
Service TechniciansChris KohnenJack Koehler
Jeff JoyJohn Christenson
Mike Smith
PartsBrad Dopp
Larry LarsonZach Anderson
TABLE OF CONTENTS
KSP Poppet Training Manual i
SECTION 1 GENERAL
1.1 PURPOSE OF THIS MANUAL ..................................................................................1 - 1
1.2 DESCRIPTION OF EQUIPMENT ..............................................................................1 - 1
1.2.1 General Description ....................................................................................1 - 11.2.2 Sludge Pump With Poppet Valves..............................................................1 - 81.2.3 Sludge Flow Measuring System (SFMS) - Poppet Valve KSP ................1 - 101.2.4 Screw Feeder .............................................................................................1 - 121.2.5 Hydraulic Power Pack.................................................................................1 - 131.2.6 Material Pipeline .........................................................................................1 - 211.2.7 Sliding Frame Silos.....................................................................................1 - 221.2.8 Push Floor ..................................................................................................1 - 231.2.9 Pipeline Lubrication System .......................................................................1 - 241.2.10 Automatic Greaser System.........................................................................1 - 25
1.3 INSTALLED EQUIPMENT LIST ................................................................................1 - 26
1.3.1 General With Data Sheets ..........................................................................1 - 261.3.2 Sliding Frame Receiving Bin.......................................................................1 - 261.3.3 Receiving Bin Conveyor .............................................................................1 - 261.3.4 Sludge Pump - KSP 140 (HD)XL................................................................1 - 271.3.5 Screw Feeder - SD 500 HD........................................................................1 - 271.3.6 Agitator Hopper - MODEL HHH..................................................................1 - 271.3.7 Hydraulic Power Pack - MODEL 2000, 200/150 HP...................................1 - 271.3.8 Agitator Hopper - MODEL HHH..................................................................1 - 281.3.9 Hydraulic Power Pack - MODEL 230, 40 HP..............................................1 - 281.3.10 Pipeline Lubrication System .......................................................................1 - 281.3.11 Automatic Greaser System.........................................................................1 - 28
1.4 SAFETY REGULATIONS ..........................................................................................1 - 29
SECTION 2 SAFETY REGULATIONS
2.1 SAFETY REGULATIONS ..........................................................................................2 - 1
2.2 SAFETY DURING INSTALLATION ...........................................................................2 - 2
2.3 SAFETY PRECAUTIONS - STARTUP ......................................................................2 - 3
2.4 SAFETY INSTRUCTIONS - ADJUSTMENTS AND CHECKS ...................................2 - 4
2.5 SAFETY DURING MAINTENANCE ...........................................................................2 - 4
SECTION 3 HYDRAULICS
3.1 RULES OF HYDRAULICS .........................................................................................3 - 1
3.2 HYDRAULIC PUMPS ................................................................................................3 - 8
TABLE OF CONTENTS
ii KSP Poppet Training Manual
3.3 VALVES .....................................................................................................................3 - 12
3.3.1 Control Valves ............................................................................................ 3 - 123.3.2 Relief Valves............................................................................................... 3 - 123.3.3 The Basic Relief Valve ............................................................................... 3 - 14
3.4 HYDRAULIC SYMBOLS ............................................................................................ 3 - 16
SECTION 4 OPERATION
4.1 BEFORE OPERATING SLUDGE PUMPS IN ANY MODE - POPPET ...................... 4 - 1
4.2 NOTES - POPPET ..................................................................................................... 4 - 2
4.3 PREVENTIVE MAINTENANCE NOTES - POPPET .................................................. 4 - 2
4.4 PRE-START-UP CHECKS ........................................................................................ 4 - 4
4.4.1 Sludge Pump .............................................................................................. 4 - 54.4.2 Screw Feeder ............................................................................................. 4 - 64.4.3 Hydraulic Power Pack ................................................................................ 4 - 74.4.4 Material Pipeline ......................................................................................... 4 - 84.4.5 Push Floor/Sliding Frames ......................................................................... 4 - 94.4.6 Pipeline Lubrication .................................................................................... 4 - 10
4.5 START-UP PROCEDURE ......................................................................................... 4 - 11
4.5.1 General With Safety Precautions - Start-up................................................ 4 - 114.5.2 Starting and Stopping ................................................................................. 4 - 114.5.3 Emergency Stop ......................................................................................... 4 - 13
4.6 MATERIAL PUMP OPERATION ............................................................................... 4 - 14
4.6.1 The Control Panel....................................................................................... 4 - 144.6.2 SFMS and Transition Pressure Setpoint Selection..................................... 4 - 154.6.3 Screw Feeder Modes ................................................................................. 4 - 164.6.4 Mode Selection........................................................................................... 4 - 164.6.5 HMI Screens............................................................................................... 4 - 18
4.7 LUBRICATION SYSTEM OPERATION ..................................................................... 4 - 25
4.7.1 Mode Selection........................................................................................... 4 - 25
4.8 MATERIAL PUMP AND SCREW FEEDER ALARM CONDITIONS........................... 4 - 26
4.9 LUBRICATION SYSTEM ALARM CONDITIONS ...................................................... 4 - 28
4.10 ADJUSTMENTS AND CHECKS DURING OPERATION .......................................... 4 - 29
4.10.1 Safety Instructions - Adjustments & Checks............................................... 4 - 294.10.2 Sludge Pump Output Adjustment - Electric ................................................ 4 - 294.10.3 Sludge Pump Output Adjustment - Manual Handwheel ............................. 4 - 304.10.4 Screw Feeder Output Adjustment - Electric................................................ 4 - 304.10.5 Screw Feeder Output Adjustment - Manual Handwheel............................. 4 - 314.10.6 Hydraulic System Checks - Rock Valve ..................................................... 4 - 324.10.7 Hydraulic System Checks/Adjust. - Poppet Valve ...................................... 4 - 324.10.8 Mechanical Checks .................................................................................... 4 - 324.10.9 Other Controls and Instruments ................................................................. 4 - 32
TABLE OF CONTENTS
KSP Poppet Training Manual iii
4.11 SHUTDOWN PROCEDURE ......................................................................................4 - 33
4.11.1 Shutdown For General Maintenance ..........................................................4 - 334.11.2 Short-Term Shutdown.................................................................................4 - 354.11.3 Long Term Shutdown .................................................................................4 - 354.11.4 Long-Term Storage.....................................................................................4 - 364.7.5 EMERGENCY STOP..................................................................................4 - 37
SECTION 5 PLANNED MAINTENANCE
5.1 SAFETY DURING MAINTENANCE ...........................................................................5 - 1
5.2 PERIODIC MAINTENANCE SCHEDULE ..................................................................5 - 3
5.2.1 General Maintenance .................................................................................5 - 75.2.2 Hydraulic power pack .................................................................................5 - 105.2.3 Push Floor Silo ...........................................................................................5 - 185.2.4 Screw Feeder .............................................................................................5 - 215.2.5 Material Pump.............................................................................................5 - 265.2.5 Pipeline Lubrication System .......................................................................5 - 33
5.3 LUBRICANT RECOMMENDATIONS .........................................................................5 - 35
5.3.1 Hydraulic oil recommendations (hydraulic power pack) .............................5 - 365.3.2 Gear-lubricant recommendations ...............................................................5 - 375.3.3 Grease recommendations ..........................................................................5 - 37
5.4 TROUBLESHOOTING ...............................................................................................5 - 38
5.4.1 Hydraulic Power Pack.................................................................................5 - 385.4.2 Push Floor Silo ...........................................................................................5 - 405.4.3 Screw Feeder .............................................................................................5 - 41
5.5 BOLT TORQUE TABLES ...........................................................................................5 - 45
5.5.1 Metric: normal threads ................................................................................5 - 455.5.2 Metric: fine threads .....................................................................................5 - 46
SECTION 6 SPECIAL MAINTENANCESERVICE AND REPAIR INSTRUCTIONS
6.1 SAFETY DURING MAINTENANCE (From you O&M Manual) ...................................6 - 2
6.2 MAINTAINING HYDRAULIC SYSTEM PRESSURES................................................6 - 3
6.3 SCREW FEEDER.......................................................................................................6 - 4
6.3.1 Auger replacement .....................................................................................6 - 4
6.4 MATERIAL PUMP.......................................................................................................6 - 6
6.4.1 Replacing piston heads ..............................................................................6 - 66.4.2 Replacing poppet valves.............................................................................6 - 14
TABLE OF CONTENTS
iv KSP Poppet Training Manual
SECTION 7 INSPECTIONS & CALIBRATIONS
7.1 SLUDGE FLOW MEASURING SYSTEM (SFMS) SET-UP .................................... 4
