Montaje Industrial

13 m Dia.
B Thickener, B60P-3 Drive
Installation, Operation, and Maintenance Manual

Altonorte
9232504935
March 2018
Copyright © 2017 by FLSmidth, All Rights Reserved.
Documents, drawings, technical manuals, and all other information contained in this manual,
provided in conjunction with the purchase of FLSmidth products and services, are the
proprietary property of FLSmidth. No part of this manual may be disclosed, copied, duplicated,
photocopied, reproduced, translated, or reduced to any electronic medium or machine-
readable form without prior written consent from FLSmidth.
The data included in this manual is not to be duplicated, used, or disclosed, in whole or in part,
for any purpose other than in the operation, maintenance, and service of the machine
described. Nothing contained herein should be construed to guarantee, modify, or enhance the
operational capabilities as described in the machinery specification. This manual does not imply
liability to the manufacturer for any or all operational capabilities that may be affected by the
misuse or neglect in operating or servicing this machine.
Table of Contents
Chapter 1: Safety
1.1 Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.3
1.1.1 Hazard Signal Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1.1.2 Safety Signs and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1.1.2.1 Mandatory Action Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.2 Prohibition Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2.3 Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Safe Working Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..7
1.2.1 Operator Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
1.2.2 General Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
1.2.4 Lockout/Tagout (Energy Isolation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.5 Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..9
1.2.6 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.9
1.2.7 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.10
1.2.8 Equipment Safety Signs and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.2.9 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.10
1.2.9.1 Emergency Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.2.9.2 Safety Trip Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.2.9.3 Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12
1.2.9.4 Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12
1.3 General Risks and Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12
1.3.1 Identifying and Controlling Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.3.2 Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .13
1.3.3 Scaffolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.13
1.3.4 Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .13
1.3.5 Elevated Work Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.13
1.3.6 Harness and Line (Fall-Arrest System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.7 Cranes and Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.8 Moving Parts on Stationary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.9 Remote Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.14
1.3.10 Confined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.14
1.3.11 Welding, Cutting, and Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.3.12 High Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.15
1.3.13 Power Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.15
1.3.14 Inclement Weather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.15
1.3.15 Noise and Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.15
Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
i
Table of Contents
1.3.16 Pinch and Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3.17 Electrical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
1.3.18 Fuels, Oils, and Lubricating Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.19 Surface Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
1.3.20 Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Hazardous Chemicals and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.1 Mineral Powders (Silica) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.2 Lime and Calcined Raw Meal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.3 Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
1.4.4 Acids and Bases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.5 Cyanide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
1.4.6 Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
1.5 Emergency Preparedness Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 2: Introduction
2.1 Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
2.2 Installation and Start-Up Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3 Shipment and Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4 Parts and Repair Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
2.5 Warranty Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
2.5.1 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5.2 Equipment Installers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6 Accessory Equipment Manufacturer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.7 FLSmidth Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
Chapter 3: Storage
3.1 Long-Term Storage Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.1 Maintaining Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Outdoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
3.3 Covered or Indoor Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4 Equipment Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
3.5 Preventing Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
3.5.1 Shop Primer Paints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.5.2 Protective Finishes or Seal Coats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5.3 Machined and Non-Coated Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.6 Storing Elastomer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.7 Storing Fiberglass Reinforced Plastic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.8 Storing Equipment After Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.9 Storing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
3.10 Environmental Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
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Table of Contents
Chapter 4: Equipment Overview

4.1 Equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .36
4.1.1 Thickener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .36
4.1.2 FLSmidth Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.36
4.1.3 Rake Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.36
4.1.4 Torque Overload Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.36
4.1.5 Local Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.36
4.1.6 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.37
4.1.7 Walkway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .37
4.1.8 Drive Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.37
4.1.9 Rake Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .37
4.1.10 Feedwell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .37
Chapter 5: Installation
5.1 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.41
5.2 Lifting the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.41
5.2.1 Shipping Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.42
5.3 Erecting the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .43
5.3.1 Installing the Tank Support Structure and Floor . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.3.2 Installing the Tank Wall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.44
5.3.3 Sealing the Tank Floor Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
5.4 Inspecting the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .45
5.4.1 Inspecting the Tank Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5.4.2 Conducting the Hydro Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5.5 Installing and Leveling the Weirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.47
5.6 Assembling and Installing the Superstructure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
5.6.1 Installing the Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.47
5.6.2 Installing the Grating and Handrails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.6.3 Installing the Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.48
5.6.4 Installing the Spiral Stairway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.7 Installing the Drive Units and Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.48
5.7.1 Inspecting the Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.7.2 Lifting the Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.49
5.7.3 Installing the Main Drive on the Bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.7.4 Inspecting the Drive for Concentricity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.7.5 Leveling the Drive (Preliminary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.7.6 Lubricating the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.51
5.7.7 Installing the Inner Section of the Monorail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
5.7.8 Installing the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.51
5.7.9 Connecting the Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

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5.7.10 Verifying Drive Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.7.11 Installing the Hydraulic Power Unit and Piping Assembly. . . . . . . . . . . . . . . . . 52
5.7.12 Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
5.8 Installing the Rake Shaft and Discharge Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.8.1 Preparing for the Rake Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.8.2 Installing the Rake Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.8.3 Installing and Adjusting the Discharge Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.9 Feedwell, Mix Trough, Feedpipe, and P-Duc Mixer Installation . . . . . . . . . . . . . . . . . . . . . . 55
5.10 Installing the P-Duc Agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
5.11 Installing the Rake Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
5.12 Inspecting the Drive for Final Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.12.1 Shimming for Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
5.13 Adjusting the Rake Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
5.14 Installing the Pickets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
5.15 Guide pocket and wear ring segment installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.16 Installing the Recirculation Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.17 Final Mechanical Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
5.18 Arrangements for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
Chapter 6: Operation
6.1 Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
6.2 Preliminary Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
6.2.1 Filling the Thickener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.3 Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 67
6.4 Process Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
Chapter 7: Maintenance
7.1 Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
7.2 Inspection Points Before Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.3 The Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
7.3.1 Verifying Drive Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3.2 Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3.3 Electrical Equipment and Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3.4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
7.3.5 Drive Maintenance Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.3.5.1 Safely Relieving Stored Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.3.6 Drive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.3.6.1 Gearbox Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.3.6.2 Gearbox Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.3.6.3 Gearbox Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
iv
Table of Contents
7.4 Maintenance and Start-Up Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.77
7.4.1 Parts and Repair Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.77
Chapter 8: Troubleshooting
8.1 Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.80
Appendix A: Lubrication
A.1 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .84
A.2 Choosing the Correct Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.84
A.3 Lubricating the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.85
A.3.1 Oil Change Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.86
A.3.2 Oil Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.86
A.4 Used Oil Cleanliness Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.87
A.5 Lubrication of Other Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.88
A.5.1 Accessory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.88
A.6 Sight Glass (Oil Gauge) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.88
A.7 Lubricants and Equivalents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.88
A.7.1 Synthetic Oils (2 SYN - 5 SYN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.88
A.7.2 Synthetic Oils (6 SYN - 8 SYN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.89
A.7.3 Mobil SHC 600 Series Synthetic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
A.7.4 Petroleum-Based Oils (2EP - 5EP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
A.7.6 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .91
A.8 Hydraulic Oil Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.91
A.8.1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .91
A.8.2 Transferring Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.92
A.8.3 Types of Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.92
A.8.4 Hydraulic Oil Equivalents List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Appendix B: Final Mechanical Inspection

B.1 Final Mechanical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.94
Appendix C: Maintenance Schedule

C.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
Appendix D: Recommended Spare Parts List

D.1 Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
06

v
Table of Contents
Appendix E: Parts List/Bill of Materials

E.1 Parts List/Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Appendix F: Drawing Package

F.1 1000259385—13 m Dia. B Thickener Top Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
F.2 1000255844—General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
F.3 1000255845—Foundation Plan and Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
F.4 1000255665—P&ID, Symbol Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
F.5 1000255667—P&ID, Motor and Valve Control Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
F.6 1000255745—P&ID, Nomenclat. and Abbrv. Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
F.7 1000255668—Piping and Instrumentation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
F.8 1000255662—Piping & Instrumentation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
F.9 1000254655—Piping and Instrumentation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
F.10 1000265435—Mechanism Steel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
F.11 1000265455—Raking Mechanism Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
F.12 1000267910—Superstructure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
F.13 1000267924—Superstructure Shop Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
F.14 1000265480—Feed and Floc. System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
F.15 1000265475—E-Volute Feedwell Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
F.16 1000265445—Flocculant Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.149
F.17 728424—B60P-3 Hydraulic Drive Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
F.18 559435—Input Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.153
F.19 544343—Basic Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.154
F.20 544340—Upper Bearing Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
F.21 593316—Nameplate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.156
F.22 728425—Hydraulic Piping Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
F.23 1000272648—B60P-X Direction Indication Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
F.24 672675—Zero Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.160
F.25 1000267930—P-Duc Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.161
F.26 1000275000—Recirculation Piping Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
F.27 1000275040—Recirc. Piping Connection & Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
F.28 1000265431—Connections and Fasteners List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
F.29 114808—Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.168

vi
Chapter 1: Safety
Contents
1.1 Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.3
1.1.1 Hazard Signal Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1.1.2 Safety Signs and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1.1.2.1 Mandatory Action Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.2 Prohibition Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2.3 Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
1.2 Safe Working Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..7
1.2.1 Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
1.2.2 General Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
1.2.4 Lockout/Tagout (Energy Isolation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.5 Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..9
1.2.6 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.9
1.2.7 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.10
1.2.8 Equipment Safety Signs and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.2.9 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.10
1.2.9.1 Emergency Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.2.9.2 Safety Trip Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.2.9.3 Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12
1.2.9.4 Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12
1.3 General Risks and Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12
1.3.1 Identifying and Controlling Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.3.2 Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .13
1.3.3 Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .13
1.3.4 Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .13
1.3.5 Elevated Work Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.13
1.3.6 Harness and Line (Fall-Arrest System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.7 Cranes and Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.8 Moving Parts on Stationary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.9 Remote Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.14
1.3.10 Confined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.14
1.3.11 Welding, Cutting, and Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.15
1.3.12 High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.15
1.3.13 Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.15
1.3.14 Inclement Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.15
1.3.15 Noise and Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.15

1
Chapter 1: Safety
1.3.16 Pinch and Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3.17 Electrical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
1.3.18 Fuels, Oils, and Lubricating Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.19 Surface Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
1.3.20 Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Hazardous Chemicals and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.1 Mineral Powders (Silica) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.2 Lime and Calcined Raw Meal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.3 Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
1.4.4 Acids and Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.5 Cyanide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
1.4.6 Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
1.5 Emergency Preparedness Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2
Hazard Symbol Symbol Description

This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury and death.
“Danger” indicates an imminently hazardous situation which,

if not avoided, could result in death.
“Warning” indicates a potentially hazardous situation which,

if not avoided, could result in death, serious injury, or
property damage.
“Caution” indicates a potentially hazardous situation which, if
not avoided, MAY result in minor or moderate injury and
property damage. It may also be used to alert against unsafe
practices.
“Notice” is used to draw attention to detailed instructions.
These notes are intended to give further important
information regarding the equipment and/or a step in a
procedure.
Chapter 1: Safety
1.1 Important Safety Information

FLSmidth recommends that equipment be installed, operated, and maintained in
accordance with all applicable governmental safety and health laws, regulations, and
generally recognized industrial standards.
The information provided in this chapter is intended to provide a general overview of
safety guidelines recommended by FLSmidth, and is not an exhaustive list of all
standard safety procedures. The specific guidelines outlined below may or may not
apply to your particular equipment. FLSmidth is neither responsible nor liable for
incorrect or unsafe practices or policies.
Follow all governing safety standards and local job site procedures.
1.1.1 Hazard Signal Indicators

Danger, Warning, and Caution indicators are located throughout the manual at
specific points of interest and alert the reader to the relative degree of a hazard.
These notices are given to prevent personal injury, death, equipment damage, and/or
improper service, and must be followed to reduce or eliminate these risks. Always
heed these notices, and practice common sense when performing any maintenance
or repair procedure.
Table 1-1: Hazard Signal Indicators

1.1.2 Safety Signs and Symbols
Additional safety signs and symbols may appear along with the Danger and Caution
indicators, and are used to specify certain hazards. These warnings describe
particular areas where special care and/or procedures are required in order to
prevent serious injury and possible death.

3
Chapter 1: Safety
1.1.2.1 Mandatory Action Symbols
Mandatory Action Symbols are referred to as Personal Protective Equipment (PPE)

and are identified by a blue circle with a white symbol in the middle signifying the
type of protective equipment required. These symbols indicate a mandatory action
required to safeguard personal health and/or avoid risk of personal injury.
FLSmidth recommends that personnel wear the correct PPE at all times, and that all
PPE meet local country standards, and where appropriate, international standards
such as ISO, ANSI and EN. Follow all governing safety standards and local job site
procedures.
The followin
Mandatory Description Mandatory Description
g table contains Action Action the compreh
Symbols Symbols
ensive list of ma ndatory actio
General Mandatory Action Wear Protective Clothing
n symbols and
their descrip
tions. The symb Refer to Instruction Manual Use Handrail ols below ma
y or may not ap ply to your e
quipment.
Wear Ear Protection Wear a Face Shield
Wear Eye Protection Wear Head Protection
Connect an Earth Terminal Wear High Visibility

to the Ground Clothing
Disconnect Plug from Wear a Mask

Outlet
Wear Opaque Eye Wear a Safety Harness

Protection
Wear Safety Footwear Disconnect Before

Carrying Out
Maintenance or Repair
Wear Protective Gloves Use This Walkway

Prohibition Description Prohibition Description
Symbols Symbols
Copyright © 2017 FLSmidth A/S. All rig hts reserved.
General Prohibition No Pushing
3/29/18
9232504935
FLSmidth is constantly striving to impro ve its product
s and must therefore reserve the right t No Smoking No Sitting o change desi
gns, materials, specifications, and price without notic
e.
4
No Open Flame, Fire, Open No Stepping on the
Ignition Source, or Smoking Surface
No Thoroughfare Do Not Use Lif in Event of

Fire
No Access for People with No Eating or Drinking

Active Implanted Cardiac
Devices
No Metallic Articles or Do Not Use Lif for People

Watches
Do Not Touch No Running
No Heavy Load No Climbing
No Reaching In Do Not Enter
Chapter 1: Safety
Table 1-2: Mandatory Action Symbols
1.1.2.2 Prohibition Symbols
FLSmidth recommends the use of prohibition symbols that are used to indicate a
prohibited action. They are identified by a red circle with a diagonal line running
through and the black symbol in the middle (sometimes accompanied by words).
These symbols signify what not do or what is prohibited.
The following table contains the comprehensive list of prohibition symbols and their
descriptions. The symbols below may or may not apply to your equipment.
Table 1-3: Prohibition Symbols

5
Chapter 1: Safety
1.1.2.3 Warning Symbols
FLSmidth recommends the use of warning symbols that are used to signify potential
danger. These symbols are identified by a triangle with a yellow background and a
black symbol in the middle signifying the danger.
Warning Description Warning Description The followi
Symbols Symbols
ng table contain s the comp
General Warning Automatic Start-Up
rehensive list of warning sy
mbols and their

Explosive Material Crushing
Floor Level Obstacle Flammable Material
Drop Fall Sharp Element
Slippery Surface Corrosive Substance
Electricity Crushing of Hands
Forklif and Other Counter Rotating Rollers

Industrial Vehicles
Overhead Load Battery Charging
Toxic Material Oxidizing Substance
Hot Surface Explosive Atmosphere
descriptions. The symbols below may or may not apply to your equipment.
There may be additional types of signage to those shown above depending on the
country or site. Ensure that you familiarize yourself with, and understand the signage
that is used at your site.

6
Table 1-4: Warning Symbols
Chapter 1: Safety
1.2 Safe Working Practices

Safe working practices are essential when working in construction areas with heavy
equipment. The high noise levels, dust conditions, and ever-present danger of high-
powered machinery demands that safety be observed by all personnel on the job
site, and most specifically by those working on or in the immediate area of the
equipment.
Do not install, operate, maintain, or repair this equipment until you have read and
fully understand the instructions and warnings in this manual. Failure to follow
these safety precautions could result in personal injury, death, or property damage.
• Proper care is your responsibility.