7.1.1 Overview of the SFMS and the Schwing Pump ....................................... 47.1.2 SFMS Calculations .................................................................................. 77.1.3 Throttle Valve Adjustment .......................................................................... 87.1.4 Throttle Check Valve Adjustment ............................................................... 97.1.5 Proximity Switch Set-up.............................................................................. 107.1.6 SFMS Functional Test #1 -KSP ............................................................... 127.1.7 SFMS Functional Test #2 - EKSP............................................................ 127.1.8 SFMS Calibration.....................................................................................137.1.9 Testing and Calibration of SFMS ............................................................. 14
SECTION 8 KSP COMPONENTS
8.1 SCREW FEEDER COMPONENTS ........................................................................... 8 - 1
8.1.1 Screw Feeder Gear Box ............................................................................. 8 - 2
8.2 SCREW FEEDER SHAFT TIMING ............................................................................ 8 - 8
8.3 SLUDGE PUMP COMPONENTS .............................................................................. 8 - 27
SECTION 9 HYDRAULIC OIL & FILTERS
9.1 RESERVOIRS ........................................................................................................... 9 - 1
9.2 HYDRAULIC OILS AND LUBRICANTS ..................................................................... 9 - 1
9.3 FLUID CONTAMINATION AND CONTROL .............................................................. 9 - 3
9.3.1 Handling, Storing, and Dispensing of Lubricating Fluids ............................ 9 - 4
9.4 FILTERS ....................................................................................................................9 - 6
9.5 TECHNICAL INFORMATION - FILTRATION RATINGS ...........................................9 - 6
9.5.1 Nominal Filtration Ratings .......................................................................... 9 - 69.5.2 Absolute Filtration Ratings.......................................................................... 9 - 69.5.3 Beta Filtration Ratio (bn)............................................................................. 9 - 69.5.4 Filter Facts.................................................................................................. 9 - 79.5.5 Technical Information - Beta Ratings ......................................................... 9 - 8
9.6 SCHWING BIOSET FILTERS ................................................................................... 9 - 9
9.6.1 KSP Return Filter........................................................................................ 9 - 99.6.2 Conditioning Loop Filter.............................................................................. 9 - 11
9.7 HYDRAULIC PUMPS ................................................................................................ 9 - 12
9.8 REXROTH VT 2000 AMPLIFIER CARD .................................................................... 9 - 18
9.8.1 Functional Description of the Rexroth VT2000 Amplifier Card ................... 9 - 18
9.9 PRESSURE SWITCHES ........................................................................................... 9 - 21
9.9.1 How To Set Pressure Switches .................................................................. 9 - 21
TABLE OF CONTENTS
KSP Poppet Training Manual v
9.9.2 Switch Adjustments ....................................................................................9 - 269.9.3 Temperature Switch Adjustment.................................................................9 - 299.9.4 Combination Level and Temperature Switch..............................................9 - 319.9.5 Dirty Oil Filter Switch ..................................................................................9 - 32
9.10 TYPES OF HEAT EXCHANGERS ............................................................................9 - 35
9.11 HYDRAULIC SCHEMATIC SERIES - KSP POPPET ................................................9 - 38
9.11.1 KSP Poppet Valve - Series #1....................................................................9 - 389.11.2 KSP Poppet Valve - Series #2....................................................................9 - 409.11.3 KSP Poppet Valve - Series #3....................................................................9 - 429.11.4 KSP Poppet Valve - Series #4....................................................................9 - 449.11.5 KSP Poppet Valve - Series #5....................................................................9 - 469.11.6 KSP Poppet Valve - Series #6....................................................................9 - 489.11.7 KSP Poppet Valve - Series #7....................................................................9 - 50
9.12 UNIT IS IN REVERSE ...............................................................................................9 - 52
9.12.1 KSP Poppet Valve - Series #8....................................................................9 - 52
9.13 EXCESS ROCKING OIL CONDITION .......................................................................9 - 54
9.13.1 KSP Poppet Valve - Series #9....................................................................9 - 54
9.14 ADDING ROCKING OIL CONDITION .......................................................................9 - 56
9.14.1 KSP Poppet Valve - Series #10..................................................................9 - 56
SECTION 10 SPECIAL TOOLS
10.1 HYDRAULIC TROUBLE SHOOTING KITS ...............................................................10 - 1
10.2 FLOW METERS AND ACCESSORIES .....................................................................10 - 2
10.3 MATERIAL CYLINDER ALIGNMENT TOOLS ...........................................................10 - 3
10.4 PISTON INSTALLATION TOOLS ..............................................................................10 - 4
10.5 ROD GLAND PACKING INSTALLATION TOOLS .....................................................10 - 5
10.6 RAM TOOLS ..............................................................................................................10 - 6
10.7 TORQUE SPECIFICATIONS FOR METERIC BOLTS AND SCREWS USED ON SCHWING EQUIPMENT ..........................................................................10 - 7
10.6.1 Dacromet 500 Screws and Nuts DIN 912, 931, 933, 934 (Hexagon, Machine Screws, and Hexagon Nuts).......................................10 - 8
10.6.2 Dacromet 500 Screws and Nuts DIN 6914, 6915 (HV Screws)..................10 - 1010.6.3 Black Screws and Nuts DIN 912, 931, 933, 934
(Hexagon, Machine Screws, and Hexagon Nuts).......................................10 - 11
10.8 CONVERSION CHART .............................................................................................10 - 13
10.9 FLUID POWER FORMULAS .....................................................................................10 - 16
10.10 DRILL SIZES FOR METRIC TAPS ............................................................................10 - 18
TABLE OF CONTENTS
vi KSP Poppet Training Manual
GENERAL SECTION 1
KSP Training Manual 1 - 1
SECTION 1 GENERAL
1.1 PURPOSE OF THIS MANUAL
This manual is designed to assist you in the Installation, Operation, and Maintenance of your custom designed Schwing Bioset Sludge Pump system. It describes storage, installation, start-up, normal operation, shut-down, periodic maintenance, and trouble shooting procedures. It also contains detailed layout drawings, hydraulic schematics, electrical schematics, and parts book drawings. The installers, operators, maintenance personnel, and everyone involved with these systems should study this manual carefully. We hope that it can help in your ongoing training and maintenance program.
1.2 DESCRIPTION OF EQUIPMENT
1.2.1 General Description
A specially sized and configured Sludge Pump System supplied by Schwing Bioset consists of one or more sets of the following equipment:
Hydraulically Driven Piston Pump
Screw Feeder/Agitator Hopper.
Hydraulic Power Pack, to power the pump and screw feeder/agitator hopper.
Special Feed hoppers or Hopper Adapters.
Material Pipeline, steel with pressure tight seals. (OPTIONAL)
Control Systems
Sliding Frames
Push Floors
Pipeline Lubrication System
They are described further in the following paragraphs and detailed specifications for the installed equipment in your O&M manual.
The system is custom designed to pump dewatered sludges or slurries through pressurized steel pipelines to dryers, incinerators, or distribution systems. The electric motor of the Hydraulic Power Pack drives hydraulic pumps that drive the cylinders of the Sludge Pump and the hydraulic motors of the Screw Feeder or Hopper Agitator.
Custom controls, monitors and sensors are installed to specifications to provide automatic, dependable operation.
SECTION 1 GENERAL
1 - 2 KSP Training Manual
Figure 1.1 - Typical KSP Installation #1 (A10V Hydraulic Pumps)
39000001
GENERAL SECTION 1
KSP Training Manual 1 - 3
Figure 1.2 - Typical KSP Installation #2 (A11VO Hydraulic Pumps)
SECTION 1 GENERAL
1 - 4 KSP Training Manual
Figure 1.3 - Typical KSP Installation #3
39000002
GENERAL SECTION 1
KSP Training Manual 1 - 5
Figure 1.4 - Typical KSP Installation #4
39000003
SECTION 1 GENERAL
1 - 6 KSP Training Manual
Figure 1.5 - Typical KSP Installation #5
39000004
GENERAL SECTION 1
KSP Training Manual 1 - 7
Figure 1.6 - Typical KSP Installation #6
FILTER
ELECTRIC MOTOR/PUMP ASSY.
DIRECTIONAL VALVE
PUSH FRAME/SLIDE GATE CYLINDER
PRESSURE SWITCH
39000237
SECTION 1 GENERAL
1 - 8 KSP Training Manual
1.2.2 Sludge Pump With Poppet Valves
The sludge pump is designated with a "KSP" prefix and a size designation of 5, 10, 12, 17, 25, 40, 45, 50, 80, 140 or 220. It is a hydraulically driven, positive displacement, twin-cylinder reciprocating piston pump. The material cylinders are in line with the differential hydraulic cylinders that power the material piston head (ram) in suction and pressure strokes.Separating the material cylinders from the differential cylinders is a fluid filled chamber called the Water Box". The fluid cools and lubricates the material ram as it moves in the material cylinder. The fluid also rinses and cools the differential cylinder rod as it passes through the water box. The chamber also provides access for checking pump wear and for changing the material piston head (ram).
Figure 1.7 - Sludge Pump With Poppet Valves
In operation the two cylinders move in opposite directions so that one cylinder is charged with material from the feed system while the other cylinder is pushing material into the pipeline.
Flow of the material into and out of the cylinders is controlled by four (4) hydraulically actuated poppet valves, one discharge and one intake valve for each cylinder. They are activated in the following sequence:
1. The pumping pistons come to the end of their stroke, that is, one fully extend-ed and one fully retracted. The hydraulic valve drive is activated and the open discharge poppet closes, and suction poppets change state respectively.
2. Both discharge poppets are now closed. Hydraulic pressure increases and the pistons start to operate in the opposite directions, one charging and one discharging. As the discharging piston moves forward, the sludge is com-pressed in the delivery cylinder.
3. At the moment when the compressed sludge in the discharging cylinder equals the pressure of the compressed sludge in the delivery line, the dis-charge poppet opens and material flows into the pipeline.
Since the poppet valve for the discharging cylinder opens only when the cylinder contents are at the same pressure as the pipeline, no material can flow back into the pump. This minimizes shocks in the pipeline.
MATERIAL PISTON (RAM) MATERIAL CYLINDER
WATER BOX
DIFFERENTIAL HYDRAULIC CYLINDERS
POPPET VALVE CONTROL HOUSING
INTAKE PORT
DISCHARGE PORT
39000007
GENERAL SECTION 1
KSP Training Manual 1 - 9
Figure 1.8 - Sludge Pump With Poppet Valve Cut-A-Way
MA
TER
IAL
PIST
ON
RA
MTR
AN
SITI
ON
PIEC
ESW
ITC
HIN
GVA
LVE
SWIT
CH
ING
VALV
EST
EEL
RO
D
DIF
FER
ENTI
AL
CYL
IND
ER
HYD
RA
ULI
CPI
STO
NH
EAD
CH
ECK
VALV
E(A
DD
RO
CK
ING
OIL
)
CH
ECK
VALV
E(S
UB
TRA
CT
RO
CK
ING
OIL
)
WA
TER
BO
X
DR
AIN
MA
TER
IAL
CYL
IND
ER,
INSI
DE
CH
RO
MED
TO.0
10"
THIC
K(.2
5MM
)
OU
TBO
AR
DB
EAR
ING
TRA
NSI
TIO
NPI
ECE
SUPP
OR
TFR
AM
EPA
CK
ING
GLA
ND
GEA
RB
OX
SIG
HT
GA
UG
E
HYD
RA
ULI
CD
RIV
EM
OTO
RG
EAR
BO
XFI
LLPL
UG
DO
UB
LESC
REW
PRES
SUR
E VA
LVE
PRES
SUR
E VA
LVE
PRES
SUR
E VA
LVE
SUC
TIO
N
DIS
CH
AR
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POPP
ET
CYL
IND
ER
SEA
L (S
EAT)
DIS
C
LIN
E
HO
USI
NG
POPP
ET
39000008
SECTION 1 GENERAL
1 - 10 KSP Training Manual
1.2.3 Sludge Flow Measuring System (SFMS) - Poppet Valve KSP
Schwing Biosets Sludge Flow Measuring System, installed on a Poppet Valve Sludge Pump, monitors the pumping cycle time and calculates pump output. It compensates for pumping (filling) efficiency and relays the flow rate to control equipment or system monitors.
The Sludge Flow Measuring System consists of two magnetic proximity sensors, two ring magnets mounted on the pressure poppet valve pistons, and special programming within the PLC that controls the Sludge Pump. The sensors are mounted on the sides of the valve cylinders to sense the closed position of the poppet valves. The poppet is closed when the piston is at the limit of its extended travel. See Fig. 1.10 below.
Figure 1.9 - Pressure Poppet With SFMS Sensor
Schwing Biosets Sludge Pumps are designed such that at the end of each stroke both pressure poppet valves are closed. During the next stroke one of the poppets stays closed and one of the poppets opens to allow flow to the pipeline (discharge). Opening of this poppet is delayed until the material is compressed and the pumping cylinder pressure is the same as that of the pipeline. The end of the stroke is signaled when both poppets are again closed.
By timing the full stroke and the compression phase of the stroke, the PLC is able to determine pumping efficiency, flow (in gallons per stroke, gallons per hour, etc.) and limited totalizing.
EXTENDRETRACT
MAGNETICPROXIMITY
SENSOR
POPPET VALVE(Closed Position)
RINGMAGNET
PRESSURE POPPETVALVE HOUSING
PISTON
VALVECYLINDER
39000009
GENERAL SECTION 1
KSP Training Manual 1 - 11
PLC Calculation
Referring to the table below, the Cycle Time for one stroke is T1. The Compression Phase is the time between both poppets closed and one of the poppets opening.
Pumping Time T2 is equal to T1 minus the compression time.
Pump Efficiency is Pumping Time divided by Cycle Time.
Flow Rate is Material Cylinder Volume times Efficiency divided by Cycle Time.
Figure 1.10 - Cycle Time Table (SFMS)
See Appendix A for parts (Pressure Poppet Valve), and section 5.4 for adjustment procedure.
T2 = T1 - COMPRESSION
EFF T2T1
=
FLOW VOLUME X EFFT1
= F ( )
T2Compression
T1
Time
BOTHPOPPETSCLOSED
BOTHPOPPETSCLOSED
DISCHARGEPOPPETOPENS
Pumping Time
Cycle Time
39000010
SECTION 1 GENERAL
1 - 12 KSP Training Manual
1.2.4 Screw Feeder
The Screw Feeder increases pump efficiency by pressurizing the material feed into the pump suction. It consists of a feed trough with twin rotating augers that receive material from a feed hopper and convey it through a transition housing to the intake of the Sludge Pump.
The augers (or screws), are driven by a gear box with a hydraulic motor driven by the Power Pack.
Figure 1.11 - Screw Feeder
Control Housing (Poppet Valve)
Discharge End
External Screw Auger Bearings for Hopper
Openings Greater Than 35 in (900 mm) Screw Feeder Intake
Opening
Double Screw Feeder
Augers
HydraulicMotor
Control Block w/Forward-Reverse
Lever Operated Valve
Water Box
39000011
GENERAL SECTION 1
KSP Training Manual 1 - 13
1.2.5 Hydraulic Power Pack
The Hydraulic Power Pack drives the Sludge Pump and its hydraulic control systems and auxiliary equipment such as a Screw Feeder or the Agitator Hopper augers. The power pack consists of an oil reservoir and steel frame with lifting eyes. The electric motor, hydraulic pump, flow control valves, and electric control enclosures are mounted on the power pack.
Additional equipment and configurations vary with each installation and may include oil coolers, auxiliary hydraulic pumps, special valves or control instruments, sound covers, etc. Please see your O&M manual for details on the unit installed for this project.
Figure 1.12 - Hydraulic Power Pack (A2 Hydraulic Pumps)
HYDRAULIC PUMPFOR SLUDGE PUMP
HYDRAULIC PUMPFOR SCREW FEEDER
RETURN LINE FILTER WITH INDICATOR SWITCH
MOTOR COUPLING ANDV-BELT DRIVE FOR AUX. PUMP
VALVE FORLEVER OPERATED SCREW FEEDER
W/ FORWARD-REVERSE VALVEW/ ADJUSTABLE RELIEF VALVE
ELECTRICMOTOR
VALVE FOR SLUDGE PUMPW/ ADJUSTABLE RELIEF VALVE
& SOLENOID FOR LEVER CONTROLLED BYPASS VALVE.
PRESSUREGAUGES
CLEAN-OUTCOVER
LIFTINGEYES
OIL TANKDRAIN
OIL LEVELSWITCH
FILLER CAP
HIGHPRESSURE
SWITCH
HIGHTEMPERATURE
SWITCH
ELECTRIC CONTROLS,LOCAL OR REMOTE LOCATED
39000013
SECTION 1 GENERAL
1 - 14 KSP Training Manual
Figure 1.13 - Hydraulic Power Pack (A10V Hydraulic Pumps)
HYDRAULIC PUMPFOR SLUDGE PUMP
HYDRAULIC PUMPFOR SCREW FEEDER
LEVER OPERATEDW/ FORWARD-REVERSE VALVEW/ ADJUSTABLE RELIEF VALVE
ELECTRICMOTOR
PRESSUREGAUGES
CLEAN-OUTCOVER LIFTING
EYES
OIL LEVELAND TEMPERATURE
SWITCH
FILLER CAP
OIL COOLER
SOLENOID OPERATEDLOAD BY-PASS VALVE
FOR SLUDGE PUMPW/ ADJUSTABLE RELIEF VALVE
HIGHPRESSURE
SWITCH
HIGHTEMPERATURE
SWITCH
RETURN LINEFILTER WITH
INDICATOR SWITCH
CIRCULATIONLOOPFILTER
HYDRAULIC PUMPFOR CIRCULATION LOOP
OIL TANKDRAIN
ELECTRIC CONTROLS,LOCAL OR REMOTE LOCATED
39000014
GENERAL SECTION 1
KSP Training Manual 1 - 15
Figure 1.14 - Electric Power Pack, Side View (A2 Hydraulic Pumps)
OIL
COOL
ER
LIFTI
NG EY
ES(FO
R LIFT
ING DE
-VI
CES P
ROVI
DED)
LOW
OIL
LEVE
LSW
ITCH
CLEA
N OU
TCO
VERS
HYDR
AULIC
RESE
RVIO
RSIG
HT G
AUGE
AND
THER
MOM
ETER
DIRT
Y OI
L FILT
ERPR
ESSU
RESW
ITCH
RETU
RN FI
LTER
FOR H
YDRA
ULIC
OIL
ELEC
TRIC
AL C
ONTR
OLPA
NEL
SCRE
W C
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YOR
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SURE
RELIE
F VAL
VE
SCRE
W C
ONVE
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CONT
ROL V
ALVE
(FORW
ARD,
NEUT
RAL,
REVE
RSE)
LIMIT
SWITC
H AN
DPO
TENT
IOM
ETER
FOR H
YDRA
ULIC
PUM
PSSC
REW
CON
VEYO
RPR
ESSU
RE SW
ITCH
HIGH
OIL
PRES
SURE
SWITC
H
TEM
PERA
TURE
SWITC
H
SLUD
GE PU
MP R
ELIEF
VALV
E
SLUD
GE PU
MP
BY-P
ASS
VALV
E
SOLE
NIOD
VAL
VE(W