• All maintenance and repair of this equipment shall be performed in accordance
with safety warnings. Failure to do so may result in personal injury or property
damage.
1.2.1 Operator Responsibilities

Machinery is to be operated by those with prior experience operating sophisticated
equipment and systems, and who have been appropriately trained and certified in
the proper use of this particular machinery.
FLSmidth recommends that equipment be installed, operated, and maintained in
accordance with all applicable governmental safety and health laws, regulations, and
generally recognized industrial standards.
1.2.2 General Safety Recommendations

FLSmidth recommends that assembly, operation, and maintenance personnel
observe the following general safety guidelines.
• The installer, operator, or a designated maintenance technician perform both a
pre-start inspection as well as a walk-around inspection.
• Do not put equipment into operation unless all regularly scheduled maintenance
and any unscheduled, but necessary, repairs have been performed.
• Adhere to the recommended maintenance schedule for machinery and
component parts.
• Use all of the systems designed to keep people safe when in the area of the
equipment, including proper safety signs and any standards appropriate to the
specific country where the site is located.
• Do not override any safety system.
• Engage the equipment controls slowly.

7
Chapter 1: Safety
• Ease components into motion gradually to prevent shock load damage and
unnecessary wear on gear cases and other moving parts.
• Keep hands and anything you are holding out of any area with moving parts.
• Prevent tripping and falling hazards around the equipment according to your site
requirements.
• Ensure all working components come to a complete stop before reversing the
controls.
• Do not leave the operator’s station unattended while the equipment is in
operation.
• All operator and maintenance personnel be familiar with the emergency
shutdown procedures and locations where they can activate an emergency stop
system shutdown.
Note: FLSmidth cannot anticipate every possible circumstance that may involve a
potential hazard, therefore, the safety and informational prompts in this manual are
not all-inclusive. If a tool, procedure, work method, or maintenance technique not
specifically recommended by FLSmidth is used, ensure its safety prior to use. Ensure
that lubrication, maintenance, or repair procedures don’t damage the machinery or
make it unsafe for operation. For more information on maintenance and repair proce-
dures for items furnished but not manufactured by FLSmidth, refer to the original
equipment manufacturer instructions.
1.2.3 Unauthorized Modifications

Unauthorized modifications to the equipment may impair its function and/or capacity
to operate safely, and may lead to shortened equipment life and unsafe operating
conditions. Do not take shortcuts on equipment repair. Read all instructions
thoroughly.
1.2.4 Lockout/Tagout (Energy Isolation)

The purpose of Lockout/Tagout (LOTO) and related procedures is to avoid
electrocution or accidental start-up of the machine(s) or parts during maintenance or
service. An unwanted start or movement can lead to serious injury or death. Follow
all governing safety standards and local job site LOTO procedures.
Examples of potential risk include:
1. A machine that was switched off is suddenly restarted from a remote control
panel or locally by mistake.
2. A machine unexpectedly energizes due to a failure in the machine control sys-
tem.
3. Residual energy such as compressed gas or liquid, as well as spring or gravity
loads, is suddenly released and applies considerable force to one or more parts.
Further, FLSmidth recommends that chains, blocking, locking pins or other hardware
be used for isolating, securing or blocking machines or equipment from mechanical
energy sources, including springs and gravity loads.

8
Chapter 1: Safety
The equipment used for securing the machinery is to be strong enough to effectively
prevent movement of the machine, for example, using a weak chain will provide a
false sense of security as it may break. Follow all governing safety standards and local
job site procedures.
1.2.5 Conveyor Belt

Conveyor belt tensioning systems store massive quantities of energy under normal
operating conditions. An uncontrolled release of this stored energy due to a belt tear
can cause serious personnel injury or even death.
When inspecting conveyor systems observe the following safety points:
• Never touch a conveyor belt or its associated moving parts such as idlers and
sheaves until you are completely sure the system has been locked out and
tagged out.
• A moving belt, idler, or coupling can catch a body part, loose clothing, or safety
ropes and pull a person into the equipment to their death.
Do not attempt maintenance or lubrication near a moving belt.
• Make sure all potential energy that could cause personnel danger is correctly
locked out and tagged out.
• Lock out systems that may feed material onto the belt, as well as nearby
equipment that may cause a hazard.
• If there is any evidence of a problem with a splice, shut down the belt and clear
the area of all personnel.
Note: If a belt breaks, it tends to spring in the direction that is in-line with the
belt, towards the ends.
• Never walk over or stand on top of a belt in case of sudden belt movement.
• Always wear your Personal Protective Equipment (PPE) when dealing with
conveyor systems.
1.2.6 Fire Extinguishers
Fire is a major cause of loss of life and property throughout the world. While fire
normally does not pose a grave danger on open construction sites with steel and
concrete as major materials, it may occur at any time and anywhere.
Have fire extinguishers available and know how to use them. Inspect and have them
serviced as recommended on their instruction plates. Follow all governing safety
standards and local job site procedures.

9
Chapter 1: Safety
1.2.7 Emergency Procedures

The best way to deal with emergencies is to prevent them in the first place. Conduct
all your on-site activities in accordance with the site safety regulations.
Each site will have its own procedures, which you will learn at your site induction. If
the emergency procedures are not provided to you, it is your duty to seek out the
emergency procedures, telephone numbers, and radio channels that are used on site.
Always follow site procedures when dealing with an emergency situation. Use your
site emergency call procedure and be ready to provide relevant information.
1.2.8 Equipment Safety Signs and Labels

Equipment supplied by FLSmidth is fitted with safety signs and labels in accordance
with global safety standards. Read and understand all safety signs and labels on your
equipment before installing, operating, lubricating, or maintaining this equipment.
Make sure safety signs and labels are legible.
Replace any safety signs and labels that are damaged or missing. If a safety sign or
label is attached to a part that is replaced, install a new safety sign or label on the
replacement part.
1.2.9 Protective Devices

Your equipment may be fitted with devices that are designed to provide protection
for personnel who are working on or around the equipment. To maintain safety it is
critical that these devices are kept in place and correctly maintained.
Protective devices may include the following:
• Emergency Stop Switches

• Safety Trip Wires
• Interlocks
• Guards
1.2.9.1 Emergency Stop Switches
Moving machines are typically fitted with emergency stop (E-stop) switches located at
strategic places on the machine. These E-stop switches will immediately cut off the
power source to the machine, and, once triggered, require manual (physical) reset
before the machine may be started again either locally or from a remote control
room.
Ensure that the distance from any moving part to the nearest E-stop switch is as short
as possible. In some cases, such as with a long belt conveyor, this would be difficult to
achieve. In this case, the conveyor would be fitted with cables running along the
length of the machine and tied to the E-stop switches. The belt can be stopped at
10
Chapter 1: Safety
anytime by pulling a cable from any location. The figure below is a typical E-stop
switch fitted to a local control station in the field.
Figure 1-1: Emergency Stop Switch
1.2.9.2 Safety Trip Wire
Trip wire assembly and switches (one cord on each side) allow equipment to be
stopped without using the control panel push buttons. Follow all governing safety
standards and local job site procedures
Trip wire cords are connected to E-stop switches. Once one of the trip wire cords is
pulled, the wiring circuit is broken and the motor will stop.
Note: If your equipment includes a vacuum pump motor, be advised that this is not
stopped by the trip wire system.
The following figure shows a typical trip wire switch that is installed along each side
of the equipment.
Figure 1-2: Trip Wire Emergency Stop Switch
Never use a trip wire or emergency stop switch as a means of isolating equipment.
Trip wire and emergency stop switches are normally controlled through software
systems and as such they do not provide positive isolation.

11
Chapter 1: Safety
1.2.9.3 Interlocks
Machines equipped with interlocks prevent a malfunction from having disastrous

consequences. The power source may be cut off if problems are detected, such as:
• Motor overload (current too large)
• Speed too slow (speed monitors)
• Part of machine out of normal range (proximity switch)
• Excessive vibrations (vibration detector)
• Excessive heating of machine (thermo couple)
Belt alignment switches are used on conveyor belts to monitor whether the belt is
properly aligned, and notify the operator if the belt is moving outside the roller path.
If you are operating a chain of transport equipment, a stop on any machine will
automatically stop all upstream machines to avoid overfilling the stopped machine.
The downstream machines will, in most cases, be allowed to continue so that they
will empty themselves.
1.2.9.4 Guards
Guards prevent the possibility of personnel becoming entangled in moving parts.

Ensure that guards are intact and securely in place at all times while the machine is
operating.
If you need to remove guards to conduct maintenance work or clear a blockage,
ensure that the equipment is shut down, isolated, and rendered safe before doing so.
Do not operate any part of the equipment if all guards are not securely in place.
There are some moving parts of the equipment for which guards are not practical.
Such unguarded areas have been evaluated as safe to work around with proper
training and safe work practices.
1.3 General Risks and Hazards

Working at industrial sites unavoidably poses hazards from various activities and
conditions. In the following sections, several well-known industry hazards are
outlined and precautions are described accordingly. Follow all governing safety

12
Chapter 1: Safety
1.3.1 Identifying and Controlling Hazards

It is important to identify and control hazards before beginning any work or task. This
is called risk management. There are four basic steps in risk management:
1. Identify the hazards: Before you begin any task on or around the equipment,
inspect the area and consider the task to ensure that you are able to identify
hazards or potential hazards.
2. Assess the risks: When you have identified the hazards or potential hazards,
assess each one to determine the overall level of risk. Risk is determined as the
potential severity of the hazard and the likelihood of an incident being caused
by it.
3. Eliminate or control the hazards: If the risk is too great, put controls in place to
eliminate or control the hazard. Controls will vary according to the situation so it
is up to the established site procedures and the personnel conducting the task
to find methods that are suitable for the conditions.
4. Reassess the risks if conditions change: Whenever the conditions that existed
when the initial assessment was conducted change, carry out the assessment of
the hazards and risks again. This is to ensure that the changed conditions do not
increase the likelihood of an incident or increase the severity of an incident.
1.3.2 Ladders
When the working height is greater than 1.8 m (6 f.) special considerations and
equipment is required. Put site emergency procedures in place when conducting
work at heights to ensure any incident will be handled with a proper emergency
response. Follow all governing safety standards and local job site procedures.
1.3.3 Scaffolds
Scaffolds are the most important means of ensuring safety when working at heights.
Ensure that anyone constructing or climbing on scaffolds is aware of the basic safety
precautions. Correct any scaffold deemed unsafe immediately. Follow all governing
safety standards and local job site procedures.
1.3.4 Railings
FLSmidth recommends that all stairways, open-sided floors, and loading docks
contain perimeter or fall protection devices such as a removable guardrail, a guardrail
fence, or two chains strong enough to withstand the weight of someone sitting on it.
1.3.5 Elevated Work Conditions

Train personnel riding in or working from the following devices to the local job site
requirements and maintain 100% tie-off procedures.

13
Chapter 1: Safety
• Personnel lifs
• Hoisting devices
• Elevated work platforms
1.3.6 Harness and Line (Fall-Arrest System)
FLSmidth recommends that fall arrest system components be properly rated and
mutually compatible. Follow all governing safety standards and local job site
procedures.
1.3.7 Cranes and Lifting Operations

Operating cranes, whether mobile or fixed, present unique risks for both the operator
and the equipment. Train crane operators by approved site management. Follow all
governing safety standards and local job site procedures.
1.3.8 Moving Parts on Stationary Equipment

The primary risk associated with stationary machinery is that anyone close enough to
the machine may get hands, arms, feet, or loose clothing caught in the moving parts:
shafs, rollers, cranks, v-belt drives, etc. This type of accident ofen occurs when the
victim is climbing on or gets too close to a machine that starts suddenly via a remote
control, or is already running. The consequences will be injuries (squeezing or
crushing of extremities), but can also result in death.
Take care to ensure the safety of all personnel near moving equipment components.
Ensure that all procedures are followed, and equipment guards are in place and
undamaged before starting work. Never place your body near any moving parts, and
always wear the correct PPE. Follow all governing safety standards and local job site
procedures.
1.3.9 Remote Starts

Remote starting of machines will normally be accompanied by a start warning, either
audible (siren) and/or visual (flashing lights). The start warning is intended to allow
employees enough time to move to a safe distance away from the machinery.
If maintenance or repair work is to be carried out, machines are furnished with a
power source or controls that permit Lockout/Tagout (LOTO). Follow all governing
safety standards and local job site (LOTO) procedures.
1.3.10 Confined Spaces

Confined Space Entry (CSE) is the entry of personnel into any space or structure not
normally intended for human occupancy, in which entry, movement within or exit is
restricted, such as underground vaults, tanks, storage bins, pits and diked areas,
vessels, silos, etc. These enclosed or partially enclosed spaces:

14
Chapter 1: Safety
• Are large enough for an employee to enter fully and perform assigned work.
• Are not designed for continuous occupancy by the employee.
• Have a limited or restricted means of entry or exit.
1.3.11 Welding, Cutting, and Brazing

FLSmidth recommends that all welding and brazing operations have proper
ventilation. Fumes such as those produced when working with Zinc, Cadmium, and
painted surfaces can be toxic.
1.3.12 High Temperatures

Operations involving high air temperatures, radiant heat sources, high humidity,
direct physical contact with hot objects, or strenuous physical activities can have a
high potential for causing heat-related illness/injury. Workplaces with these
conditions may include iron and steel foundries, nonferrous foundries, cement
plants, rubber products factories, electrical utilities (particularly boiler rooms),
chemical plants, mining sites and smelters. Potential Hazards are thermal burns due
to contact with hot equipment or exposure to high temperatures. Follow all
1.3.13 Power Lines

Be aware of power lines in the area and consider all power lines energized unless
proper measures have been taken for de-energizing. Follow all governing safety
1.3.14 Inclement Weather

The local Health and Safety Executive (HSE) or business management can provide a
means to determine the weather forecast for the project location. FLSmidth
recommends that you take precautionary measures during severe conditions. Follow
all governing safety standards and local job site procedures.
1.3.15 Noise and Vibrations

Prolonged exposure to loud noise can impair hearing or cause permanent hearing
loss. To protect from hearing loss, FLSmidth recommends the following:
• Always wear PPE to protect against noise.
• Measure the noise levels for areas that may be considered a noise hazard.
• All personnel working in areas that exceed permissible exposure levels are
required to wear job site-approved ear protection.

15
Chapter 1: Safety
Excessive noise can permanently damage your hearing. If you need to raise your
voice to be heard, wear hearing protection.
Some tools and equipment can expose employees to vibrations which potentially can
be harmful if not properly mitigated. Some vibration when operating this equipment
is to be expected. However, excessive vibration is ofen an indication of a problem
with the machine. Trace the sources of excessive vibration and rectify any problems
as soon as possible. Do not allow yourself to be exposed to vibration for long periods
of time. Follow all governing safety standards and local job site procedures.
1.3.16 Pinch and Crush Points

Pinch points or crush points are a major hazard for personnel working around
equipment. Loose clothing or hand tools that are placed anywhere near a pinch point
can result in the person being dragged into rotating or moving equipment.
• Always be aware of pinch point hazards.
• Never attempt to remove material from a moving conveyor or other equipment.
• Never place your hands, any part of your body, or anything you are holding in a
location where rotating or moving parts could pinch the item and drag you in.
• Never work on any part of a conveyor or equipment that is running.
• Never work on a stopped conveyor unless it has been correctly shut down,
isolated, locked out, and tagged out.
Crushing and shearing points can occur in the following locations on equipment:
• Between the belt and drive pulley.

• Between the belt and take-up rolls.
• Between the best and idler rolls.
This equipment may be provided with casings and covers, specifically at the discharge
and feeding points, to reduce injuries from pinching or crushing. Ensure that
maintenance and repair is done only by specifically instructed personnel.
1.3.17 Electrical Energy

Electrical hazards have the potential to cause serious injury to personnel or damage
to equipment. FLSmidth recommends that only trained, competent, and authorized
personnel work on electrical components and equipment. Follow correct isolation
procedures when working on electrical equipment. FLSmidth further recommends
that the following precautions be taken:
• Do not override or bypass any electrical safety functions.
• Keep control panel doors closed at all times.
• Do not use oversized fuses, buss bars, or heaters.
• Connect the motor drives and accessories to an electrical ground, such as an
underground water piping system, the frame of a building, etc.