ITH M
ANUA
LOV
ER-R
IDE)
PRES
SURE
GAUG
E SHU
T-OF
FVA
LVE
SLUD
GE P
UMP
PRES
SURE
GAUG
E
SCRE
W C
ONVE
YOR
PRES
SURE
GAU
GE
39000015
SECTION 1 GENERAL
1 - 16 KSP Training Manual
Figure 1.15 - Electric Power Pack, Top View (A2 Hydraulic Pumps)
VEE-
BELT
DRIV
E
ROTE
XCO
UPLIN
G
VEE-
BELT
(MAT
CHED
SET)
SCRE
W C
ONVE
YOR
HYDR
AULIC
PUM
PM
ECHA
NICA
L ADJ
USTM
ENT
FOR F
LOW
OF H
YDUA
LIC PU
MP H
YDRA
ULIC
PUM
P FOR
SLUD
GE PU
MP
480 V
AC, 3
PHAS
E #2 M
OTOR
(ADJU
STS H
YDRA
ULIC
FLOW
FOR
SLUD
GE PU
MP)
480 V
AC, 3
PHAS
E #3 E
LECT
RIC
MOT
OR(AD
JUST
S HYD
RAUL
IC PU
MP FL
OWFO
R SCR
EW C
ONVE
YOR)
#1 M
OTOR
480 V
AC, 3
PHAS
E
39000016
GENERAL SECTION 1
KSP Training Manual 1 - 17
Figure 1.16 - Electric Power Pack, Side View (A10VO Hydraulic Pumps)
LIFTI
NG EY
ES(FO
R LIFT
ING DE
-VI
CES P
ROVI
DED)
LOW
OIL
LEVE
LSW
ITCH
CLEA
N OU
TCO
VER &
FILL
ER C
AP
HYDR
AULIC
RESE
RVIO
RSIG
HT G
AUGE
AND
THER
MOM
ETER
RETU
RN FI
LTER
FOR H
YDRA
ULIC
OIL
ELEC
TRIC
AL C
ONTR
OLPA
NEL
SCRE
W C
ONVE
YOR
PRES
SURE
RELIE
F VAL
VE
ELEC
TRIC
MOT
OR
SCRE
W C
ONVE
YOR
CONT
ROL V
ALVE
(FORW
ARD,
NEUT
RAL,
REVE
RSE)CO
NDITI
ONIN
GLO
OP FI
LTER
HIGH
OIL
PRES
SURE
SLUD
GE PU
MP
SLUD
GE P
UMP
PRES
SURE
GAUG
E
SCRE
W C
ONVE
YOR
PRES
SURE
GAU
GE
39000240
SECTION 1 GENERAL
1 - 18 KSP Training Manual
Figure 1.17 - Electric Power Pack, Top View (A10VO Hydraulic Pumps)
SCRE
W C
ONVE
YOR
HYDR
AULIC
PUM
P AA1
0VSO
28EL
COND
ITION
ING
LOOP
PUM
P
FORW
ARD/
REVE
RSE V
ALVE
FOR S
CREW
FEED
ER H
AND
LEVE
R CO
NTRO
LLED
W/ A
DJ.
RELIE
F VAL
VEBY
PASS
/LOA
D VA
LVE
FOR S
LUDG
E PUM
PSO
LENO
ID C
ONTR
OLLE
DW
/ ADJ
. REL
IEF V
ALVE
BALL
VAL
VE 1
"NPT
COOL
ER W
ATER
DRA
INBA
LL V
ALVE
1"N
PTCO
OLER
WAT
ER SU
PPLY
WAT
ER-O
IL CO
OLERHY
DRAU
LIC PU
MP A
A10V
SO FO
R SLU
DGE P
UMP
MILL
TRON
ICS U
NIT
39000241
GENERAL SECTION 1
KSP Training Manual 1 - 19
Figure 1.18 - Electric Power Pack, Side View (A11VO Hydraulic Pumps)
LIFTI
NG EY
ES(FO
R LIFT
ING DE
-VI
CES P
ROVI
DED)
LOW
OIL
LEVE
LSW
ITCH
CLEA
N OU
TCO
VER &
FILL
ER C
AP HYD
RAUL
IC RE
SERV
IOR
SIGHT
GAU
GE A
NDTH
ERM
OMET
ER
RETU
RN FI
LTER
FOR H
YDRA
ULIC
OIL
DIRT
Y OI
LFI
LTER
SWITC
H
SCRE
W C
ONVE
YOR
PRES
SURE
RELIE
F VAL
VERO
TEX
COUP
LING
DRAI
NSC
REW
CON
VEYO
RCO
NTRO
L VAL
VE(FO
RWAR
D, NE
UTRA
L,RE
VERS
E)PRES
SURE
GAUG
E SHU
T-OF
FVA
LVE
SLUD
GE P
UMP
PRES
SURE
GAUG
E
SCRE
W C
ONVE
YOR
PRES
SURE
GAU
GE
COND
ITION
ING
LOOP
FILT
ER
HIGH
OIL
PRES
SURE
SLUD
GE PU
MP
ELEC
TRIC
AL C
ONTR
OLPA
NEL
ELEC
TRIC
MOT
OR
39000238
SECTION 1 GENERAL
1 - 20 KSP Training Manual
Figure 1.19 - Electric Power Pack, Top View (A11VO Hydraulic Pumps)
HYDR
AULIC
PUM
PA1
1VO1
30EP
2DHY
DRAU
LIC PU
MP
A11V
O60E
P2D
HYDR
AULIC
PUM
PV2
0101
F8
HYDR
AULIC
CON
TROL
BLOC
K W/L
EVER
BYPA
SS V
ALVE
BALL
VAL
VE 1
"NPT
COOL
ER W
ATER
DRA
INBA
LL V
ALVE
1"N
PTCO
OLER
WAT
ER SU
PPLY
WAT
ER-O
IL CO
OLER
39000239
GENERAL SECTION 1
KSP Training Manual 1 - 21
1.2.6 Material Pipeline
The pipeline used to convey the sludge from the pump to its destination may be supplied by Schwing Bioset or others. Generally it is pressure-tight steel pipe with bolted couplings. See Sludge Pump Installation drawing in your O&M manual for size and configuration of the discharge pipeline. Pump connection to the material pipeline must allow for safe disconnection from the pipeline to allow service of internal pump parts.
Figure 1.20 - Recommended Pipeline Connection
Pipeline
ANSI Flange
In-line Fully PortedShut-off Valve
1/2" Dutchman
Spool Piece
2" Fully PortedBleed Valve SchwingTwo Bolt
Clamp SchwingSludge Pump
Discharge
39000017
SECTION 1 GENERAL
1 - 22 KSP Training Manual
1.2.7 Sliding Frame Silos
The Sliding Frame is a bridge-breaker; when in operation it ensures mass movement of material through the silo and into the receiving conveyor or pump.
The Sliding Frame, which is inside the silo, is attached to the Extension Shafts which pass through the wall of the silo and attach to the cylinders which are on the outside. The silo wall openings are effectively sealed by means of the Stuffing Bpx seals on the Extension Shafts.
Figure 1.21 - Sliding Frame
39000243
GENERAL SECTION 1
KSP Training Manual 1 - 23
1.2.8 Push Floor
The push floor system is designed to receive and temporarily store the large and periodic quantities of material. The push floor can take these uneven loads and provide a consistent discharge through the conveyors and pumps. The push floor moves the material to the inlet of the extraction screw conveyor. The screw conveyor will then move the material to the screw conveyor outlet. The push floor moves the material through the use of the moving frame sections. Hydraulic rams move a push bar down the length of the floor. The floor scrapers are designed to push material in one direction, while minimizing material movement on the return stroke. The floor sections are constantly moving, with the two outside sections moving in the opposite direction of the middle section for multiple scraper configuration.
Figure 1.22 - Push Floor
39000244
SECTION 1 GENERAL
1 - 24 KSP Training Manual
1.2.9 Pipeline Lubrication System
The pipeline is used to convey the sludge from the pumps to either the sludge loading station or the post liming station. Due to the nature of the material being pumped, pipeline pressure may build up under certain conditions. Wet biosolids sludge tend to pump well and does not usually require lubrication. The higher the solids concentration of the biosolids, the more resistance to pumping and higher the resulting pipeline pressure. The pipeline lubrication systems are provided to inject a layer of water in the pipeline, reducing fiction along the pipe walls, and reducing the pipeline pressure. The lubrication pumps supply a small quantity of water to a lubricating ring. The ring installed in the pipe injects a constant flow, forming a thin film of water along the inside surface of the pipe. The pump can be set to automatically start whenever the pipeline pressure exceeds a given pressure for a sustained time period. Initial setting for pump start-up is 300 psi.
Figure 1.23 - Pipeline Lubrication System
39000259
GENERAL SECTION 1
KSP Training Manual 1 - 25
1.2.10 Automatic Greaser System
The automatic greaser system serves to minimize the need for frequent lubrication maintenance by supplying periodic injections of grease to the equipment. The lubrication system provides grease to the push floor hydraulic cylinders, bearings on the metering screw conveyors and the seals on the twin screw augers. The system is a simple electric pump that runs on a timer. Grease is pumped to the equipment based on a programmed timing interval. The time can be independently programmed for each of the application points.
Figure 1.24 - Automatic Greaser System
30358024
SECTION 1 GENERAL
1 - 26 KSP Training Manual
1.3 INSTALLED EQUIPMENT LISTPROJECT: Sample Only
1.3.1 General With Data Sheets
Equipment supplied:
Qty Model Description
1 -- Sliding Frame Recieving Bin - RBSF
2 -- Recieving Bin Conveyors - RBC-1, RBC-2
2 KSP140 (HD) XL Sludge Pump, vertical horizontal configuration, with poppet valves, rock valve - RP-1, RP-2
2 SD500 HD Screw Feeder with Outboard Bearings
HHH Agitator Hopper
2 200/150 HP Hydraulic Power Pack - RPPP
HHH Agitator Hopper
2 230/40 HP Hydraulic Power Pack - RBSFPP
2 Milroy C Pumps Pipeline Lubrication Pumps - PLP-1, PLP-2
1 Lincoln 1827 Automatic Greaser system
APPENDIX 'F' in the O&M manual contains data sheets with serial numbers, and other information, for the major components of the Sludge Pump System supplied.
1.3.2 Sliding Frame Receiving Bin
Refer to installation drawings (Section 6) in the O&M manual for the general arrangement and overall dimensions. See Section 9 for additional details. The hydraulic circuits for the sliding frame hydraulic rams are detailed in Section 7 in the O&M manual. Electrical details are included in Section 8 in the O&M manual.
1.3.3 Receiving Bin Conveyor
Refer to installation drawings (Section 6) and electrical drawings (Section 8) in the O&M manual. Detailed information on the conveyor is contained in Section 10 in the O&M manual.
GENERAL SECTION 1
KSP Training Manual 1 - 27
1.3.4 Sludge Pump - KSP 140 (HD)XL
V Configuration:The Sludge Pump is configured with one cylinder above the other, that is, they are aligned in a vertical plane ("V"). The Installation Drawing in Section 6 in the O&M manual gives overall dimensions of the equipment. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual.
"H" configuration:The Sludge Pump is configured with one cylinder along side of the other, that is, they are aligned in a horizontal plane ("H"). The Installation Drawing in Section 6 in the O&M manualgives overall dimensions of the equipment. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual.See Appendix A for Sludge Pump assembly drawings and Bills of Material for replacement parts.Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information.
1.3.5 Screw Feeder - SD 500 HD
The installed Screw Feeder is configured as shown on the Assembly Drawing in Appendix B.The Installation Drawings in Section 6 give overall dimensions. The pressure settings are shown on the hydraulic schematic in Section 7 in the O&M manual.Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information.
1.3.6 Agitator Hopper - MODEL HHH
The installed Agitator Hopper is configured as shown on the Assembly Drawing in Appendix B. The installation drawing in Section 6 in the O&M manual gives overall dimensions. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual.
Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information.
1.3.7 Hydraulic Power Pack - MODEL 2000, 200/150 HP
The installed Hydraulic Power Pack is configured as shown on the Assembly Drawing. See Appendix C for Bills of Material and replacement parts.
The installation drawings in Section 6 in the O&M manual give overall dimensions. The pressure settings are given on the hydraulic schematics in Section 7 in the O&M manual.
SECTION 1 GENERAL
1 - 28 KSP Training Manual
Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information.
1.3.8 Agitator Hopper - MODEL HHH
The installed Agitator Hopper is configured as shown on the Assembly Drawing in Appendix B. The installation drawing in Section 6 in the O&M manual gives overall dimensions. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual.
Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information.
1.3.9 Hydraulic Power Pack - MODEL 230, 40 HP
The installation drawings in Section 6 give overall dimensions. The pressure settings are given on the hydraulic schematics in Section 7 in the O&M manual.
Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information.
1.3.10 Pipeline Lubrication System
Refer to installation drawings (Section 6) in the O&M manual for the general arrangement. Electrical controls are detailed in Section 8 in the O&M manual. See Appendix I in the O&M manual for detailed information on the lubrication system.
1.3.11 Automatic Greaser System
See Appendix G (Catalog Cuts) in the O&M manual for detailed information on the Lincoln Automatic Greaser System.
GENERAL SECTION 1
KSP Training Manual 1 - 29
1.4 SAFETY REGULATIONS
When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following paragraphs contain some supplementary recommendations.
ANSI standards "ANSI 2244.1-1952" set down minimum safety requirements covering lockout or tagout of energy sources for personal safety. These should be reviewed before any maintenance or inspection.
WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.
WARNING! DANGER OF AMPUTATION! Keep hands out of the screw feeder and agitator hopper.
WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the dis-charge valve housing (rock valve or poppet valves).
Operation and maintenance of this equipment shall be performed only by trained, capable, and authorized personnel.
Only Certified Licensed Electricians shall be allowed to work on electrical systems.
WARNING! DANGER OF ELECTROCUTION! Before working on electrical sys-tems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency.
Keep unauthorized personnel away from the work area during maintenance.
Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Good Preventative Maintenance programs are essential for a good Safety Program.
Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation.
Other sections of this manual contain specific safety recommendations for INSTALLATION, STARTUP, ADJUSTMENTS & CHECKS, AND MAINTENANCE. See the Table of Contents and study and review these sections also.
!
!
!
!
SECTION 1 GENERAL
1 - 30 KSP Training Manual
SAFETY REGULATIONS SECTION 2
KSP Training Manual 2 - 1
SECTION 2 SAFETY REGULATIONS
2.1 SAFETY REGULATIONS
When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, Facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following paragraphs contain some supplementary recommendations.
OSHA standards 1910.147 (subpart J) set down minimum safety requirements covering lockout or tagout of energy sources for personal safety. These should be reviewed before any maintenance or inspection.
Operation and maintenance of this equipment shall be performed only by trained, capable, and authorized personnel.
Only Certified Licensed Electricians shall be allowed to work on electrical systems.
WARNING! DANGER OF ELECTROCUTION! Before working on electrical sys-tems, be sure that the main circuit breakers are TURNED OFF and SECURED, machines might have multiple sources. Check for voltage before touching any electrical point. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned gov-erning agency.
Figure 2.1 - Warning Decal (P/N 30333417)
!
39000018
WARNING
Multiple power sources. Check for voltage before touching any point.
30333417 A
SECTION 2 SAFETY REGULATIONS
2 - 2 KSP Training Manual
Whenever doing any maintenance on the inside of the pump, i.e. replacing poppet valves or piston heads, the pump discharge must be disconnected from the pipeline prior to starting work on the pump.
WARNING! DANGER - CONFINED SPACE! When entering a silo to perform any work, follow the guidelines below. Serious injury or death may occur if proper guidelines are not followed.
ALWAYS -Establish a confined space entry program. Perform a confined space hazard analysis and follow local regulations dealing with confined space entry.ALWAYS -Clean the silo of material to prevent hazardous gases or collapse of bulk materials.ALWAYS -Wear personal protective equipment required (hard hat, boots, respirator, hearing protection, etc.).ALWAYS -Have a rescue plan established BEFORE a person enters a confined space. Safety lines attached to the person working in the confined space, and a means to pull them to safety, can prevent a rescuer from being exposed to the same hazard encountered by the worker.ALWAYS -Provide adequate ventilation of fresh air. Natural ventilation alone may not be sufficient to maintain breathable quality air.ALWAYS -Have air quality tested by a qualified person BEFORE entering a confined space, and continually monitor until the work is completed.ALWAYS -Have at least two (2) persons present when performing work in confined spaces; one (1) person must stay outside of confined space as an observer in case of emergency.
Keep unauthorized personnel away from the work area during maintenance.
Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel.
Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation.
Other sections of the O&M manual contain specific safety recommendations for INSTALLATION, STARTUP, ADJUSTMENTS & CHECKS, AND MAINTENANCE. See the Table of Contents and study and review these sections also.
2.2 SAFETY DURING INSTALLATION
Supplementary recommendations:
Read and review the O & M Manual and relevant contract drawings for installation information.
Lifting equipment, cables, chains, etc. are to be connected only at the lifting points provided.
!
SAFETY REGULATIONS SECTION 2
KSP Training Manual 2 - 3
Keep unauthorized personnel away from the work area during positioning of equipment or installation.
Installation work should only be done by qualified, authorized personnel.
Only Certified Licensed Electricians shall be allowed to work on electrical systems.
WARNING! DANGER OF ELECTROCUTION! Before working on electrical sys-tems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency.
Do not install or repair damaged pipes, fittings, or hoses. Replace damaged hydraulic hoses immediately
2.3 SAFETY PRECAUTIONS - STARTUP
Before start-up the operator shall perform all necessary pre-start-up checks as described in Section 2.4, Page 2 - 4 if this is a testing start-up, first time start-up, restart after maintenance, or restart after Long Term Shutdown
At start-up observe the following safety precautions:
Keep area clear of unauthorized personnel.
Be observant for leaks or unusual noises.
DOUBLE CHECK THAT ALL HAND VALVES ARE IN NEUTRAL POSITION and/or BYPASS SWITCH IS IN "BYPASS" (NOTE INDICATOR LIGHT) BEFORE STARTING.
Review the "Sequence of Operation" that is included on the Electrical Schematic in Section 8 to understand what happens at start-up of system.
WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.
WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the screw feeder and agitator hopper.
WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the dis-charge valve housing (rock valve or poppet valves).
All covers, guards and safety decals must be in place before start-up.
!
!
!
!
SECTION 2 SAFETY REGULATIONS
2 - 4 KSP Training Manual
2.4 SAFETY INSTRUCTIONS - ADJUSTMENTS AND CHECKS
Only trained and authorized personnel shall perform adjustments to the sludge pump and related equipment.
Read and study all of the adjustment procedures before making any adjustment. One adjustment may have an effect on another.
Covers for rotating parts must be in place during adjustments and checks.
All personnel shall know the location and operation of EMERGENCY CONTROLS. See the sequence of operation and control layout drawings on the electrical schematic in your O&M manual.
2.5 SAFETY DURING MAINTENANCE
When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, Facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following are some supplementary recommendations:
Read and review this O & M Manual and relevant contract drawings for maintenance information.
Keep unauthorized personnel away from the work area during maintenance.
Maintenance work should only be done by qualified, authorized personnel.
Whenever doing any maintenance on the inside of the pump, i.e. replacing poppet valves or piston heads, the pump discharge must be disconnected from the pipeline prior to starting work on the pump.
WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.
WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the screw feeder and agitator hopper.
WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the dis-charge valve housing (rock valve or poppet valves).
Only Certified Licensed Electricians shall be allowed to work on electrical systems.
WARNING! DANGER OF ELECTROCUTION! Before working on electrical sys-tems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency.
Before working on hydraulic systems, depressurize the whole system and secure the electrical and hydraulic controls in OFF or NEUTRAL position.
!
!
!
!
SAFETY REGULATIONS SECTION 2
KSP Training Manual 2 - 5
WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE THE PRESSURE on the line by selecting the reverse position of the pump for several strokes.
Sludge discharge lines are operating under high pressure. Extreme caution and proper safety practices should be followed whenever the flanges are being loosened or the clamps removed from the sludge discharge line.
To relieve the pressure in a sludge discharge line, follow these steps:
1. Place the screw conveyor or conical hopper in the reverse position.
2. Tighten down the throttle valves until they are completely closed, then open them 1/2 turn. (Located on the control block)
NOTE: If your pump is equipped with the SFMS (Sludge Flow Measuring System) you must fully open the throttle check valves located on the discharge poppet hydrau-lic cylinders.
3. On manually operated control blocks (older models) place the S-1 spool in the reverse position and let the pump kit stroke in reverse for a short period of time.
4. Observe the hydraulic cylinder rods for the discharge poppets to verify that they are moving. (If they are not moving assume that the line is still pressur-ized.)
5. Observe the hopper to see if any sludge is coming from the pump into the hop-per. Also observe the discharge line pressure gauge to see if it is dropping (if so equipped).
6. Open the pressure bleed off valve to release any residual pressure remaining (if so equipped).
7. Shut the pumping unit off and disconnect all power sources. Remove the flanges and clamps, using the proper safety procedures.
Do not install or repair damaged pipes, fittings or hoses. Replace damaged hydraulic hoses immediately.
Lifting equipment, cables, chains, etc., are to be connected only at the lifting points provided.
Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Good Preventative Maintenance programs are essential for a good Safety Program.
!
SECTION 2 SAFETY REGULATIONS
2 - 6 KSP Training Manual
Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation.
Figure 2.2 - Recommended Pipeline Connection
WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE THE PRESSURE on the line by selecting the reverse position of the pump for several strokes.
39000017
Pipeline
ANSI Flange
In-line Fully PortedShut-off Valve
1/2" Dutchman
Spool Piece
2" Fully PortedBleed Valve SchwingTwo Bolt
Clamp SchwingSludge Pump
Discharge
!
SAFETY REGULATIONS SECTION 2
KSP Training Manual 2 - 7
Figure 2.3 - Typical Decal Location - KSP
Deca
l Loc
atio
n Dw
g.-1
of 5
KSP w
/Pow
er P
ack
KSPp
umpk
it(Ty
pica
l)Dr
awn
By
Date
Appr
oved
REV.
3035
8014
RE08
/23/
01
n/a
REV.
CHAN
GE /
E.C.O
#NA
ME
DAT
E30
3580
14Jo
b Nu
mbe
r:
Job
Nam
e:
Labe
l Ass
ign
men
t by:
Assig
nm
ents
:
1. B
yp
ass
: Use
#
Wri
te in
num
ber
Wri
te in
num
ber
3112
11
(Choose
betw
een:
322670
338672)
2. M
oto
r ra
ting
:
Date
:
3. R
ev/F
wd
: Use
#
4. P
ress
ure
lab
els
:
Slu
dg
e p
um
p:
Scr
ew
feed
er:
Acc
um
ula
tor:
Slid
e g
ate
:
Slid
e fra
me:
Push
flo
or:
Hyd
raulic:
3031
4576
3031
1258
3031
1257
3035
55x6
3035
55x7
3035
55x8
3035
55x9
(Use
3112
63 fo
r tab
le 1,
3, 5,
7;
Use
311
262
for t
able
2, 4,
6, 8)
460V
316189
oth
er
575V
317932
WAR
NING
: Byp
ass-L
oad
does
not
stop
scre
w fe
ed - 3
0311
211
WAR
NING
: Byp
ass-L
oad
stops
bot
hsc
rew
feed
er an
d slu
dge p
ump
- 303
2267
0or
or
WAR
NING
: Scr
ew fe
eder
and
sludg
epu
mp
have
sep
arat
e By
pass
-Loa
dsw
itche
s - 3
0338
672
WAR
NING
: Do
not p
utha
nds i
n w
ater
box
3031
9872
WAR
NING
: Do
not p
utha
nds i
n ho
pper
3031
9869
(Both
sides
of ma
terial
cylin
ders)
WAR
NING
: Sta
rtsau
tom
atica
lly30
3370
69 WAR
NING
: Saf
ety
Guar
d is
miss
ing
3033
7004
(in th
e wate
rbox
,u
nde
r the
gua
rd)
Fwd/
Rev -
311
262
Lift h
ere
3031
7940
Main
ID ta
g30
3017
33
Main
ID ta
g30
3017
33
or Re
v/Fw
d - 3
1126
3
Lette
ring
per
hydr
aulic
sche
mat
ic
3611
29
26
14
15
4
8
27
1 6
9
SECTION 2 SAFETY REGULATIONS
2 - 8 KSP Training Manual
Figure 2.4 - Typical Decal Location - Power Pak
Deca
l Loc
atio
n Dw
g. - 2
of 5
KSP w
/Po
wer
Pac
kDr
awn
By
Date
Appr
oved
REV.
3035
8014
RE08
0901
A
POW
ER PA
CK
(Typi
cal)
REV.
CHAN
GE /
E.C.O
.NA
ME
DATE
3035
8014
Texa
co H
D 46
(get #
from
dec
al)
ATTE
NTIO
N: C
hang
efi
lter -
303
1405
0W
ARNI
NG:Th
is Eq
uip.
star
ts Au
tom
atica
lly30
3370
69 (b
oth Sid
es)W
ARNI
NG: H
yd.
Accu
mul
ator
- 30
3245
99(un
its w
ith ac
cum
ulat
ors)
Pow
er Pa
ckSe
rial N
umbe
rPl
ate
- 303
0431
4
Sludg
e Pu
mp
Pres
sure
- 30
3112
57Ac
cum
ulat
orPr
essu
re -
3031
4576
Scre
w Fe
eder
Pres
sure
- 30
3112
58Sli
de G
ate
Pres
sure
- 30
3555
66Sli
de Fr
ame
Pres
sure
- 30
3555
67Pu
sh Fl
oor
Pres
sure
- 30
3555
68Hy
drau
lic Pr
essu
re(ge
neric
) - 30
3555
69
Fwd
/ Rev
- 303
1126
2
Lette
ring
per h
ydra
ulic
sche
mat
ic
WAR
NING
:Stor
edHy
d. en
ergy
- 303
3497
6(un
its w
ith ac
cum
ulat
ors)
(Insid
e of E
lec.
pane
l) W
ARNI
NG: m
ultip
le po
wer
so
urce
s-30
3334
17
WAR
NING
: Sta
rts
Attn
: One
-W
ay
WAR
NING
: Do
not
oper
ate
with
out
train
ing
- 303
3701
3
Safe
ty In
stru
ctio
ns:
Safe
ty ru
les
3031
2298
Safe
ty In
stru
ctio
ns:
Ac
cum
ulat
or ru
les -
3031
411
5(un
its w
ith ac
cum
ulat
ors)(
locate
her
e an
d ne
ar ac
cum
ulat
or)
IMPO
RTAN
T:Re
orde
r inf
o30
3332
69
War
nin
g:
Haza
rdou
s vol
tage
WAR
NING
:Hyd
.
Accu
mul
ator
-303
2459
9(un
its w
ith
accu
mul
ator
s)(lo
cate
here
an
d
Safe
ty In
stru
ctio
ns:
Accu
mul
ator
rule
s - 3
0314
115
WAR
NING
:Bypa
ss-L
oad
does
not
stop
scre
w fe
ed - 3
0311
211
WAR
NING
:Bypa
ss-L
oad
stops
bot
hsc
rew
feed
er an
d slu
dge p
ump
- 303
2267
0
WAR
NING
:Scre
w fe
eder
and
sludg
epu
mp
have
sep
arat
e By
pass
-Loa
dsw
itche
s - 3
0338
672
or or
SCHW
ING
AB
C
One o
r mor
e of
thes
e,lo
cate
d un
der p
ress
ure
gaug
es
198
7 34 2
31
3311 29 36
30
14
21
58
2831 30
335
SAFETY REGULATIONS SECTION 2
KSP Training Manual 2 - 9
Figure 2.5 - Typical Decal Location - Screw Feeder
REV.