16
Chapter 1: Safety
Do not undertake electrical work if you are not trained, competent, and authorized
to do so.
FLSmidth recommends that electrical systems comply with the relevant electrical
provisions. Ensure that work done on the electrical system is carried out by certified
electricians only. Ensure that all electrical components are interconnected and
grounded according to correct and safe electrical procedures. Follow all governing
1.3.18 Fuels, Oils, and Lubricating Fluids

During the operation of this equipment, you may come into contact with fuels,
coolant, lubricating oils, and/or specialized greases. These products can be hazardous
if safety procedures are not followed when handling them. FLSmidth recommends
that you do the following:
• Always read, understand, and follow the directions on the relevant Safety Data
Sheet (SDS) before handling any chemical, fluid, or grease.
• Use the correct PPE for any task you conduct. Some SDS sheets will specify extra
PPE.
• Some systems use an acid wash containing hydrochloric (muriatic) or other
acids. These acids can cause severe burns, irritation of mucous membranes, and
skin irritation even in dilute solutions. Fumes may cause respiratory problems.
Eye protection, skin protection, and respiratory masks are required when
working with this material.
• Avoid long periods of contact between your skin and any fluids associated with
this equipment.
• Avoid breathing mist and vapors from fluids associated with this equipment.
• Do not touch your eyes, mouth, or face with dirty hands.
• Clean up fluid spills immediately using approved job site procedures.
• Do not carry oily rags in your pockets.
• Change out of oil-soaked clothing as soon as possible.
• Ensure operators know what they are handling and whether it presents special
problems. When the filtered product has known hazardous characteristics, keep
specific antidotes and appropriate first aid supplies in the immediate area.
• Report any significant contact with fluids or greases to your supervisor.
1.3.19 Surface Heat

Certain components on equipment can become hot during operation. Ensure that
you are aware of potential hot components in your working area and treat them with
caution.

17
Chapter 1: Safety
FLSmidth recommends that if any components seem disproportionately hot, shut

down the equipment and investigate and report immediately. Excessively hot
components can indicate a mechanical problem and may result in equipment damage
and/or unsafe situations for personnel.
During commissioning, operation, maintenance, repair, and shutdown, contact of hot
machine components or electrical equipment may occur. Instruct all personnel
accordingly.
Never place your hands on any item of equipment until you are certain it is at a safe
temperature.
1.3.20 Lines, Tubes, and Hoses

FLSmidth recommends that operators and maintenance personnel take precautions
to isolate and de-pressurize, if necessary, any pressurized lines or vessels before they
are opened. Observe the following safety points:
• Inspect all lines, tubes, and hoses carefully.
• Do not use your bare hands to inspect for leaks.
• Tighten all connections to the recommended torque.
• Do not bend or strike high pressure lines.
• Do not install bent or damaged lines, tubes, or hoses.
• Repair any loose or damaged hydraulic oil lines, tubes, and hoses.
Leaks can cause fires.
Note: Even though the equipment is switched off and electrically isolated, the con-
tents of pipes and vessels may still be under high pressure.
If high-pressure water or air hoses are being used, FLSmidth recommends that all
quick-connectors are fitted with a safety clip similar to one shown in the figure below.
Figure 1-3: Safety Clip

18
Chapter 1: Safety
1.4 Hazardous Chemicals and Materials

Many materials used in the industry contain hazardous ingredients that potentially
pose health risks to employees. FLSmidth recommends that the appropriate Safety
Data Sheet (SDS) be obtained for all hazardous materials used on site, and that the
SDS be available for personnel and supervisors working with these chemicals. Careful
study of the SDS and adherence to the required safety precautions can improve on-
site safety.
FLSmidth also recommends that chemicals be properly labeled. Follow all governing
1.4.1 Mineral Powders (Silica)

Mineral powders may be natural, such as sand or gravel, but very ofen they are an
intermediate product in the cement or mining industry (ore concentration). Mineral
powders will also be generated as dust from grinding or cutting operations in stone or
concrete, or by handling dry soil. Follow all governing safety standards and local job
site procedures.
1.4.2 Lime and Calcined Raw Meal
Lime and Calcined Raw Meal is a fine powder consisting of a mixture of calcined (heat
treated) natural minerals, primarily calcined limestone (CaO) and clay/silicates.
Smaller amounts of aluminum, iron and magnesium compounds as well as reaction
products such as calcium-silicates and calcium-aluminates may also be present in the
mix, together with trace amounts of other metal compounds. Follow all governing
1.4.3 Cement
FLSmidth recommends that anyone who uses cement, or mixtures containing it, or is
responsible for managing or supervising its use, is aware that it may be a hazard to
health and safety, and to use safe working practices to minimize risks. Follow all
1.4.4 Acids and Bases

Strong acids include nitric (HNO3), sulphuric (H2SO4), hydrochloric (HCl) and
phosphoric (H3PO4) acid. Of especially dangerous nature is hydrofluoric acid (HF).
Strong acids give off heat when diluted with water, which may lead to vapor
explosions. Follow all governing safety standards and local job site procedures.
1.4.5 Cyanide
In some processes, including gold mining, the use of cyanide (Calcium cyanide CaCN;
Potassium cyanide KCN; Sodium cyanide NaCN) is common. Any work with a direct

19
Chapter 1: Safety
risk of interacting with cyanide requires additional training. Follow all governing
1.4.6 Solvents
The most abundant toxic materials are solvents; other toxic materials include
pigments (lead), paint, binders (epoxies, polyesters) and additives (organotin). Follow
all governing safety standards and local job site procedures.
1.5 Emergency Preparedness Plan

Refer to your site emergency preparedness plan.
Note: Emergency preparedness plans are a critical component of safety.

20
Contents
2.1 Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .22
2.2 Installation and Start-Up Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.23
2.3 Shipment and Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.23
2.4 Parts and Repair Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .24
2.5 Warranty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .24
2.5.1 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.24
2.5.2 Equipment Installers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.25
2.6 Accessory Equipment Manufacturer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.7 FLSmidth Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .26
21
2.1 Using this Manual

This manual describes the FLSmidth® 13 m dia. B Thickener and outlines its
installation, maintenance, and operational procedures. It also includes a number of
FLSmidth-recommended best practices.
FLSmidth has designed this equipment to provide dependable, efficient, and
economical operation throughout its entire period of service. In order to achieve the
desired level of performance and ensure full warranty coverage, it is required that
users thoroughly read, understand, and follow the contents of this manual before
carrying out the installation, making any adjustments, or operating the equipment.
Regular care and maintenance must also be performed as outlined in this manual.
The accessory items, (items furnished but not manufactured by FLSmidth) shall be
stored, installed, operated, and maintained according to the original equipment
manufacturer instructions for complete warranty protection.
Note the following:
• The Manual set includes an Installation, Operations, and Maintenance Manual.

• The procedures described in this manual do not relieve users of their
responsibility to exercise caution and common sense.
Users are responsible for their own personal safety when operating this
equipment.
Users must comply with all safe working procedures and instructions relevant
to their work site at all times.

• Pictures, descriptions, and technical data may not match your equipment in
every aspect.
• The information, specifications, and illustrations in this manual are written
according to information available at the time it was produced, therefore, this
information may change at any time. These changes could include one or more
of the following: lubrication, storage, installation instructions, maintenance, etc.
FLSmidth reserves the right to make changes without notice and without
obligation to replace existing manuals.
• FLSmidth will not furnish editable electronic copies of any data, manuals, and/or
drawings at any time and accepts no liability whatsoever for unauthorized
changes and/or alterations to the data provided.
• All information contained in this manual is the property of FLSmidth. None of the
content may be copied or made public without prior written consent from
FLSmidth.
• English is the governing language. When manuals are translated into any other
language, FLSmidth is not liable for damages caused by errors in translation. The
English translation will govern in case of discrepancies. In the event there is
confusion, notify your FLSmidth representative immediately. Refer to http://
www.flsmidth.com/en-US/Contact for applicable address and telephone
numbers for the FLSmidth Office nearest you.
• FLSmidth accepts no liability to update the information contained in this manual.
These materials are provided "AS IS" WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED
WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR
NON-INFRINGEMENT. YOU ASSUME COMPLETE RESPONSIBILITY AND RISK FOR

22
USE OF THESE MATERIALS. Some jurisdictions do not allow the exclusion of

implied warranties, so the above exclusion may not apply to you.
• BY USING THIS MANUAL YOU AGREE THAT YOU HAVE READ, UNDERSTAND, AND
AGREE TO THE TERMS OF USE.
2.2 Installation and Start-Up Services

Experienced FLSmidth engineers and service personnel are available to assist in the
installation, safety training, and start-up of your FLSmidth equipment. These
personnel have technical expertise and firsthand knowledge of this equipment, as
well as the backing of the engineering and research facilities of FLSmidth.
Service personnel instruct on proper safety, operating and maintenance procedures,
advise on best practices and troubleshooting assembly, and can supervise the entire
installation and start-up.
To request this assistance, make arrangements at the earliest possible date, outlining
the services required and the approximate duration of needed service.
Refer to your FLSmidth representative or http://www.flsmidth.com/en-US/Contact to
submit your request concerning the availability and/or charges for these services.
2.3 Shipment and Receiving

Although every precaution is taken by our shipping department to ensure your items
arrive as ordered and undamaged, we strongly recommend that you carefully inspect
the shipment upon receipt. If equipment packaging is damaged, photos of the
damage as well as notification to FLSmidth will be required within five days of
shipment receipt.
Note: All equipment must be stored in their original shipping containers, especially
when such containers are wooden crates or cardboard cartons as this will maintain
necessary storage protection.
• Refer to the installation lifing instructions before handling the equipment.
• Boxes opened for inspection must be carefully handled to prevent damage or
loss of contents, and all parts must be repacked or stored in a safe place with all
protective covers reinstalled until assembly.
In case of damage or missing parts, immediately notify the carrier and your FLSmidth
representative at http://www.flsmidth.com/en-US/Contact.
You must notify FLSmidth within the time frame specified in your contract in the
event of shortages and/or discrepancies on the shipment. FLSmidth is not
responsible for replacing items if notification occurs outside the contractual time. If
no time-frame has been specified in your contract, you must notify FLSmidth within
30 days.

23
2.4 Parts and Repair Orders

Please contact FLSmidth for parts, repair orders, and/or equipment service, referring
to http://www.flsmidth.com/en-US/Contact for the FLSmidth Office nearest you.
To make sure the right replacement parts are received and to avoid undue delay,
please provide the following information with each order:
• Size and Type of Unit: 13 m dia. B Thickener
• Tag Number: 682-400-A-TH01
Note: This is found on the unit nameplate.
• FLS Order Number: 9232504935

• Specific Component Part Numbers and Descriptions: (See individual component
part nameplates included on the drawings for these part numbers.)
• Special Field Modifications: This is important if the original material or design
has been changed. Include drawings and/or other descriptive information.
2.5 Warranty Conditions

Your FLSmidth-provided equipment (the “Equipment”) is designed with dependability
in mind. However, this unit can be damaged through misuse and by failing to follow
the storage, installation, and maintenance procedures outlined in this manual.
FLSmidth will not be responsible for damage to the Equipment, component parts, or
other related structures, nor will the warranty coverage on the Equipment be valid if
any of the following apply:
• The Equipment is operated in an incorrect or negligent manner.
• The Equipment is not maintained in accordance with provided instructions.
• Operating conditions fall outside those specified for the Equipment, as originally
designed and supplied.
The Equipment must be installed only by trained personnel who have been
thoroughly trained in the safety procedures pertaining to it.
2.5.1 Limited Warranty

a. FLSmidth warrants the Equipment to be free from defects in material and work-
manship. Refer to your contract for specific warranty terms and conditions.
b. FLSmidth warranties are subject to the Equipment being properly stored,
erected, installed, maintained and operated in accordance with FLSmidth
instructions and good industry practice and exclude ordinary wear and tear,
improper loading of Sofware and/or Firmware, corrosion, erosion, chemical or
abrasive action, power failures, power surges, other fluctuations in power,
excessive heat, improper lubrication, extended storage before start-up, unau-
thorized repair, replacement, modification or alteration of the Equipment; or
application outside the contractual design limitations of the Equipment.

24
c. Buyer shall provide FLSmidth with written notice of a defect in materials or

workmanship, including a full description thereof, within 14 days afer the
defect is or should have been detected and in any event before expiration of the
warranty period.
d. FLSmidth agrees to repair or, at its option, replace at its expense, FCA shipping
point (Incoterms 2010) any Equipment or parts and components thereof, exclud-
ing the costs of dismantling and re-installation of the Equipment and/or parts
and components, that prove during the warranty period to contain defects in
materials or workmanship.
e. The remedies stated in this Article are Buyer’s exclusive remedies for breach of
this FLSmidth warranty. In no event shall the exclusive remedies in this Article be
considered or alleged to have failed their essential purpose. Buyer agrees that if
there are any discrepancies or inconsistencies between this Limited Warranty
and the warranty terms and conditions accompanying the Contract, the war-
ranty terms and conditions accompanying the Contract shall always govern.
f. EXCEPT FOR THE EXPRESS WARRANTY STATED IN THIS ARTICLE, FLSMIDTH
EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED,
STATUTORY, AT LAW OR IN EQUITY. THERE ARE NO IMPLIED WARRANTIES OF
MERCHANTABILITY, FITNESS OF PURPOSE, OR OTHERWISE.
2.5.2 Equipment Installers

FLSmidth does not anticipate problems with installation of the Equipment. However,
if a problem develops due to fabrication or engineering errors, FLSmidth will not
accept back charges unless they are authorized in advance and in writing by an
FLSmidth Project Manager. Before corrective work is started, the installer/erector
must obtain an FLSmidth Field Work Order that must include a cost limitation.
Payment may be refused for corrective work that is done without the above
authorization.
Authorized charges will be paid only on the basis of standard direct field labor hours,
material, and variable overhead. Other charges will not be allowed.
All drawings and erection or installation instructions must be followed. Drawings
provided will always govern. In the event of any discrepancies, notify your FLSmidth
representative immediately, referring to http://www.flsmidth.com/en-US/Contact for
contact information.
2.6 Accessory Equipment Manufacturer Information

Whenever the installation, lubrication, maintenance, or operation of an accessory
piece of equipment (item which is furnished by FLSmidth but is fabricated by a third
party) is discussed in the FLSmidth instruction manual, this information is provided
only as a courtesy, and is as-is, with no warranty expressed or implied. This
information must be verified by consulting the original equipment manufacturer
manuals, which are the ruling documents for any accessory equipment.
As manufacturer instructions or recommendations may change over time, it is the
user’s responsibility to periodically consult the manufacturer to obtain the most up-
to-date information, including maintenance instructions and recall information.

25
In the event of any discrepancies between the information found in the FLSmidth
instruction manual and the information in the OEM manuals, notify your FLSmidth
representative immediately, referring to http://www.flsmidth.com/en-US/Contact.
As with any mechanical equipment, there are safety concerns associated with the
installation of the primary and accessory equipment. It is absolutely essential that
installers, operators, maintenance personnel, and supervisors be instructed in safe
working practices.
2.7 FLSmidth Offices
Afer completion of the contract, all service and spare parts will be supported by the
closest FLSmidth Regional Headquarters. 
Refer to http://www.flsmidth.com/en-US/Contact for the FLSmidth Office nearest
you.

26
Chapter 3: Storage
Contents
3.1 Long-Term Storage Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.28
3.1.1 Maintaining Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.28
3.2 Outdoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .28
3.3 Covered or Indoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.28
3.4 Equipment Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .29
3.5 Preventing Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .29
3.5.1 Shop Primer Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.29
3.5.2 Protective Finishes or Seal Coats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.5.3 Machined and Non-Coated Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.6 Storing Elastomer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.30
3.7 Storing Fiberglass Reinforced Plastic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.8 Storing Equipment After Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.31
3.9 Storing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .32
3.10 Environmental Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.33
27
Chapter 3: Storage
3.1 Long-Term Storage Introduction

The storage procedures in this manual are general guidelines and standard practices
that aid in maintaining the condition of the equipment during long-term and pre-
commissioning storage. If storage time is between 3 and 24 months, the following
procedures shall be followed. If storage time is to exceed 24 months, contact
FLSmidth for further instructions.
3.1.1 Maintaining Warranty

FLS warranties are subject to the equipment being properly stored as outlined below.
Items with bearings must be rotated (pulleys, idlers, motors, and drives) according to
the bearing manufacturer’s requirements. For items with lubrication requirements,
refer to Appendix A: “Lubrication” on page 83 for more details. Failure to follow these
instructions, in addition to the manufacturer’s requirements, will void component
warranty.
When storing items for extended periods—six months or longer—detailed records
shall be created, maintained, and submitted to FLSmidth to show that all equipment
and components are properly maintained during storage period. A paid periodic
inspection by an FLSmidth Service Personnel may be required to maintain the
warranty. For the specific terms and conditions of your equipment warranty please
contact your FLSmidth representative.
Failure to comply with these storage instructions will void the FLSmidth warranty.
3.2 Outdoor Storage

Site selection for outdoor storage of FLSmidth supplied equipment and accessories
shall be:
• Level, well-drained, firm surface, clean, and dry
• Isolated or barricaded from possibility of physical damage from transport
vehicles
• Accessible for periodic inspection and maintenance
• Away from direct sunlight, moisture, and excessive vibration
• Away from high concentrations of dust or corrosive gas
• Sensitive components must be covered with a well drained and ventilated tarp
or tent structure
• Painted and protective corrosion resistant coating must be inspected on
monthly intervals, repaired, re-applied, or replaced as necessary
• Substantial corrosion (other than loose surface rusting) consult FLSmidth for
recommendations for corrective action
3.3 Covered or Indoor Storage

Covered storage consists of any structure with a roof to protect the equipment and
components from the sun and rain.

28
Chapter 3: Storage
Indoor storage consists of a closed-in structure that will protect from sun, rain, wind
and dust.
Refer to Table 3-1 on page 32 for electrical sensors, wiring, and motor storing
methods.
Covered or indoor storage shall have the following conditions:
• A constant temperature (between 5°C and 40°C [41°F and 104° F]), with no
sudden temperature fluctuation
• A relative air humidity of ≤ 50%
• Relatively free of dirt or dust deposits
3.4 Equipment Support

Large fabricated equipment components must be supported in a manner that will
allow free air flow under and around the component being stored. Place supports
(steel beams or wood timbers—not supplied by FLSmidth) of significant size and
strength at appropriate load-bearing locations. Store and support all components
shipped on skids and pallets or in crates and shipping containers in a manner that will
allow free air flow under and around the skid, pallet, crate, or shipping container.
3.5 Preventing Corrosion

Equipment that is in storage or that is out of service for more than 30 days must be
protected against corrosion damage.
Regularly scheduled equipment inspections are critical for proper storage of
FLSmidth supplied equipment and components. These inspections include the
following:
• Inspect primer paints, protective finishes, seal coats, and corrosion protection
treatments thoroughly on a monthly schedule.
• Repair, re-apply, or replaces protective coatings as necessary.
• If there is substantial corrosion (other than loose surface rusting), contact
FLSmidth for recommendations for corrective action.
FLSmidth will not be responsible for the condition of protective coatings afer the
equipment leaves the contracted fabrication facility. FLSmidth assumes no
responsibility for field surface preparation or touch up of shipping damage to
protective coatings.
Identification tags that are removed for field painting prior to assembly must be
reattached to the original components for correct identification.
3.5.1 Shop Primer Paints

In some cases, equipment is supplied with shop primer paint only. Regularly inspect
these finishes for deterioration.

29
Chapter 3: Storage
Shop primer paints are intended to serve only as a bonding coat between metal
surfaces and protective finishes or seal coats and to act as a minimal protective finish.
In such cases, protective finishes or seal coats shall be applied as soon as possible.
When this is not possible, remove rust or oxidation and re-apply shop primer paints
as needed.
All shop primer paints must be applied using the paint manufacturer’s recommended
processes and environmental conditions. Shop primer paints for repair purposes are
not supplied by FLSmidth.
3.5.2 Protective Finishes or Seal Coats

In most cases, equipment is supplied with a complete protective finish or seal coat.
Regularly inspect these finishes for deterioration. If rust or oxidation is found, clean
the surfaces and re-apply the appropriate protective finishes.
All paint must be applied using the paint manufacturer’s recommended processes
and environmental conditions. Protective finishes or seal coats for repair purposes
are not supplied by FLSmidth.
3.5.3 Machined and Non-Coated Surfaces
All machined and other non-coated surfaces (uncoated machined surfaces, shafing,
mating surfaces, threaded holes, and piping flange faces) must be clean and free of
rust and other foreign matter. All machined and non-coated surfaces must have a
corrosion protection treatment applied that is adequate for the selected storage
conditions. All corrosion protection treatments must be applied using the
manufacturer’s recommended processes and environmental conditions. Corrosion
protection treatments for repair purposes are not supplied by FLSmidth. Some
examples of corrosion protection treatments include the following:
• A.W. Chesterton Company (740 Heavy Duty Rust Guard)
• Esgard Inc. (920 Equipment Kote)
• Tectyl Industrial Products (Tectyl 506EH-WD)
• Houghton International Inc. (Rust Veto 342)
Note: There are many other brands and types of corrosion protection treatments
available in the market. If in doubt about a particular product, contact FLSmidth for
recommendations and/or approval of the product in question.
3.6 Storing Elastomer Components

Elastomer and Elastomer-covered (Urethane, Polyurethane, Natural Rubber,
Neoprene, Nitrile, EPDM, and M.O.R.) products in storage can be adversely affected
by temperature, humidity, ozone, sunlight, oils, solvents, corrosive liquids and fumes,
insects, rodents, and radiation. Proper care shall be taken to meet the following
requirements.
• Elastomer parts shall be protected from physical damage by objects that can cut
or tear.

30
Chapter 3: Storage
• If stored below 0°C (32°F), some products may become stiff and will need to be
warmed before being placed in service. Do not store elastomer products near
sources of heat, such as radiators and base heaters.
• To protect against the adverse effects of ozone, do not store elastomer products
near electrical equipment that may generate ozone or in geographical areas of
known high ozone concentrations. Avoid exposure to direct and reflected
sunlight.
• Whenever feasible, store elastomer products in their original shipping
containers, especially when such containers are wooden crates or cardboard
cartons, since this will provide protection against the deteriorating effects of
oils, solvents, and corrosive liquids. This will also afford some protection against
ozone and sunlight.
• Since certain rodents and insects thrive on rubber products, provide adequate
protection against them.
• Rotate all elastomer products on a first-in, first-out basis. Even if all above
conditions are met, a prolonged length of time in storage will result in the
deterioration of elastomeric products.
3.7 Storing Fiberglass Reinforced Plastic Components

Fiberglass reinforced plastic products (Safety Guards or Receiver Tanks) in storage can
be adversely affected by temperature, ozone, sunlight and corrosive liquids and
fumes. Proper care shall be taken to meet the following requirements.
• The ideal storage temperature for fiberglass reinforced plastics is 0°C to 32°C
(32°F to 90°F) with a maximum limit of 38°C (100°F). If stored below 0°C (32°F),
some products may become brittle and caution shall be taken when placing
Outdoor
Outdoor
Covered
Covered
these components into service. Fiberglass reinforced plastic products shall not
Storage
Storage
Storage
Storage
Storage
Storage
Indoor
Indoor
be stored near sources of heat, such as radiators and base heaters.
• Whenever feasible, fiberglass reinforced plastic products shall be stored in their
original shipping containers, especially when such containers are wooden crates
or cardboard cartons, since this will provide protection against the deteriorating
effects of corrosive liquids & fumes and will also afford some protection against
ozone and sunlight.
• All fiberglass reinforced plastics products shall be on a first-in, first-out basis.
Even if all above conditions are met, a prolonged length of time in storage will
result in the deterioration of fiberglass reinforced plastics products.
PartClassification
3.8 Storing Equipment After Operation

If the equipment will be removed from service for two months or longer afer it has
been in use, additional steps will be required for proper storage. Refer to Chapter 7:
“Maintenance” on page 71 for detailed instructions on properly storing the
equipment afer operation.

31
Chapter 3: Storage
3.9 Storing Methods

The table below provides a basic classification of parts supplied by FLSmidth along
with the preferred storage locations for each part. Selection of the storage method
will depend greatly on the size and quantity of parts being stored, as well as the
preventative measures needed during the storage period.
Whenever possible, the preferred storage method shall be chosen and the
Equipment-SpecificParts
appropriate preventative measures followed. If the preferred storage method is not
possible, the optional storage method can be chosen. When neither the preferred or
optional storage methods are possible; contact FLSmidth for additional instructions
on tertiary storage methods and preventative measures.
Preferred Optional
Storage Method Storage Method
Heavy Fabrications X X
BHSAs X X
Electric Motors X X
Gearboxes X X
Blowers X X
Compressors X X
Pumps X X
HPUs X X
Hydraulic & Pneumatic X X
Actuators
Instruments X X
Valves X X
Bearings X X
Seals X X
Temperature
UVExposure
Cleanliness
Ventilation
Elastomer & Elastomer X X

Humidity
Covered Components
V-Belts X X
Sheaves & Bushings X X
Fiberglass Components X X
Table 3-1: Preferred Storage Methods

32
Chapter 3: Storage
Table 3-1: Preferred Storage Methods
3.10 Environmental Precautions

The following tables highlight the major environmental precautions that must be
addressed in order to maintain proper condition throughout and afer long-term
storage. Table 4-2 outlines the specific precautions for equipment that is stored for
up to six months, and Table 4-3 outlines the precautions for equipment that has been
in use prior to storing.
Environmental Precautions
Items
Metal and Machined Parts N Y Y Y N
Elastomer parts (Urethane, Y N Y Y Y

Polyurethane, Rubber)
Fiberglass Parts N N N Y Y
Polypropylene Filter Plates Y Y N N Y
Table 3-2: Environmental Precautions - Storage up to 6 Months

Temperature
UVExposure
33
Cleanliness
Ventilation
Humidity
Chapter 3: Storage
Environmental Precautions
Items
Metal and Machined Parts Y Y N N Y
Elastomer parts (Urethane, Y N Y N Y

Polyurethane, Rubber)
Fiberglass Parts N N N N Y
Polypropylene Filter Plates Y Y N N Y
Table 3-3: Environmental Precautions - Installed Equipment Idle 30 Days or More

34

Contents
4.1 Equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .36
4.1.1 Thickener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .36
4.1.2 FLSmidth Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.36
4.1.3 Rake Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.36
4.1.4 Torque Overload Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.36
4.1.5 Local Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.36
4.1.6 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.37
4.1.7 Walkway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .37
4.1.8 Drive Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.37
4.1.9 Rake Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .37
4.1.10 Feedwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .37
35
4.1 Equipment Overview
4.1.1 Thickener
The 13 m diameter thickener is a bridge-supported thickener.
4.1.2 FLSmidth Drive Assembly

The drive assembly consists of a rake drive enclosed in separate housings with seals
between the rotating and fixed components. All gears and bearings require oil bath
lubrication. No gears and bearings of any type are located below water level. The
drive is shop assembled and test-operated prior to shipment. The support base is
designed for bolting to the support structure.
Oil sight glasses are included for oil reservoirs. Readily accessible lubricant fill and
drain pipes (with necessary fittings) are also provided.
4.1.3 Rake Drive Unit

The rake drive contains a heat-treated steel main spur gear and is mounted on a
separate four-point contact precision bearing. The main spur gear is driven by three
alloy steel pinions and reducers. The reducers are directly coupled to hydraulic
motors. All gearing components, as well as the main bearings, are totally enclosed in
a dust-tight steel housing with oil bath lubrication.
The main gear is designed in accordance with AGMA standards for 24-hour
continuous duty.
Note: The main bearing is separate from the main gear.
4.1.4 Torque Overload Control

Hydraulic pressure serves as the means for overload cut out (torque control).
4.1.5 Local Control Panel

A local control panel is provided. This enclosure is mounted on the handrail and is
pre-wired with terminal strip for field connections. (Field wiring and conduit not by
FLSmidth.) The enclosure will include:
• Rake start/stop push button station
• one (1) local torque indication and 4 to 20 ma output
• Alarm horn

36
4.1.6 Superstructure
The beam type bridge is designed to support the walkway, feed pipe, and all normal
operating loads. The bridge is designed to support all dead loads plus a 4.8 kPa
walkway live load. The bridge is supported on the tank wall.
4.1.7 Walkway
Walkway access to the center drive platform is from both sides of the tank periphery.
The walkway surface is 1 1/4 by 3/16 in., welded HDG steel grating. The handrail is 1
1/4 in., DN32 pipe with two rails. The toe plate uses a steel angle (as part of the
support structure) along both sides of the walkway.
4.1.8 Drive Platform

The drive platform is an expanded section surrounding the drive, to provide easy
access and maintenance workspace. The platform surface is 1 1/4 in., galvanized steel
grating. The handrail is 1 1/4 in., DN32 steel pipe with two rails and a steel angle as
part of the support structure.
Note: The handrail steel angle will act as a toe plate around the service platform.
4.1.9 Rake Arms

Two (2) long rake arms are used to rake settled solids to the 3.0 m diameter center
discharge cylinder.
4.1.10 Feedwell
The no. 2.5 Evolute feedwell is supported from the bridge. It is designed to assist
flocculation and promote proper flow patterns within the thickener basin.

37

THIS PAGE INTENTIONALLY LEFT BLANK
38
Contents
5.1 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .41
5.2 Lifting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .41
5.2.1 Shipping Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.42
5.3 Erecting the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .43
5.3.1 Installing the Tank Support Structure and Floor . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.3.2 Installing the Tank Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.44
5.3.3 Sealing the Tank Floor Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
5.4 Inspecting the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .45
5.4.1 Inspecting the Tank Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5.4.2 Conducting the Hydro Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5.5 Installing and Leveling the Weirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.47
5.6 Assembling and Installing the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
5.6.1 Installing the Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.47
5.6.2 Installing the Grating and Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.6.3 Installing the Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.48
5.7 Installing the Drive Units and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.48
5.7.1 Inspecting the Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.7.2 Lifting the Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.49
5.7.3 Installing the Main Drive on the Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.7.4 Inspecting the Drive for Concentricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.7.5 Leveling the Drive (Preliminary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.7.6 Lubricating the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.51
5.7.7 Installing the Inner Section of the Monorail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
5.7.8 Installing the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.51
5.7.9 Connecting the Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
5.7.10 Verifying Drive Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.52
5.7.11 Installing the Hydraulic Power Unit and Piping Assembly . . . . . . . . . . . . . . . .52
5.7.12 Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.53
5.8 Installing the Rake Shaft and Discharge Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.8.1 Preparing for the Rake Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.8.2 Installing the Rake Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.54
5.8.3 Installing and Adjusting the Discharge Scraper . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.9 Feedwell, Mix Trough, Feedpipe, and P-Duc Mixer Installation . . . . . . . . . . . . . . . . . . . . . .55
5.10 Installing the P-Duc Agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.56
5.11 Installing the Rake Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.56
5.12 Inspecting the Drive for Final Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.56

39
5.12.1 Shimming for Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.59
5.13 Adjusting the Rake Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .60
5.14 Installing the Pickets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .61
5.15 Guide pocket and wear ring segment installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
5.16 Installing the Recirculation Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.63
5.17 Final Mechanical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.63
5.18 Arrangements for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.64

40
5.1 Installation Overview
This section provides tips and guidelines for erecting, assembling, and installing an
FLSmidth and associated equipment. The recommendations in this assembly guide
are based on FLSmidth’s previous field erection and supervisory experience with
similar projects. If you have problems or questions regarding installation, contact
your FLSmidth representative. Refer to http://www.flsmidth.com/en-US/Contact for
the FLSmidth Office nearest you.
This equipment has been designed for a specific duty cycle. The project requirements
and specifications, operating conditions, and safety factors comprise the design
parameters for this system. As its intended design use is specific, the system must not
be used for other purposes. If it is so used, the owner assumes full liability.
The instructions and recommendations in this erection and assembly guide are
general in nature. They are designed to accommodate common variations in
equipment designs. Therefore, the actual assembly requirements for your equipment
may vary somewhat from these guidelines. In all cases, the actual project drawings in
this document package take priority over these instructions.
FLSmidth field service professionals are also available to guide site contractors
through common variations to these instructions. For assistance, refer to http://
www.flsmidth.com/en-US/Contact for the FLSmidth Office nearest you.
Prior to beginning installation of the equipment, make sure all of the assembly
drawings are readily available and all installation personnel are familiar with them.
These drawings can be found in Appendix F: “Drawing Package” on page 123 of this
manual.
5.2 Lifting the Equipment

All structural components must be lifed and handled as covered below. Proper
handling is necessary to protect special coatings or coverings, and to ensure ease of
assembly during equipment installation.
Do not pull, drag, push, or dump the structural components of of the carrier.
Stand clear as the equipment is lifted.
Do not use chains for lifting components that are painted or have special coatings
or coverings.
1. Verify that the equipment being lifed and the lifing equipment cannot come
into contact with overhead structures or electrical cables.
2. Verify that the rigging and hoist equipment are of adequate lifing capacity.