CHAN
GE /
E.C.O
. #
NAM
EDA
TE30
3580
14
Deca
l Loc
atio
n Dw
g. - 3 o
f 5KS
P w/
Pow
er P
ack
Draw
n B
yDa
teAp
prov
ed
REV
.
3035
8014
RE08
0901
n/a
Scre
wfe
eder
(Typi
cal)W
ARNI
NG: S
afet
yGu
ard
is M
issin
g30
3370
04(As
Req
'd)
WAR
NING
: Kee
p Ha
nds O
utOf
Ag
itato
r As
sy.-30
3122
97(If
Equi
pped
with
hop
per)
(Both
Sides)
WAR
NING
: Sta
rts Au
tom
atica
lly-3
0337
069
(Both
sides
of ho
using
, if
expo
sed)
WAR
NING
: Byp
ass-L
oad
does
not
stop
scre
w fe
ed - 3
0311
211
Lette
ring
per h
ydra
ulic
sche
mat
ic
or WAR
NING
: Byp
ass-L
oad
stops
bot
hsc
rew
feed
er an
d slu
dge p
ump
- 303
2267
0or W
ARNI
NG: S
crew
feed
er an
d slu
dge
pum
p ha
ve s
epar
ate
Bypa
ss-L
oad
switc
hes -
303
3867
2
WAR
NING
: Byp
ass-L
oad
does
not
stop
scre
w fe
ed - 3
0311
211
or WAR
NING
: Byp
ass-L
oad
stops
bot
hsc
rew
feed
er an
d slu
dge p
ump
- 303
2267
0or W
ARNI
NG: S
crew
feed
er an
d slu
dge
pum
p ha
ve s
epar
ate
Bypa
ss-L
oad
switc
hes -
303
3867
2
WAR
NING
: Kee
p Ha
nds O
utOf
Scre
w Fe
eder
-303
1126
4(Bo
th Sid
es)
Lift h
ere
3031
7940
918
8
11 29
11 29 36
16
4
SECTION 2 SAFETY REGULATIONS
2 - 10 KSP Training Manual
Figure 2.6 - Typical Decal Location - Lube Pumps
REV.
CHAN
GE /
E.C.O
. #
NAM
EDA
TE30
3580
14
Deca
l Loc
atio
n Dw
g. - 4
of 5
KSP w
/Po
wer
Pac
k - Lu
be p
umps
Draw
n B
yDa
teAp
prov
ed
REV.
3035
8014
RE08
0901
n/a
LUBE
PU
MP
CON
TRO
L PA
NEL
IMPO
RTAN
T:Re
orde
r inf
o30
3370
13
WAR
NING
:M
ultip
le po
wer
sou
rces
3033
3417
WAR
NING
:Ha
rzar
dous
volta
ge in
side
3033
6368
WAR
NING
:M
achi
ne m
ay st
art
at a
ny ti
me
3033
7069
IMPO
RTAN
T:Do
cum
enta
tion
orde
ring
info
3033
3269
SAFE
TY IN
STRU
CTIO
NSSa
fety
ope
ratin
gin
stru
ctio
ns -
KSP
3031
2298
IMPO
RTAN
T:Do
cum
enta
tion
orde
ring
info
3033
3269
SAFE
TY IN
STRU
CTIO
NS:
Safe
ty o
pera
ting
inst
ruct
ions
- KS
P30
3122
98
WAR
NING
:M
achi
ne m
ay st
art
at a
ny ti
me
3033
7069
WAR
NING
:Do
not
ope
rate
with
out t
rain
ing
3033
7013
7
35 34 8 33
19 33
19
8 7
SAFETY REGULATIONS SECTION 2
KSP Training Manual 2 - 11
Figure 2.7 - Safety Reminder - Electrical Disconnections
Figure 2.8 - Safety Reminder - Guards And Shrouds
ELECTRICAL DISCONNECTS SHOULD HAVE PADLOCKSACCESSIBLE TO REPAIR PERSONNEL OR SET-UP MECHANICS.
39000022
SUITABLE GUARDS AND SHROUDS HELP PREVENTOPERATORS FROM INJURING THEMSELVES.
39000023
SECTION 2 SAFETY REGULATIONS
2 - 12 KSP Training Manual
Figure 2.9 - Safety Reminder - Good Housekeeping
CONSTANT ATTENTION TO SAFETY AND GOOD HOUSEKEEPINGIS THE BEST WAY TO PREVENT COSTLY ACCIDENTS.
39000024
HYDRAULICS SECTION 3
KSP Training Manual 3 - 1
SECTION 3 HYDRAULICS
3.1 RULES OF HYDRAULICS1. Hydraulic pressure always takes path of least resistance.
2. Hydraulic pressure is created equal in all directions (Pascal's Law).
3. Liquids (oil) are relatively incompressible.
12
3
4
The bottle is filled with a liquid, which is not compressible
If the bottom has an area of 20 square inches and each square inch is pushed on by 10 pounds of force, the entire bottom recieves a 200 pound push.
A 10 pound force applied to a stopper with a surface area of one square inch......
Results in 10 pounds of force on every square inch (pressure) of the container wall
Pascal's Law
1000 lbs of Force
1000 lbs of Force
OIL
AIR
OIL
AIR
SECTION 3 HYDRAULICS
3 - 2 KSP Training Manual
4. When hydraulic pressure and flow is not converted into work it is converted into heat.
5. When oil is heated it will expand (5% or more).
6. When oil is heated the viscosity of it changes.
Open relief (Heat)
Vacuum formed as
hydraulic oil cools
Atmospheric pressure
forces water past seals
Seals
Hydraulic Cylinder
Water Box
6 bar
HYDRAULICS SECTION 3
KSP Training Manual 3 - 3
7. In industrial applications the recommended maximum fluid velocity is 17 FPS (Feet Per Second).
8. GPM (Gallons Per Minute) only determine the speed at which the actuator (motor or cylinder) oper-ates.
9. P.S.I. (Pounds Per Square Inch) determine only the amount of force exerted upon the load by the actu-ator.
M35 psi P
0 GPM 10 GPM
1000 PSI
10 gallon maximum
capacity cylinder
10,000 LBS
LOAD
10 inch of area on
cylinder piston
SECTION 3 HYDRAULICS
3 - 4 KSP Training Manual
10. The resistance created in a hydraulic circuit, whether by the amount of the load on the actuator and/or the pressure drop in a circuit, is what determines how much work is required.
F
P A
F = FORCE (in pounds) (lb)P = PRESSURE(in pounds per square inch) (P.S.I.)A = AREA (in square inches) (in 2 )F = P x A
P = F /AA = F/P
F = FORCE (in kilograms) (Kg)P = PRESSURE(in kilograms per square centimeter) (Kg/cm2 )A = AREA (in square centimeters) (cm2 )
U.S.
METRIC
Q = FLOW RATE(unit of volume per time period)P = PRESSURE(unit of force per unit of area)
GENERAL
POWER =CONSTANT
Q x P
HP = HORSEPOWERGPM = GALLONS PER MINUTEPSI = POUNDS PER SQUARE INCH
U.S.
1714 = KNOWN CONSTANT
HP =1714
GPM x PSI
KW = KILOWATTSLPM = LITERS PER MINUTEBAR = METRIC UNIT OF PRESSURE
METRIC
600 = KNOWN CONSTANT
KW =600
LPM x BAR
HYDRAULICS SECTION 3
KSP Training Manual 3 - 5
Mechanical Versus Hydraulic
Transfer of Energy
10 lb.(44.48 N)
100 lb.(444.82 N)
1. Ten pounds (44.48 N) here...
3. if this arm is 10 timesas long as...
4. this arm.
2. will balance 100 lb(444.82 N) here...
A. SIMPLE MECHANICAL LEVER
COMPARISON OF MECHANICAL FORCESVERSUS HYDRAULIC FORCES
10 lb.(44.48 N)
100 lb.(444.82 N)
1. An input force of10 lb.(44.48 N) on aone square inch(6.45 cm ) piston...
2. develops a pressure of10 pounds per square inch(psi)(.69 bar) (68.94 kilopascals)throughout the container.
3. This pressure willsupport a 100 lb.(444.82 N) weight ifthis is a 10 sq. in.(64.52 cm ) piston.2
INPUT OUTPUT4. The forces are proportionalto the piston areas.
10 lb. (44.48 N)1 sq. in (6.45 cm 2 ) =
100 lb. (444.82 N)10 sq. in (64.52 cm2 )
B. SIMPLE HYDRAULIC PRESS
2
10 sq. in.(64.51 cm 2 )
1 sq. in.(6.45 cm )2
10 lb.(44.48 N)
100 lb.(444.82 N)
1. Moving the small piston 10 in.0.25 m) displaces 10 cu. in.(163.87 cm3 ) of liquid.(1 sq. in. x 10 in. =10 cu. in.)(6.45 cm 2 x 25.40 cm = 163.87 cm 3 )
10 in(0.25 m)
1 in(0.02 m)
10 cu. in. (163.8 cm 3 ) of liquidwill move the larger piston only1 in. (2.54 cm)(10 sq. in. x 1 in. = 10 cu. in.)(64.52 cm x 2.54 cm = 163.87 cm )
2.