41
Note: Weights for major components are listed in Appendix E: “Parts List/Bill of
Materials” on page 107.
3. Have experienced personnel do all rigging and lifing.
4. Before removing the equipment from the carrier, ensure that the blocking, brac-
ing, and banding that are securing it to the carrier have been removed, and
ensure that the equipment is ready to be moved.
5. Use multiple-point lifing whenever possible.
6. Verify that the included angle between slings from a common hook or eye does
not exceed 60°.
7. When lifing structural members of this equipment, such as rake arms or super-
structures, avoid twisting or bending the members.
8. Use spreader beams, as necessary, to fully support the pieces as they are lifed.
9. Verify that the shop provided camber is maintained when lifing the superstruc-
ture.
10. Lif the equipment 25-51 mm (1-2 in.) off the carrier to make sure that it is free
to be moved and that it is balanced correctly. Adjust, as necessary.
11. Do not move the equipment suddenly or in jerks. Do not allow the equipment to
strike the ground, tank, or other equipment.
12. When lifing components, use rubber belting, burlap, or other padding between
the lifing cables and the equipment to prevent damage to the protective cover-
ings. Refer to Figure 5-1.
1- Included angle must be less than 60° (typ- 2- Typical structural component
ical)
Figure 5-1: Structural Component Lifting
5.2.1 Shipping Braces

1. Shipping braces may be used to protect segmented superstructures and rake
arms from damage during shipping. This bracing must be removed.

42
Note: Shipping braces are marked “Shipping Brace Only” in white or purple
painted letters. Support braces, bars and banding must not be removed until
necessary.
2. Burn the braces from the chords, angle braces, or structural members, as
required.
3. Do not attempt to scarf braces, as this may cause weakening of the structural.
5.3 Erecting the Tank

Erect the tank according to the fabricator’s instructions. Refer to F.2 “1000255844—
General Arrangement” on page 125, F.10 “1000265435—Mechanism Steel
Assembly” on page 135 and F.3 “1000255845—Foundation Plan and Loads” on
page 127 drawings for orientation and height specifications.
5.3.1 Installing the Tank Support Structure and Floor

1. Ensure all column footings are in place and are properly cured. Clean all pads of
any debris and ensure level tolerance to within ± 5 mm across the extent of all
footings. Ensure that the tops of the supports have been adequately scrabbled
(not by FLSmidth).
2. Inspect the location of all anchor bolts. These must be located within ± 2 mm of
the locations shown on F.3 “1000255845—Foundation Plan and Loads” on
page 127.
3. Place the discharge cylinder in position on temporary blocking, orienting as
specified.
4. Afer noting correct orientation of columns in relation to site, position the outer
columns onto their respective footings. Install, but do not secure, the anchor
nuts.
5. Position the inner columns onto their respective footings. Install, but do not
secure, the anchor nuts.
6. Vertically align the inner and outer columns to within 1/500. Make level all col-
umn top flanges in radial sets to within ± 1 mm, shimming under the columns, as
required. These tolerances are the required tolerances afer the floor is com-
plete.
7. Inspect chord dimensions at the tops of the columns.
Note: If adjustment is necessary to maintain correct chord dimensions, the ver-

tical alignment of the affected columns will need to be reinspected.
8. When all columns are correctly positioned and aligned, the diagonal bracing
must be installed to prevent any unplanned movement of the columns. The
erectors may wish to install alternate rows, or omit selected rows initially, in
order to facilitate access to the structure, which is acceptable, but the same
principles regarding bracing and tolerances must be applied.
Note: Do not install grout under the column base plates until the tank floor seg-
ments have been installed.

43
Due to the possibility of the columns moving during the installation of other
components, it is essential to monitor and maintain the relevant column
dimensions and tolerances while the other structural components are being
installed. The tops of the columns must remain in a true circular pattern and
the columns must remain vertical.
9. Place the first floor segment in position on the outer and inner columns, and in
alignment with the connection surface on the discharge cylinder.
10. Connect the floor segment to the discharge cylinder and to the outer and inner
columns, using the fasteners specified. Do not secure the fasteners at this time.
11. Place the remaining floor segments in position, as described above. Install, but
do not secure the tank flanged connection fasteners.
12. Ensure that the outer ends of the floor segments are concentric with the center
of the tank and in alignment with each other. If in doubt as to how to proceed,
contact FLSmidth immediately!
13. Use a laser leveler (not by FLSmidth) to ensure that the outer top rims of the
floor segments are level with each other and level in the horizontal plane. Adjust
the outer columns, as necessary, shimming under the column base plates.
14. Secure the fasteners connecting the floor segments to the columns and dis-
charge cylinder.
15. Secure the fasteners at the flanged tank floor connection.
16. Complete installation of the diagonal bracing, as required.
17. When the tank support structure and floor installation has been completed and
signed off by the relevant parties, grout under the column bases using a non-
shrinking type grout. Allow the grout to set completely before proceeding with
tank erection.
5.3.2 Installing the Tank Wall

The tank wall sections will be shipped direct from the fabricator.
1. Look for any match marking made by the fabricator to identify the respective
tank sections. The tank shell plates will usually be as large as shipping restric-
tions allow, and will be rolled for horizontal strakes.
2. Inspect the orientation of the bridge support brackets and launder sections. The
orientation of the tank components, as shown on the fabricator’s tank assembly
drawings, is important and must be followed carefully during tank erection.
Until the tank wall is completely assembled, the structure will be prone to adverse
reactions from the efects of wind loads. It is therefore essential that temporary
internal bracing be used during the construction of the tank. Any scafolding to be
used during the construction may be utilized to assist with this requirement.

44
3. Secure the tank wall flanged connection fasteners, referring to the fabricator’s
tank assembly drawings.
5.3.3 Sealing the Tank Floor Sections

1. Apply Sikaflex 291 sealant along all flanged tank connections: floor segments,
floor segments to tank wall sections, and floor segments to the discharge cylin-
der. Refer to Figure 5-2 below.
Note: Sealant must not be applied between any flanges.
2. Allow the sealant to cure completely.

1- Tank flange 2- Sikaflex 291 sealant 3- Tank fasteners
Figure 5-2: Seal Tank Floor Sections
5.4 Inspecting the Tank

Reference F.2 “1000255844—General Arrangement” on page 125.
The tank must conform to specification in order to accommodate the mechanism. If
the tank fails to meet these specifications, requiring any modifications of the
equipment, FLSmidth will not accept the charge. Inspect the tank as follows:
1- Bridge mounting surface 2- Tank bottom center 3- Bottom of discharge cylinder

4- Tank true center 5- Wall diameter 6- Centering of discharge cylin-
der
7- Bridge mounting holes 8- Launders 9- Tank bottom specified slope
10- Plan view 11- Side view 12- Bridge supports
13- Bridge centerline 14- Tank centerline

45
5.4.1 Inspecting the Tank Dimensions

1. Verify the elevation at the bridge mounting surface at (1) only.
2. Verify the elevation at the bottom center at (2) and the bottom of the discharge
cylinder at (3).
3. Inspect the bridge mounting bolt hole locations (7) for alignment with true cen-
ter at (4) and for correct orientation. Launders at (8) must be specified elevation
and size.
4. Inspect the tank bottom for specified slope (9) at approximate 90° locations
around the tank.
Figure 5-3: Tank Points of Inspection
5. Verify the location and orientation of under-tank pumps (not supplied by FLS) as
shown on F.2 “1000255844—General Arrangement” on page 125 for proper
installation of discharge nozzles.
5.4.2 Conducting the Hydro Testing

1. Conduct the hydro testing.
a. Blank off all tank nozzles.
Note: Hydro testing involves slowly filling the tank with water while closely
observing the tank for any leaks or structural anomalies.
b. Inspect for any settlement of the tank at the footings and repair as necessary.
Note: Ensure that the hydro testing of the tank is successfully concluded prior
to commencing installation of the superstructure or mechanism.

46
2. Drain the tank.
5.5 Installing and Leveling the Weirs

1. Install the weirs and adjust them in their mounting holes for the liquid level
shown on F.2 “1000255844—General Arrangement” on page 125. Snug-tighten
the fasteners.
2. If the weirs do not fit flush with the launder, apply a mastic sealer or silicone
sealant (not supplied by FLSmidth) between the launder and the top and/or bot-
tom of the weirs. This is to prevent leakage when the tank is full, and only a rec-
ommendation.
1- Weir 2- Seal 3- Launder

Figure 5-4: Weir Illustration
3. The weirs must be level. Inspect them in a dry tank with a surveyor’s level, or
later with water. Adjust for level as necessary and make sure all fasteners are
secure.
5.6 Assembling and Installing the Superstructure
5.6.1 Installing the Bridge

1. Make sure the bridge support bearing surfaces on the tank are clean and
smooth.

47
2. Assemble the bridge and install this assembly on the walkway supports, orient-
ing it as shown on F.2 “1000255844—General Arrangement” on page 125. Do
not force the connections at the tank wall.
Note: If necessary, elongate the mounting holes at the ends of the walkway.
Leave the nuts loose.
3. Inspect the center opening for the drive unit to make sure it is located directly
over the center of the tank by suspending a plumb line.
4. Inspect the drive-mounting surface on the bridge for specified elevation and
level.
Note: Adjust the bridge as necessary. In some cases shimming may be necessary.
Secure the mounting bolts.
5.6.2 Installing the Grating and Handrails

1. Install the grating for the walkway and drive platform.
2. Make sure the grating sections clear the unit components and fit together with-
out any dangerous gaps or openings. They must fit flush without sharp corners
or edges, and they must be secure.
3. Install the handrails. They must be plumb, square, and level. They must be
anchored securely and all edges and corners must be smooth.
Note: When dissimilar materials are used for the bridge and the grating, the sur-
faces must be separated by material that prevents galvanic action. FLSmidth rec-
ommends a Bi-Metallic adhesive backed neoprene tape for all aluminum to steel
connections.
5.6.3 Installing the Nameplate

Install the FLSmidth nameplate as shown on F.12 “1000267910—Superstructure
Assembly” on page 141.
5.6.4 Installing the Spiral Stairway

Install the spiral stairway referring to the fabricator’s tank assembly drawings.
5.7 Installing the Drive Units and Wiring

Reference drawings: F.19 “544343—Basic Drive Assembly” on page 154, F.2
“1000255844—General Arrangement” on page 125, F.10 “1000265435—Mechanism
Steel Assembly” on page 135, F.28 “1000265431—Connections and Fasteners List” on
page 166, and F.29 “114808—Torque Values” on page 168.
The basic drive assembly and input drive assemblies are shipped, assembled, and
installed as a unit.

48
The weight of the drive is not symmetrically distributed; therefore, special care is
required during lifting. When lifting the drive, the assembly must be stabilized by
attaching cables as required. A spreader bar or beam (not supplied by FLSmidth) is
further recommended.
1. If the drive motor was removed to facilitate transportation, install the motors on
the drive before installing the drive on the bridge.
Note: For more detail installation information, refer to the drive motor manu-
facturer’s instructions.
The gearboxes, planetary reducers, and hydraulic systems are shipped without
oil. Operation of the drive, hydraulic components, or lift components without
the recommended oils filled to the specified levels will void the warranty.
For information about the filling procedures, types, and quantities of lubricant
used in this machinery, refer to Appendix A: “Lubrication” on page 83. Make
sure that the entrapped air has been removed by allowing time for the oil to
settle, or running the machinery briefly, and reinspecting the oil levels.
5.7.1 Inspecting the Drive Assembly

1. Make sure the drive is fully assembled.
2. Inspect the bottom of the drive base and the drive mounting surface for spatter,
dirt, and other foreign material. Remove as necessary for a clean, flat surface.
5.7.2 Lifting the Main Drive

1. Lif the drive assembly; use the appropriate lifing gear.
2. Stabilize the assembly by attaching cables as necessary.
Note: A spreader bar or beam (not supplied by FLSmidth) is further recom-

mended to avoid any damage to the reducer and drive assemblies.
3. Keep the drive level at all times.
5.7.3 Installing the Main Drive on the Bridge
1. Orient the drive assembly as shown on F.2 “1000255844—General Arrange-
ment” on page 125.
2. Raise the drive above the bridge and slowly and carefully lower the drive down
through the superstructure until the drive base frame comes to rest on top of
the mounting frame. Align the drive mounting holes with the mounting holes in
the drive mount on the superstructure.

49
3. Install the fasteners from the drive to the drive mount, but leave the nuts loose.
4. Install the superstructure top strut. Refer to F.12 “1000267910—Superstructure
5. Mount the monorail on the superstructure, using the fasteners specified. Refer
to the bolt tightening instructions on F.12 “1000267910—Superstructure Assem-
bly” on page 141. Mount the stop angles on the monorail, using the fasteners
specified.
5.7.4 Inspecting the Drive for Concentricity

1. Inspect the center of the drive output flange compared with the true center of
the tank for concentricity.
2. Adjust the drive as required.
5.7.5 Leveling the Drive (Preliminary)

Adjust the drive to near level using a machine level. Afer installation of the rake shaf
and arms, the drive will need to be adjusted for final level by shimming.
Note: Do not walk on the superstructure during the leveling. Stand straddling the
superstructure centerline to ensure the accuracy of the leveling.
1. Remove points, burrs, and other foreign material for greater accuracy.
2. Inspect for level using a carpenter’s level. Verify in two directions at 90° to each
other.
a. Inspect the level for accuracy by turning the level 180° and reinspecting it.
3. If the drive is level within tolerance, no further action is necessary. If the level is
not within tolerance, proceed as follows:
a. Loosen the base frame fasteners and adjust the frame for level by using the
jackscrews.
b. Support the frame with wedges adjacent to the jackscrews and insert the
supplied shims around each base plate mounting bolt.
c. Snug tighten the drive mounting bolts equally.
Figure 5-5: Drive Initial Level
1- Leveling jackscrew 2- Wedge 3- Drive-to-mount fasteners

4- Drive housing 5- Drive mount

50
5.7.6 Lubricating the Drive

Refer to the lubrication instructions in Appendix A: “Lubrication” on page 83
The drive is shipped from the factory without lubricating oil and/or grease.
Prior to being operated, the drive, including all accessory equipment components,
must be lubricated.
5.7.7 Installing the Inner Section of the Monorail

Install the inner section of the monorail referring to F.12 “1000267910—
Superstructure Assembly” on page 141.
5.7.8 Installing the Control Panel

Install the control panel by referring to F.2 “1000255844—General Arrangement” on
page 125. FLSmidth does not locate or install the control panel.
5.7.9 Connecting the Electrical Wiring

FLSmidth does not furnish, locate, or install the interconnecting wiring. All
interconnecting wiring must meet local electrical codes.
Note: The drive motors must be wired so an automatic restarting of the motors can-
not occur afer an automatic shutdown following a torque overload.
The rake drive torque indicator is located in the electrical control panel.

51
The rake electrical wiring can be completed now or afer the drive is final leveled.
Connect the torque cutout and torque alarm pressure switches on the power unit to
the electrical control panel.
5.7.10 Verifying Drive Rotation

The drive is designed for only one direction of rotation. If more than one input drive
assembly is furnished, all drive motors must be connected for that direction as
specified on F.2 “1000255844—General Arrangement” on page 125. If they are not,
that will void the drive warranty and FLSmidth will not pay for damage.
Remove the drive motor from each input drive assembly, then inspect the motor
drive for direction of rotation. Reinstall the motor(s).
Verify direction of pump rotation, shown by the arrow on the coupling guard or on
the pump housing.
Note: Jog the pump motor with the START and STOP buttons.
If rotation is not correct, reverse the two lead wires to the motor. Reinspect the
rotation.
Severe pump damage can occur by operating the drive in the wrong direction.
5.7.11 Installing the Hydraulic Power Unit and Piping

Assembly
Drawing reference: F.2 “1000255844—General Arrangement” on page 125 and F.22
“728425—Hydraulic Piping Assembly” on page 157.
1. Referring to F.2 “1000255844—General Arrangement” on page 125 and the
hydraulic power unit manufacturer's instructions, place the hydraulic power unit
in position on the superstructure.
2. Mount the hydraulic power unit on the platform grating using the support clips
and fasteners specified.
3. Mount the hydraulic lines mounting tower on the drive cover using the existing
drive cover to drive base fasteners.
4. Mount the hydraulic distribution block on the hydraulic lines mounting tower
using the fasteners specified.
5. Install the hydraulic hoses between the hydraulic distribution block and the
hydraulic motors.
6. Install the hydraulic hoses between the hydraulic distribution block and the
hydraulic power unit.
7. Afer electrical wiring has been connected to the hydraulic power unit, use the
hydraulic power unit to purge the hydraulic system of air, collecting any spilled

52
hydraulic oil in an appropriate container. Refer to A.8 “Hydraulic Oil Precau-

tions” on page 91.
5.7.12 Torque Control
Hydraulic pressure serves as the means for overload cut out (torque control).
The drive motor(s) must not be able to restart automatically after a torque
overload. Refer to section 5.7.9 “Connecting the Electrical Wiring” on page 51.
The pressure relief valve on the hydraulic power unit works as secondary torque
control.
If adjustment or maintenance is required, it must be done by an FLSmidth Certified

Personnel with a torque calibration kit.
Contact an FLSmidth representative. Refer to http://www.flsmidth.com/en-US/

Contact for the FLSmidth Office nearest you.
If the drive unit stops due to an overload, do not attempt to restart the unit until
the cause of the overload has been located and corrected. Refer to 7.3.5 “Drive
Maintenance Warning” on page 75.
Hydraulic pressure must be relieved before starting operation of the drive again.
Refer to 7.3.5.1 “Safely Relieving Stored Energy” on page 75.
The drive motor(s) has been selected for the specified torque and output speed
required for this mechanism.
Do not change motor power or motor output speed without consulting FLSmidth
for engineering evaluation and comments.

53
Do not operate this equipment, if guards have not been installed, or if they have
been removed or damaged.
All guards must be properly installed and must be functional before this equipment
is operated.
All guards and safety devices, which are not furnished by FLSmidth, must meet all
current local and national safety codes.
5.8 Installing the Rake Shaft and Discharge Scraper
5.8.1 Preparing for the Rake Shaft Installation

1. Place the pocket guide and discharge scraper inside the discharge cylinder.
Note: This must be done before installing the rake shaf because the scraper will
not fit past the installed shaf.
5.8.2 Installing the Rake Shaft

1. Set the rake arm assembly in the center of the tank, supported in an upright
position by shoring as required.
2. Inspect the rake shaf for alignment/run-out.
a. Use a long straight edge and two blocks of equal thickness (not supplied by
FLSmidth).
b. Measure the distance from the straight edge face to the rake shaf at two
points 305 mm (1 f) below the flanges.
c. Inspect for run-out in two places at 90° intervals on the rake shaf.
d. The measurements must be within 0.8 mm (1/32 in.).
3. Adjust the Rake Shaf for Alignment.
a. To adjust the rake shaf for alignment, shim between the connecting flanges.
b. Place the shims adjacent the H.S. Bolts.
c. Snug tighten the H.S. Bolts only at this time; do not torque tighten them.
d. Reinspect the rake shaf alignment.
5.8.3 Installing and Adjusting the Discharge Scraper

The discharge scraper is bolted to the rake shaf where it is adjusted for centering/
alignment by shimming.

54
1. Install the discharge scraper.

a. Raise the discharge scraper and connect it to the rake shaf. Refer to F.11
“1000265455—Raking Mechanism Assembly” on page 139.
b. Use the bolts, nuts, and washers specified to secure the discharge scraper to
the rake shaf.
c. Snug tighten the bolts and nuts only at this time; do not torque tighten them.
2. Inspect the discharge scraper.
a. Inspect the discharge scraper for centering in the discharge cylinder.
b. Adjust for run-out that exceeds 13 mm (½ in.) by shimming at the connecting

flange.
3. Adjust the discharge scraper for alignment.
a. To adjust the discharge scraper for alignment, shim between the connecting
flanges.
b. Place the shims adjacent to the bolts.
c. Snug tighten the bolts and nuts only at this time; do not torque tighten them.
d. Reinspect the discharge scraper for centering in the discharge cylinder.
4. Afer the rake shaf and discharge scraper are aligned, tighten the bolts and nuts
at the discharge scraper-to-rake shaf connections, referring to F.11
5.9 Feedwell, Mix Trough, Feedpipe, and P-Duc Mixer

Installation
1. Referring to the part numbers on F.15 “1000265475—E-Volute Feedwell Assem-
bly” on page 147, assemble the feedwell on shoring above the rake arms. Orient
the pieces as shown on the drawings for final position. When lifing the feedwell
sections, take care to prevent changing the radius (curve) of the sections. Lif
the feedwell sections using the lifing lugs provided. Use a spreader beam to
provide a vertical lif.
2. Adjust the feedwell for alignment of the sections and upper rim and secure all
fasteners.
3. Referring to F.10 “1000265435—Mechanism Steel Assembly” on page 135,
mount the feedwell supports to the superstructure, using the fasteners speci-
fied.
4. Raise the assembled feedwell, using multi-point lifing from the lifing lugs, and
attach it to the feedwell supports, as shown on F.10 “1000265435—Mechanism
Steel Assembly” on page 135 using the fasteners specified.
5. Inspect the feedwell upper rim for elevation and level all around.
6. Adjust as necessary and secure all fasteners.

55
7. Referring to the F.14 “1000265480—Feed and Floc. System Assembly” on

page 145, mount the P-Duc mix trough to the feedwell, using the fasteners spec-
ified.
mount the feed pipe supports to the superstructure, using the fasteners speci-
fied.
9. Mount the feed pipe nozzle section to the P-Duc mix trough, using the gasket
and fasteners specified.
mount the P-Duc mix trough to the superstructure, using the specified fasteners.
11. Install the feed piping, including all necessary gaskets, fasteners, valves and cou-
plings. All incoming piping must be independently supported.
5.10 Installing the P-Duc Agitator

Install the P-Duc agitator referring to F.10 “1000265435—Mechanism Steel
5.11 Installing the Rake Arms

1. Place the arms on blocking such that the arms will run parallel with the tank
floor with the bottom of the blades clearing the floor by the amount shown on
F.2 “1000255844—General Arrangement” on page 125.
2. Position the rake shaf to align the arm connections on it with the connections
on the rake arms.
3. Using the fasteners specified, connect the arms to the rake shaf, without forcing
the connection.
4. Remove the blocking equally from each arm, beginning at the shaf and working
outward. Use jacks to assist in the removal.
Note: A final inspection for arm level will be made later.
5.12 Inspecting the Drive for Final Level

The main bearing of the rake drive must be level for proper operation of the
mechanism and maximum bearing life.
The drive will be inspected for level by measuring the level of the drive at the end of a
rake arm, at various points around the tank. It will then be shimmed for level.
The drive must be leveled within a maximum out-of-level tolerance of 0.005 inches
(0.0127 cm) in 12 inches (30.48 cm) distance. This tolerance will be measured on a
large scale using the rake arm, rather than the relatively small area of the drive cover.
Note: Inspecting and leveling must be done when the steel is a uniform temperature,
such as early in the morning or on an overcast day.

56
1. Set up a surveyor's level near the center of the tank.

2. Using the instrument, mark four level benchmarks on the tank wall at the same
height and spaced approximately 90° apart. (Refer to Figure 5-6 "Finding Bench-
marks on the Tank Wall" on page 57 and Figure 5-7 "Rake Arm Reference Marks"
on page 58).
1- “d1” 2- “d2” 3- Use carpenter level to reach

from arm to tank wall
4- Level bench marks (4 places 5- Surveyor's level 6- Reference mark from rake
around the tank) arm
7- Rake arm 8- Note: d1 and d2 are 180 oopposite
3. Rotate the drive and stop one (and the same) rake arm at each of the four level
points marked around the tank.
4. Using a carpenter's level as an extension from that arm to the tank wall, make
the second marks. (These are the “reference marks” in Figure 5-7 "Rake Arm
Reference Marks" on page 58.)
Note: To ensure accuracy, do not walk on the walkway during the inspection. Anyone
on the walkway must stand straddling the centerline.
1- “d 1” 2- “d2” 3- 90°
4- Jackscrews (drive leveling 5- Bridge (walkway) mounted 6- Tank
screws) drive unit
7- Walkway centerline 8- 45°
Figure 5-6: Finding Benchmarks on the Tank Wall

57
Mechanism Diameter Maximum Out-of-Level
Tolerance (d minus d )
1 2
15,240 mm (50 ft) or less 6.35 mm (1/4 in.)
30,480 mm (100 ft) or less 12.70 mm (1/2 in.)
45,720 mm (150 ft) or less 19.05 mm (3/4 in.)
60,960 mm (200 ft) or less 25.70 mm (1 in.)
76,200 mm (250 ft) or less 32.05 mm (1-1/4 in.)

Referring to Figure 5-6 "Finding Benchmarks on the Tank Wall" on page 57 and
Figure 5-7 "Rake Arm Reference Marks" on page 58, compare the difference in
dimensions between the level benchmarks and the rake arm reference marks at
diametrically opposite sides of the tank (two directions, 90° apart).
The difference between the two observed dimensions (d1 minus d2) must not exceed
the maximum out-of-level dimension below:
Figure 5-7: Rake Arm Reference Marks

58
5.12.1 Shimming for Level

Table 5 - 1: Maximum Out-of-Tolerance
Shimming may be necessary to level the drive. Maximum bearing life of the drive unit
main bearing is dependent on proper leveling and shimming. Perfect final leveling is
not practical; however, it must be as accurate as possible. As the diameter of the
mechanism increases, it becomes increasingly difficult to obtain an accurate
adjustment.
In making a final shimming adjustment, take care to tighten the drive mounting bolts
equally and to support each drive mounting bolt, as necessary, with the proper
thickness of shims. Uneven tightening and shimming may cause deformation of the
bearing race, causing shortened bearing life.
Shims:
Use only the stainless steel shims furnished by FLSmidth and attached to the drive
unit. They are provided in sizes and quantities to satisfy most requirements. If more
shims are needed, contact FLSmidth (refer to http://www.flsmidth.com/en-US/
Contact for the FLSmidth Office nearest you), and refer to the parts list for the shim
package part number.
Shimming:
1. Use the jackscrews (drive leveling screws) provided in the base casting to level
the drive.
2. Be sure to release the drive mounting bolts.
3. Remove the support wedges, if used.
4. Using a feeler gauge, inspect clearances at the bolts.
5. Mark clearances on the drive base for ready reference.
6. Shim at the mounting bolts using the FLSmidth-furnished shims (refer to

Figure 5-8 "Using Shims to Level the Drive" on page 60).
Note: Because the shims ensure the level of the drive for optimum service life of the

59
Figure 5-8: Using Shims to Level the Drive

1- Drive base 2- Jackscrew (drive leveling screw) 3- Shim
4- Mounting bolts 5- Example of trimming shims for uneven mounting surface
7. Tighten the mounting bolts.

8. Back off the jackscrews so the drive is supported only by the shims.
9. Reinspect the level of the drive by rotating the arm to the level marks.
10. Adjust, if necessary, until the drive is within specified level tolerance.
5.13 Adjusting the Rake Arms

The purpose of this alignment inspection is to ensure that both rake arms have
proper and equal clearance with the tank bottom so that each arm shares its load and
does not cause uneven loading on the mechanism and drive. This must follow the
final inspection for level of the drive unit.
1. Inspect each rake arm for proper and equal clearance with the tank bottom by
placing several markers (or piles of sand) in a straight line radially from the cen-
ter of the tank along a radial beam, (refer to Figure 5-7 "Rake Arm Reference
Marks" on page 58), then rotating each arm to the reference markers (or piles of
sand) and inspecting the clearances.
60
1- Radial Beam 2- Scallop Bottom Plate 3- Marker (Piles of sand)

Figure 5-9: Rake Arm Adjustment
2. Adjust the arms according to the measures (or piles of sand). Use jacks under
the arms to assist in this adjustment. Add or remove shims at the rake arm to
shaf connections as necessary for arm clearance. Since arms will deflect, it will
be necessary to determine the amount of shims before the arms are moved.
3. Reinspect the arm adjustments for blade clearance. Adjust the arms so that all
blades will be brought to the same exact clearance.
4. Securely tighten all arm-to-rake shaf connection fasteners, referring to F.11
5.14 Installing the Pickets

1. Referring to F.11 “1000265455—Raking Mechanism Assembly” on page 139,
insert the pickets down through the picket sleeves on the rake arm supports and
into position on the rake arms.
2. Weld all the picket-to-rake arm and picket-to-rake arms support connections as
specified on F.11 “1000265455—Raking Mechanism Assembly” on page 139.
The fumes given of during welding and cutting can be injurious to the opera-
tor’s health.
Some fumes, such as those produced when working with Zinc, Cadmium, and
painted surfaces, can be toxic.
Use the piece being welded as the ground to prevent drive unit damage due to
electrical circuit contact.
3. Complete all field touch-up painting, as required.

61
5.15 Guide pocket and wear ring segment installation

1. Mount the wear ring segments in position on the guide pocket, using the fasten-
ers specified.
Figure 5-10: Plan View: Mounting the Wear Ring on the Guide Pocket
1- Guide pocket 2- Wear plate 3- Lower rake shaf
4- Inspect for concentricity and 5- Weld, as specified 6- Discharge cylinder
clearance
2. Adjust the guide pocket with wear plates assembly for concentricity with the
rake shaf.
3. Rotate the rake shaf and ensure that the shaf has proper clearance with the
wear plates all around. The wear plates must not rub on the rake shaf.
4. Weld the guide pocket to the discharge cylinder, as specified on F.11
The fumes given of during welding and cutting can be injurious to the operator’s
health.
Some fumes, such as those produced when working with Zinc, Cadmium, and
painted surfaces, can be toxic.
Use the piece being welded as the ground to prevent drive unit damage due to
electrical circuit contact.

62
1- Guide pocket 2- Wear plate 3- Lower rake shaf
4- Inspect for concentricity and 5- Weld, as specified 6- Discharge cylinder
clearance
5.16 Installing the Recirculation Piping
1. Install the piping and supports as shown on the F.26 “1000275000—Recircula-
tion Piping Assembly” on page 162 using the fasteners called out on F.27
“1000275040—Recirc. Piping Connection & Fasteners” on page 165.
2. Install the recirculation pumps and valves per the manufacturer’s recommenda-
tions.
3. Install the wedge anchors and fully weld supports afer final leveling.
5.17 Final Mechanical Inspection

At the completion of erection or installation of the equipment, an FLSmidth service
representative must complete a final field mechanical inspection of the equipment.
Unless accepted and signed off by the service representative at the completion, the
warranty will not be in effect.
Previous inspections will not count towards final acceptance unless a sign-off is
obtained, in writing, from the service representative. Also, depending on any
Figure 5-11:
previous Mounting
inspections, the Wear
this final Ring onmay
inspection thebe
Guide Pocket an additional paid
considered
service call.