3. The energy transfer here equals10 lb. x 10 in. (44.48 N x 0.25 m)or 100 in. lb. (11.30 Nm)
4. The energy transfer here also is100 in. lb. (11.30 Nm)(1 in. x 100 lb. = 100 in. lb.)(.02 m x 444.82 N = 11.30 Nm)
10 sq. in.(64.51 cm2 )
1 sq. in.(6.45 cm 2 )
ENERGY CAN NEITHER BE CREATED NOR DESTROYED
SECTION 3 HYDRAULICS
3 - 6 KSP Training Manual
Hydraulic Jack
Linear & Rotary Actuators
PISTON
HYDRAULIC
ROD
8"
PUMP
PUMP
MOTOR
ROTARYDRIVE SHAFT
LOAD
1.The pump pushes thehydraulic liquid into lines.
2. Lines carry the liquid toactuators which are pushedto cause a mechanical outputto move a load.
3. Some actuators operate ina straight line (linear actuators).They are called cylinders or rams.They are used to lift weight, exertforce, clamp, etc.
PISTON & ROD
TO RESERVOIR
ROTARY ACTUATORLINEAR ACTUATOR4. Rotary actuators or motors give the system rotating output.They can be connected to pulleys,gears,rack-and-pinions, conveyors, etc.
HYDRAULICS SECTION 3
KSP Training Manual 3 - 7
Basic Hydraulic Components
Check Valve
Throttle Valve
Throttle Check Valve
Switching Valve
SECTION 3 HYDRAULICS
3 - 8 KSP Training Manual
3.2 HYDRAULIC PUMPSHydraulic pumps are used to create flow (GPM) in a hydraulic system.(Hydraulic pumps do not create pressure)
There are 4 basic designs of hydraulic pumps:
1 Piston Pumps:a. Radial Pistonb. Axial Piston
I. Bent AxisII. Swash Plate
STYLES: AVAILABLE CONTROLSFixed Displacement 1. ManualVariable Displacement 2. Horse-power regulated
3. Pressure Compensated4. Pressure cut-off
Piston pumps are rated in CC (Cubic Centimeters) or CID (Cubic Inch Displacement) perrevolution.
The efficiency of this pump design remains high throughout its pump life. The efficiencydrops off very quickly at the end of the pumps life.
They are designed for high pressure and high range of RPM.
2 Gear Pumps:a. External Gearb. Internal Gear
I. GerotorII. Crescent
Gear pumps have a nominal rating in GPM at 1000 PSI and 1200 RPM. They are gener-ally designed for medium range hydraulic pressure and RPM.
The efficiency of this pump design declines gradually throughout its pump life. It is sogradual that it is hardly noticeable until it has deteriorated considerably.
3 Vane Pumps:
Vane pumps have a nominal rating in GPM at 1000 PSI and 1200 RPM. they are gener-ally designed for medium range pressure and RPM.
The efficiency of this pump remains high throughout its pump life and drops quickly at theend of the pumps life.
4 Screw Pumps:
These pumps operate at various pressure ranges and RPM's. There design is mainlyused when a hydraulic system can't tolerate any hydraulic pulsations.
HYDRAULICS SECTION 3
KSP Training Manual 3 - 9
Figure 2.10 - Different Types of Pumps
Figure 2.11 - Different Types of Axial Piston Pumps
notsiPraeG
Screw Vane
Bent Axis Swash Plate
SECTION 3 HYDRAULICS
3 - 10 KSP Training Manual
Figure 2.12 - Pumping Action In Bent-axis Pumps
Figure 2.13 - Increasing/Decreasing Piston Pump Output
to outlet
from inlet
Piston is withdrawingfrom bore at inlet
Rotating shaft causespistons to reciprocate
Universal link
Piston rod
Piston
Cylinder block
Oil forced to outlet as pistonis pushed back into cylinder
39000040
Maximum piston stroke Reduced stroke
No stroke
Maximum angle Less angle
No angle
39000041
HYDRAULICS SECTION 3
KSP Training Manual 3 - 11
Figure 2.14 - Internal and External Gear Pumps
Drive Gear
Outlet pressure against teeth causes heavy side-loading on shafts as indicated by arrows.
through this port.Oil entering here....
(4) OUTLET
INLET
Vacuum is created here as teeth unmesh. Oil enters from reservoir.
(1)
...and forced out of pressure port as teeth go back into mesh.
(3)
Oil is carried around housing in chambers formed between teeth, housing, & side plates...
(2)
External Gear Pump
(1)
by the constant withdrawal of teeth on this inner gear...
Cresent seal
from the spaces between the teeth of this inner gear...
(3)is carried in these spaces...
(4)
to this point, where constant meshing of two gears forces the oil...
(5)
(6)
Internal Gear Pump
(2)
39000042
SECTION 3 HYDRAULICS
3 - 12 KSP Training Manual
3.3 VALVES
3.3.1 Control Valves
Control valves are designed to direct and control the flow of oil to or from the work in a hydraulic circuit.
These operating mechanisms of the valves are:
1 MANUAL OPERATED:a. Hand lever b. Push buttonc. Pedal operated
2 SOLENOID OPERATION:a. AC coilsb. DC coils
3 PILOT OPERATEDa. Hydraulic pilot b. Air pilot
3.3.2 Relief Valves
Relief valves are designed to regulate the maximum amount of pressure that can be built in a hydrauic circuit.
They are built in three designs:
1. Direct acting
2. Pilot operated
3. Solenoid operated.
HYDRAULICS SECTION 3
KSP Training Manual 3 - 13
Figure 2.15 - Different Types of Activation Devices
Figure 2.16 - Typical Spool-type 4 Way Valve
ManuallyActuated
Push Button
A
P
B
T
Hand Lever
A
P
B
T
Foot Pedal or Treadle
A
P
B
T
Mechanically Actuated Symbol
A
P
B
T
Hydraulic Pilot
A
P
B
T
Air Pilot
A
P
B
T
Solenoid
A
P
B
T 39000043
A B A B
T P P T
Pressure to "b" port, "a" port to tank Pressure to "a" port, "b" port to tank
A B
P T
39000044
SECTION 3 HYDRAULICS
3 - 14 KSP Training Manual
3.3.3 The Basic Relief Valve
This is a direct acting non adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style pressure relief is not adjustable except by changing the internal spring.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring. When this direct acting design relieves it causes pulsations in the system.
Figure 2.17 - Direct Acting Non-adjustable Relief Valve
This is a direct acting adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style is adjustable though a external control which varies the spring tension on the relief poppet.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring.
Figure 2.18 - Direct Acting Adjustable Relief Valve
Tank
Pressure
39000045
39000046
Tank
Pressure
39000046
HYDRAULICS SECTION 3
KSP Training Manual 3 - 15
This is a pilot operated adjustable relief valve. The relief poppet has a small orifice in it that allows the hydraulic pressure to also be applied on the back side of the poppet. This internal chamber is hydraulically locked and it will hold the main poppet closed as long as it has equal pressure on the front side and the back side. There is also a much smaller pilot poppet, that is operator adjustable. This smaller poppet, with a smaller area, can have a smaller spring controling it. Once this pilot poppet opens we lose our hydrau-lic lock, the pressure is reduced on the back side and thus the main poppet can relieve the excess pressure to tank. With this design we are able to control large volumes of oil at high pressures with minimal sized springs.
Figure 2.19 - Pilot Operated Adjustable Relief Valve
Tank
Pressure Pressure
39000047
SECTION 3 HYDRAULICS
3 - 16 KSP Training Manual
3.4 HYDRAULIC SYMBOLS
Figure 2.20 - American-German Symbol Comparison
A.N.S.I. D.I.N.
A.N.S.I.
D.I.N.
A.N.S.I. = AMERICAN NATIONAL STANDARDS INSTITUTEDIN = DEUTSCHE (GERMAN) INDUSTRIAL NORM
HYDRAULICS SECTION 3
KSP Training Manual 3 - 17
Figure 2.21 - Hydraulic Symbols - Sheet 1
LINES CROSSING
LINES JOINING FOUR WAY VALVE, TWO POSITIONMANUALLY OPERATED
LINE, WORKING (MAIN)FOUR WAY VALVE,THREE POSITION,LEVER OPERATED, W/ DETENT
LINE, PILOT (FOR CONTROL) OIL LEVEL SIGHT GLASSW/ THERMOMETER
PORTFOUR WAY VALVE, THREEPOSITION, SOLENOID AND PILOTOPERATED, SPRING RETURN
LINE W/ THROTTLE VALVE
CHECK VALVE W/ NO SPRING
CHECK VALVEW/SPRING RETURN FLOAT-TYPE SWITCH
TANK
FILTER
DOUBLE ACTING CYLINDER RODEND CYLINDER SHUT-OFF VALVE
PUMP,VARIABLEDISPLACEMENT,NON-COMPENSATEDUNIDIRECTIONAL
PRESSURE SWITCH
HYDRAULIC MOTOR,BI-DIRECTIONAL OIL COOLER
PRESSURE GAUGE
TL
M
PRESSURE RELIEF VALVE
TA