63
5.18 Arrangements for Service

Complete the Appendix B: “Final Mechanical Inspection” on page 93 for each
mechanism furnished before you contact your FLSmidth representative to arrange for
the final field mechanical inspection.
Make arrangements for field mechanical inspection at least two weeks in advance
with your FLSmidth representative. Refer to http://www.flsmidth.com/en-US/Contact
for the FLSmidth Office nearest you.
Do not fill the tank with water.
The final field mechanical inspection cannot be done if the tank is filled with water.
If the final field mechanical inspection cannot be performed, you will be charged for
an additional paid service day.

64
Contents
6.1 Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .66
6.2 Preliminary Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .66
6.2.1 Filling the Thickener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.66
6.3 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . .67
6.4 Process Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .69

65
6.1 Operation Overview

The section explains how to operate the sedimentation equipment and related
systems safely and efficiently.
6.2 Preliminary Start-Up

Determine the following prior to thickener start-up:
• The process in which the thickener is installed and its general duty.
• Dilution required for optimal feed solids concentration.
• Expected (target) underflow (U/F) solids concentration.
• Screen analysis of feed.
• Expected tonnage (dry solids) through the thickener.
• Chemical properties of the feed (alkaline and acid).
• Solids throughput (tons per 24 hours) for thickener design and any other
pertinent settling properties.
• Expected overflow clarity.
• If flocculants will be used, the type and expected dosage.
Note: FLSmidth may be consulted for some of this information.
Become familiar with the plant layout piping including:
• Method of feeding.
• Method of discharging overflow from thickener tank.
• Method of discharging the U/F.
• Piping at the discharge cone. Make sure that provisions for a high-pressure water
line have been installed between the discharge cone and pump for back
flushing, if necessary, and that the valves are installed for proper control.
Miscellaneous inspections include:
• Ensuring the rake mechanism is lubricated in accordance with Appendix A:
“Lubrication” on page 83.
• Inspecting the rake mechanism assembly and performance during several
revolutions of the arms (with the tank dry).
Note: Visualize possible operating difficulties. Minor adjustments or corrections
may be made by on-site personnel. If major corrections are necessary, contact
http://www.flsmidth.com/en-US/Contact for the FLSmidth Office nearest you.
• Ensure ancillary systems such as feed pumps, overflow launder, piping and tank,
U/F pumps, and flocculant dosing system are in good working order.
6.2.1 Filling the Thickener
The thickener should be filled with process water or clear process liquor initially, so
that the feedwell will function correctly when slurry feed is commissioned.

66
It is not recommended to fill the thickener with slurry or starting feed to the
thickener when empty due to poor flocculating and settling conditions.
Thickeners started up without filling with process water will usually produce high
solids in the overflow and (if used) will require excessive flocculant addition until
operational stability has been achieved.
Note: Typically, filling the thickener to bottom of feedwell is sufficient.
6.3 Start-Up
Remember that the only way the thickener will operate properly is to withdraw solids
at the same rate they are fed to the tank. Most thickeners are not designed for
storage and so accumulated solids will overload the rake mechanism resulting in
shutdown.
Note: Some thickeners are designed for limited storage, but they are a special case
and operation is subject to special considerations.
1. In starting operation, start with a full tank of process water or process liquor as
explained in 6.2.1 “Filling the Thickener” on page 66. Otherwise, the solids set-
tle rapidly and excessive time is required to balance thickener operation.
2. If applicable, (if using flocculant), start the flocculant dosing pumps, prior to
slurry feed; open flocculant distribution valves 100%.
3. Start the rake mechanism and the U/F pumps. It may be desirable to bleed in
some water at the U/F sump to ensure solids fluidity during start-up.
Note: It may be necessary to turn U/F pumps off at start to build up solids bed
inventory inside the thickener.
4. The objective is to get the thickener "in balance" as soon as possible. "In bal-
ance" means the screen analysis and tonnage of the underflow are the same as
the feed.
5. The best procedure is to start initial operation at reduced capacity, say 50%. The
U/F pump must be operating at sufficient capacity to prevent deposition of
coarse material in the U/F line. 

If U/F is recirculated to the feedwell during start-up, the total volume of the
recirculated U/F plus the feed should not exceed the design volume of the feed.
When the tank is full, the overflow rate will then equal the feed volumetric flow.
Maintain this operation until the solids or slurry accumulation results in a U/F
mixture of coarse and fines that approaches a “balanced” condition. However, if
the slimes reach the surface, the feed must be reduced or shut off and recircula-
tion continued until the objective is achieved. In some cases, adding extra floc-
culant may be necessary.
6. To expedite a “balanced” condition, particularly in large thickeners, operators
frequently “bed in” the space underneath the raking blades usually with sand,
which should be compacted.

When the thickener floor is concrete, the floor is usually constructed parallel to
the bottom of the rake blades; “bedding in” is not required.

67
7. Before reaching a “balanced” condition, there will be a gradual change in the U/

F sand-slime ratio from mostly sand to a “balanced” sand-slime ratio matching
that of the fresh feed. Slime is usually considered to be the minus 200-mesh frac-
tion. As the slime content increases, the settling rate of the sand or coarse frac-
tion decreases. Eventually, sufficient sand-slime mixture will accumulate in the
hindered settling zone of the thickener tank to retard the deposition of the fast
settling coarse fraction, resulting in the “balanced” condition.
8. During the slimes build-up period, the U/F withdrawal flow rate must be gradu-
ally reduced in order to increase the bed level and U/F solids concentration. This
reduction should not be started until sufficient slime is present to give the U/F
fluidity. Recirculation may be discontinued and U/F may be discharged to the
downstream unit operation as soon as the target U/F solids concentration has
been achieved.

Selecting a mud bed level that will result in target U/F solids concentration
depends on the material being handled. Some slurries will compact to a higher
solids concentration than others at the same bed level. The operator can ascer-
tain the optimum level by trial and error. 
The overflow should be clear during this initial operating period. Do not over-
flow slimes, which serve as the lubricant required to give fluidity to the sands. If
slimes overflow, cut off the feed until the slimes settle a reasonable distance
below the liquid surface. The best practice is to reduce the feed before the slime
level rises too high. In some instances, additional flocculant can be used to accel-
erate the slimes settling rate.
9. During initial operation, the rake torque must be carefully monitored. Consoli-
dated sand on the thickener floor and in the discharge sump can lead to a rapid
increase in torque if the withdrawal rate is insufficient. A gradual increase in
torque is to be expected. However, either increase U/F withdrawal or reduce the
feed before the torque reaches the alarm setting.
10. If the rake mechanism is equipped with a lifing device, lifing the rake can
reduce torque. However, the feed rate must be reduced or the U/F withdrawal
rate increased if the rake elevation approaches the upper limit. Allowing the
torque to increase to the cut-out set point would stop the rake.
11. Changing the fluidity of the sandy fraction with the addition of chemicals has
minimized operating difficulties during initial operation with sandy pulp. The
procedure to find a suitable chemical is to take a small feed sample, let the solids
settle for a few minutes and then try to empty the contents by gently tilting the
container. If the sandy solids do not empty cleanly, the sand in the pulp may
cause high torque in the thickener. Therefore, try various chemicals until one is
found that will increase the fluidity of the sands. Add this chemical to the fresh
feed at the start and add later to the recirculated U/F. The amount to be added
can be determined by frequent U/F sampling.
12. A portion of the thickened slurry is removed from the sump through a duty or
standby recirculation port for shear thinning. The ports feed directly into a set of
duty and standby pumps, which recirculate the slurry to a) one of three sump
return nozzles, b) all three sump return nozzles, c) thickener knuckle radius, d)
feed pipe, or e) the duty or standby underflow purge line. The DCS controls auto-
matic valve position for the selected recirculation pump and for each recircula-
tion flow option. The pump must be selected before a flow option is chosen;
both selections must be made before any automatic valves open.

68
If the rake torque exceeds the cut-out set point and a drive interlock stops the rake,
do not “bypass” the drive interlock under any circumstances to restart the rake, as
continued operation may cause structural failure or injury to personnel.
6.4 Process Performance

The sedimentation equipment process performance is dependent upon many factors,
including feed quality and quantity, required chemical additives, retention time,
temperature, rate of flow change, sizing criteria used, and operating conditions.
Therefore, unless a written Process Performance Warranty has been included,
FLSmidth cannot assume any liability or responsibility for performance results that
the user of the equipment is expecting or has predicted.
If assistance is required with equipment operation, due to unexpected conditions, or
if additional components or thickener structural changes are required to meet
performance targets, FLSmidth can, at additional cost, provide the service of experts
to assist you in determining what actions must be taken. Contact http://
www.flsmidth.com/en-US/Contact for the FLSmidth Office nearest you.
69

70
Contents
7.1 Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.72
7.2 Inspection Points Before Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.72
7.3 The Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .73
7.3.1 Verifying Drive Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.74
7.3.2 Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.74
7.3.3 Electrical Equipment and Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
7.3.4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .74
7.3.5 Drive Maintenance Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.75
7.3.5.1 Safely Relieving Stored Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
7.3.6 Drive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.75
7.3.6.1 Gearbox Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.75
7.3.6.2 Gearbox Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
7.3.6.3 Gearbox Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
7.4 Maintenance and Start-Up Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.77
7.4.1 Parts and Repair Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.77
71
7.1 Maintenance Overview

This chapter provides detailed information on maintaining the equipment and its
systems safely and efficiently. Regular care and maintenance must be performed as
outlined in this chapter.
For maintenance instructions specific to an accessory piece of equipment (item
which is furnished by FLSmidth but is fabricated by a third party) refer to the original
equipment manufacturer documentation.
Do not install, operate, maintain, or repair this equipment unless you have read
and understand the instructions and warnings in Chapter 1: Safety. Failure to follow
these safety precautions could result in personal injury, death, or property damage.
7.2 Inspection Points Before Start-Up

1. The drive and mechanism must be level and must be inspected by an authorized
FLSmidth representative before start-up.
2. Refer to the 5.17 “Final Mechanical Inspection” on page 63, and Appendix B:
“Final Mechanical Inspection” on page 93.
3. Remove any foreign material from inside the tank.
4. Remove any blocking or shoring used in the erection of the equipment.

5. Make sure the thickener tank is clean and free of debris and extraneous materi-
als.
6. Inspect the oil levels and lubricate all equipment.
7. Make sure all preservation oil has been drained from and new oil has been
added to both the planetary gearbox and hydraulic motor.
8. Inspect the drive assembly’s components. Refer to F.19 “544343—Basic Drive
9. Inspect the direction of rotation of the drive. Refer to 5.7.10 “Verifying Drive
Rotation” on page 52.
10. Inspect the jackscrew assembly and lif screw for lubrication. Refer to Appendix
A: “Lubrication” on page 83.
11. Make sure the bridge’s drive platform and walkway are clean and free of oil,
debris, and tools.
12. Make sure all drive cover guards are in place.

72
Do not operate this equipment if the guards have been removed or are dam-
aged. All guards and safety devices must be properly installed and must be
functional before operating this equipment.
13. Rotate the rake arms for at least four or five revolutions. Make all observations
from outside the tank. Conduct this procedure when distortion due to heat from
sunlight would be at a minimum, such as, early morning or an overcast day.
a. Inspect for clearance of the rake arm blades with the tank bottom and side
wall.
b. Inspect for loose parts, bolts, and nuts.
14. Make sure the preparation water to be used for the flocculant is free of solids.
Note: The effectiveness of flocculant is drastically reduced if the primary or sec-

ondary dilution water contains solids. These solids will adversely affect the floc-
culant addition rate.
15. Inspect for proper functioning of the underflow and pumps (not supplied by FLS-
midth) and recirculation pumps (by FLS).
16. Verify the functioning of the underflow pump and piping (not supplied by FLS-
midth) and recirculation pumps (by FLSmidth) by operating with water.
17. Inspect the flocculant pump (not supplied by FLSmidth) and flocculant lines by
operating the system with water.
Note: If possible, calibrate the actual flow through the pump versus the indi-
cated flow or speed.
18. Verify the calibration of the rake torque and bed level instruments.
Note: If these instruments have not been calibrated correctly, the operation of
the thickener will be adversely affected.
19. Verify the positioning of the flocculant sparges and verify that flocculant can
enter the feed pipe and feedwell at the required positions.
20. Verify that the flocculant system is ready to dose fully-activated flocculant.
21. Verify that the underflow pumps (not supplied by FLSmidth) are ready to dis-
charge material.
7.3 The Drive Unit

As designed, the rotating mechanism and gearbox are low maintenance items. The
main items that require scheduled maintenance are the planetary gearbox, drive
components, and hydraulic actuators.
Refer to the respective manufacturers’ instructions for comprehensive information
on motors, planetary gearboxes, hydraulic components, and electrical content.

73
7.3.1 Verifying Drive Rotation

1. Inspect a new hydraulic motor for proper direction of rotation before the motor
is attached to the reducer assembly. Refer to 5.7.10 “Verifying Drive Rotation”
on page 52.
If the hydraulic motor is not connected for the proper direction of rotation, the
drive unit warranty will be void and FLSmidth will not be responsible for drive
unit damages.
7.3.2 Drive Components

The main drive mechanism consists of three hydraulic motors that are mounted to
three planetary gearboxes which run the main gear. The rake shaf is suspended from
the gearbox output flange.
Hydraulic oil flow volume (rate of flow) determines the speed of the hydraulic motor.
The hydraulic system is fitted with fixed displacement gear pumps that are pre-
selected to provide the correct rotation speeds. Refer to Chapter 6: “Operation” on
page 65.
7.3.3 Electrical Equipment and Enclosures

Electrical enclosures for the motor and control panel, if furnished by FLSmidth, are
listed on the drawings and the parts list (refer to Appendix E: “Parts List/Bill of
Materials” on page 107). If any electrical equipment, including the motor, is to be
replaced, it must be of equal or better rating.
Refer to the latest edition of the NEMA ICS (National Electrical Manufacturer’s
Association Industrial Control Standards) and NEMA MG 1 (N.E.M.A. Motors and
Generators) for a description of those enclosure designations.
7.3.4 Lubrication
Refer to the lubrication instructions in Appendix A: “Lubrication” on page 83.

74
7.3.5 Drive Maintenance Warning
When a raking mechanism drive shuts down due to high torque load, it may have
stored energy. This energy can be dangerous to those who service the drive unit in
returning it to operation, if the energy is not relieved in a safe way.
The stored energy is most likely in the elastic deformation of the rake arms and
shaft assembly, which is caused by the torsional load. The high torque is shown on
the local control panel.
Do not disassemble a drive unit while there is stored energy in the rake mechanism
or drive. Parts of it may release suddenly when some of the fasteners are loosened,
and cause serious injuries and machine damage.
Before any work is undertaken on either the rake mechanism or the hydraulic unit
itself, it is necessary to relieve the stored energy.
7.3.5.1 Safely Relieving Stored Energy
These instructions are to be read in conjunction with the manufacturer’s instructions

and drawings.
1. To relieve the pressure in the hydraulic circuit, solenoid S1 must be manually
activated and pressure supplied to point P4 by means of a hydraulic hand pump
(not supplied by FLSmidth).
a. Manually activate the hand pump, while activating S1, until the drive has
returned to its lowered position.
b. Release solenoid S1.
2. The drive must only be lowered once all obstructions have been removed.
3. Make sure that the pressure gauge reflects zero pressure.
7.3.6 Drive Maintenance

Refer to the manufacturer’s instructions.
7.3.6.1 Gearbox Removal
The drive can be disassembled and reassembled in place, or it can be removed and
sent to a shop for repairs. If the drive is to be removed, refer to 5.7 “Installing the
Drive Units and Wiring” on page 48 for instructions on lifing and re-installing the
drive.
1. Hydraulic Lines:
a. Disconnect the hydraulic lines to the hydraulic drive.

75
b. Remove the hydraulic lines/piping necessary for gearbox removal.

c. Plug the hydraulic fittings, the motor, and any open ends of the hydraulic oil
system lines/piping to prevent contamination or spilling of the hydraulic oil.
2. Disconnect all controls or cables from the hydraulic motor assembly.
3. Drain the oil from the main drive planetary gearbox. Refer to Appendix A: “Lubri-
cation” on page 83.
4. Safely block and sling the rake arms and the rake shaf in position.
5. Match mark the connecting flanges so that they can be reconnected in their
original positions.
6. Disconnect the rake shaf flange from the gearbox flange.
7. Remove the diagonal bracing and top horizontal beam of the bridge above the
location of the scissor lif and drive.
Note: Make sure the structural integrity of the bridge will not be compromised
by any unnecessary external loads being applied to the bridge during removal
(e.g. excessive personnel/ installation equipment located on the bridge).
8. Remove the guards before lifing.
9. Use suitable D shackles and slings. Make sure the slings are long enough to clear
the planetary drive motor.
10. Use all of the lifing eyes that are fitted to the base of the gearbox to lif the
gearbox clear of the drive frame.
Note: Take care not to damage the output drive flange.
7.3.6.2 Gearbox Overhaul
For instructions on overhauling the gearbox, refer to the manufacturer’s instructions

and drawings.
Use only the torque values in the manufacturer’s instructions for fasteners that are
part of the gearbox assembly.
7.3.6.3 Gearbox Installation
1. Do not reuse the same bolts again. Replace all bolts with new bolts. For bolt-
tightening instructions, refer to F.29 “114808—Torque Values” on page 168.
2. Use all of the lifing eyes that are fitted to the base of the gearbox to lower the
gearbox into position on the drive frame.
a. Use suitable D shackles and slings. Make sure the slings are long enough to
clear the planetary drive motor.

76
b. Take care not to damage the output drive flange.

3. Use the fasteners specified to secure the gearbox to the frame. Refer to F.29
“114808—Torque Values” on page 168.
4. Reinstall the guards.
5. Reconnect all controls and cables to the hydraulic motor assembly.
6. Lubricate the main drive planetary gearbox. Refer to Appendix A: “Lubrication”

on page 83.
7. Reconnect the rake shaf flange to the gearbox flange. Use the match marks to
locate the original position of the connecting flanges.
8. Remove the blocking and slings that are holding the rake arms and the rake
shaf in position.
9. Inspect the drive for level. Refer to 5.12 “Inspecting the Drive for Final Level ” on
page 56.
10. Inspect the drive for proper operation.
7.4 Maintenance and Start-Up Services

Experienced FLSmidth engineers and service personnel are available to assist in the
start-up and maintenance of the equipment. They offer the benefits of their technical
experience and firsthand knowledge of the equipment, plus the backing of
FLSmidth’s entire engineering and research facilities.
They can instruct on proper operating and maintenance procedures, advise on
troubleshooting, and supervise the entire start-up if necessary, depending on
requirements.
If such assistance is wanted, make arrangements at the earliest possible date,
outlining the services required and giving the approximate duration of such services.
Charges for the services will be arranged at that time.
Contact an FLSmidth representative. Refer to http://www.flsmidth.com/en-US/
Contact for the FLSmidth Office nearest you.
7.4.1 Parts and Repair Orders

Refer to 2.4 “Parts and Repair Orders” on page 24 for ordering information.

77

78
Contents
8.1 Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.80
79
8.1 Troubleshooting Overview

The following chart describes a potential problem or operating condition and then
defines the most common cause or source of the problem with suggestions for
Problem Possible Cause Corrective Action
Overload alarm sounds or a. Torque build-up at rake drive 1. Stop feed to thickener and inspect for
drive operates at high mechanism operating problem. Refer to operating
torque for several days instructions.
2. Increase speed on “shear thinning”
pump.
3. Inspect for foreign object in tank.
b. Heavy build-up of solids at the rake 1. Agitate sludge in front of arms with rods,
blades water, or air.
2. Modify flocculant dosage to prevent a
“doughnut” or dam on the floor.
3. Shut down thickener and drain tank.
Drive stops a. Loss of electrical power 1. Inspect power source.
2. Inspect control fuse.
b. Drive control cutout 1. Locate problem. Drain tank, if necessary.
Reset primary drive control at control panel.
Do not by-pass drive control.
2. Inspect secondary drive control switches.
Refer to 7.3.5 “Drive Maintenance
Warning” on page 75.
c. Drive motor cutout 1. Inspect drive motor or hydraulic power
unit for overheating or other upset
condition.
Underflow slurry too thin a. U/F withdrawal rate too high 1. Decrease withdrawal rate.
2. Raise bed level to increase slurry
detention time.
b. Feed rate is too high 1. Decrease pulp feed flow rate.
c. Inadequate flocculation (if used) 1. Inspect clarification zone for finely
dispersed solids. Increase chemicals.
2. Refer to chemical feed manufacturer’s
instructions.
Solids in overflow effluent a. Overloading of thickener 1. Inspect flow rate and feed solids content.
2. Inspect sludge withdrawal rate.
b. Inadequate flocculation (if used) 1. Inspect clarification zone for finely
dispersed solids. Increase chemical dosage.
2. Refer to chemical feed manufacturer’s
instructions.
corrective action.
Problem Possible Cause Corrective Action

Excessive growth on a. Accumulation of solids causes algae 1. Increase frequency of cleaning.
overflow weir
Table 8-1: Troubleshooting

Table 8-1: Troubleshooting
81

82
Contents
A.1 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .84
A.2 Choosing the Correct Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.84
A.3 Lubricating the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .85
A.3.1 Oil Change Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.86
A.3.2 Oil Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.86
A.4 Used Oil Cleanliness Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.87
A.5 Lubrication of Other Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.88
A.5.1 Accessory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.88
A.6 Sight Glass (Oil Gauge) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.88
A.7 Lubricants and Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.88
A.7.1 Synthetic Oils (2 SYN - 5 SYN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.88
A.7.2 Synthetic Oils (6 SYN - 8 SYN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.89
A.7.3 Mobil SHC 600 Series Synthetic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
A.7.6 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .91
A.8 Hydraulic Oil Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.91
A.8.1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .91
A.8.3 Types of Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .92
A.8.4 Hydraulic Oil Equivalents List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.92

83
A.1 Lubrication Chart

The B60P-3 drive may be a combination of FLSmidth-manufactured drive components
and accessory equipment purchased from other manufacturers. These instructions
apply only to the FLSmidth-manufactured components.
Note: EIMCO drives are shipped from the factory without oil.
Initially, fill the drive housing to the level indicated on the sight glass. Refer to A.3.1
“Oil Change Intervals” on page 86.
A.2 Choosing the Correct Lubricant

Refer to the planetary reducer manufacturer for lubrication information.
A lubricant plate (shown in Figure A-1: Lubricant Number Plate, on page 84) is
mounted to the main drive housing at the oil fill opening. The “Lubricant No.” (No. 1
or No. 2) indicated on this plate refers to the “Lubricant Number” shown on the
lubrication plate mounted on the drive unit’s chain guard (see Figure A-2: Lubrication
Plate, on page 85).
Figure A-1: Lubricant Number Plate
1. Using the specified lubricant number (1 or 2), determine the type of oil to be
used in the drive. 
The type of oil will vary based on the ambient temperature range expected at
the equipment installation site.
Note: For temperatures outside of those ranges shown on the Lubrication Plate,
contact the FLSmidth Engineering Department. (Refer to http://www.fls-
midth.com/en-US/Contact for the FLSmidth Office nearest you.)

84
Figure A-2: Lubrication Plate
A.3 Lubricating the Drive

Note: Although a Mobil product is specified, any equivalent product can be used.
When food grade oil is required, contact FLSmidth for recommended lubricant equiv-
alents.
1. Inspect oil levels weekly. 
A general oil level inspection can be made while the drive is operating, but to
get a more accurate reading, stop the drive and allow the oil to settle for a few
minutes.
Note: Adding oil in excess of the amount required will cause oil to overflow.
2. Drain condensate once a week. 

This will keep the oil free of water and other contaminants.
3. Refill oil to operating level.
4. Clean the sight glass (oil gauge) vent opening once a month.
Note: If the vent opening in the top screw plug is clogged or dirty, the sight glass
will not show the correct oil level; it might not even show any oil level at all.
Inspect monthly.
5. Inspect the condition of the drive oil 500 hours afer initial start-up and every six
months thereafer:
a. Take an oil sample (100 ml or 4 oz.) from the drive unit’s drain piping:
 Use a clean receptacle to collect the sample.
 Allow the oil to flow from the drain until water and other settled contam-
inants are no longer present and the oil consistency is uniform.

85
Table A-1: Drive Oil Quantities

b. Refill the drive housing to operating level.

Model Main Gear Upper Bearing Planetary Stacks 6. Send the sam
Housing
pl e to a commercia
B60P-3 70 gallons 1/2 gallon each 4.35 gallons per
l lu Bonfig. bricant laborator
(approximately); 13
yf gallons total or analysis. The sa
(approximately)
mp le of
Mobil oil must conform to the used oil cleanliness specifications (see A.4 “Used
Oil Cleanliness Specifications” on page 87).
7. Replace the oil, if required.
A.3.1 Oil Change Intervals

If you do not have the oil tested through qualified oil analysis, then follow these
directions:
• Initial replacement
Drain
the gear housing and refill with fresh oil (refer to “Oil fill procedure”
below) afer the first 500 operating hours.
• Regular oil replacement
Replace mineral oil each year, unless ambient temperatures dictate other-
wise.
Replace synthetic oil every two years.
A.3.2 Oil Fill Procedure

1. Stop the drive.
2. Drain the housing and refill with fresh oil.
3. Allow the drive to sit at least 10 to 15 minutes afer filling to inspect the oil level.
Note: Due to settling time, trapped air, and other factors, a sight glass will not
Lubricant Used Oil Analysis Specifications show a
n accura
t Mobil SHC636 Mobil Mobilgear Mobil Mobilgear e oil le
v 600 XP 150 600 XP 460 el unti
l Appearance Bright and clear, Bright and clear, Bright and clear, the oi
l not cloudy not cloudy not cloudy settles
.
Kinematic Viscosity at 40 C per ASTM D445
 551-784cSt 122-166cSt 373-506cSt
4. Rei
Total Acid Number (TAN) < 2.0 increase < 2.0 increase < 2.0 increase
n from new from new from new spect t
h Oxidation by FTIR < 10 < 10 < 10 e level
w Karl Fischer H 2O per ASTM D 1744 < 0.1 < 0.1 < 0.1 hile th
e CU FT-IR < 30 ppm < 30 ppm < 30 ppm drive i
s FE FT-IR < 50 ppm < 50 ppm < 50 ppm opera

t SN FT-IR < 30 ppm < 30 ppm < 30 ppm ing.
SI FT-IR < 45 ppm < 70 ppm < 70 ppm
Note:
AL FT-IR < 30 ppm < 30 ppm < 30 ppm
A dding t
Possible sources of contamination:
o o muc
Cu = Copper (bearing cages, bronze worm gears)
h oil wil
Fe = Iron (steel gears & other components, bearings, corrosion)
l cause
Sn = Tin (bronze worm gears, bearings)
i t to ov
Si = Silicon (bronze worm gears, casting sand)
e rflow.
Al = Aluminum (bronze worm gears)
Vent holes in vented pipe plugs (if used) must be kept clear of dirt, paint, or other
foreign material.

86
A.4 Used Oil Cleanliness Specifications
The above “Lubricant Used Oil Analysis Specifications” chart is not all inclusive. For
additional information regarding used oil analysis, contact your local Mobil
distributor or call Mobil Customer Service at 1-800-662-4525.
Mobil oil that does not meet the above “Lubricant Used Oil Analysis Specifications”
must be replaced.
Note: Although a Mobil product is specified, any equivalent product can be used.
Alternate oil manufacturers will have their own test qualifications; consult for
requirements when testing those brands of oil.
87
A.5 Lubrication of Other Equipment
A.5.1 Accessory Equipment

Lubrication instructions for motors, reducers, and other accessory equipment
supplied but not built by FLSmidth, can be found in the original manufacturers’
instructions.
Accessory equipment must be properly lubricated, as specified in the

manufacturer's instructions, to maintain the equipment warranty.
If you have any questions regarding proper lubrication of accessory equipment

provided by FLSmidth, contact your FLSmidth representative (refer to http://
www.flsmidth.com/en-US/Contact for the FLSmidth Office nearest you).
A.6 Sight Glass (Oil Gauge) Replacement

If you replace the oil level sight glass (oil gauge), be sure to notch the new sight glass
to show the oil level, as shown on the Drive Assembly drawing. Do likewise for drives
shipped without the oil level notched.
A.7 Lubricants and Equivalents

Note: Consult a qualified lubrication engineer or your FLSmidth representative before
Manufacturer Synthetic Oils (2 SYN - 5 SYN)
o
AGMA Equivalent Number/Viscosity cSt AT 40 C
2 SYN/ISO 68 4 SYN/ISO 150 5 SYN/ISO 220
MOBIL *SHC 626 *SHC 629 *SHC 630
TRIBOL 800/150 800/220

using synthetic bearing and gear oil that is not listed below as an equivalent.
Manufacturer Synthetic Oils (6 SYN - 8 SYN)
o
* Synth
6 SYN/ISO 320 7 SYN/ISO 460 8 SYN/ISO 680
e sized h
y MOBIL *SHC 632 *SHC 634 *SHC 636 drocar
b on
TRIBOL 800/320 800/460 800/680
Copyright ©
2 Mobil Mobil Mobil Mobil Mobil Mobil 017 FLSmidt
h A/S. All right
s
SHC 626 SHC 629 SHC 630 SHC 632 SHC 634 SHC 636 reserved.
3/29/18
Product Number 60293-8 60294-6 60295-3 60298-7 60291-2 60299-5
ISO Viscosity Grade 68 150 220 320 460 680 9232504935

FLSmidth is c
o
n
Specific Gravity 0.858 0.866 0.866 0.867 0.867 0.867 nstantly strivi
g to improve
it s products an
d Gravity, API 33.16 32.4 331.9 31.7 31.4 31.7 must therefor
e reserve the ri
g  
Pour Point, C ( F) max,  -54 (-65) 45 (-49) -45 (-49) -42 (-44) -42 (-44) -42 (-44) ht to change
d esigns, mater
ia ASTM D 97 ls, specificatio
n s, and price
w A.7.1 o Synthetic
o Oils245(2(473)
SYN245
- 5(473)
SYN)250 (482) 250 (482) 250 (482) 250 (482)
ithout notice.
88 Flash Point, C ( F) min, 
ASTM D 92
Viscosity, ASTM D445      

cSt at 40 C 69.9 142.8 217.7 325.8 436.4 663.8
 10.9 18.3 25.9 38.6 44.9 62.8

cSt at 100 C
Viscosity Index,  147 144 152 169 159 165
ASTM D 2270
Copper Corrosion 24 Hrs at 121 1B 1B 1B 1B 1B 1B

C, ASTM D130
Rust Protection ASTM D665A Pass Pass Pass Pass Pass Pass
and 665B, Distilled and
Synthetic sea water
FZG Scuffing, Fail stage, DIN 11 13 13+ 13+ 13+ 13+
51534
Color, ASTM D1500, Max 3.5 3.5 3.5 3.5 3.5 3.5
TOST Life, Hrs., ASTM D943-2 10,000+ 10,000+ 10,000+ 10,000+ 10,000+ 10,000+
A.7.2 Synthetic Oils (6 SYN - 8 SYN) Appendix A: Lubrication
* Synthesized hydrocarbon
A.7.3 Mobil SHC 600 Series Synthetic Oils

89
Manufacturer Petroleum-Based Oils (2EP - 5EP)

o
2EP/ISO 68 4EP/ISO 150 5EP/ISO 220
MOBIL/EXXON Mobilgear 600 XP 68 Mobilgear SHC 150 Mobilgear SHC 220

Spartan EP 68 Mobilgear 600XP 150 Mobilgear 600 XP 220
Spartan EP 150 Spartan EP 220
AMOCO Permagear EP #68 Permagear EP #150 Permagear EP #220
GULF OIL Physical characteristics

EP LubricantofH.D.
Mobil
68 SHC
EP 600 seriesH.D.
Lubricant synthetic
150 oils are listedH.D.
EP Lubricant below:
220
TEXACO Meropa 68 Meropa 150 Meropa 220
PHILLIPS All Purpose Philgear All Purpose Philgear All Purpose Philgear
(ISO Grade 68) (ISO Grade 150) (ISO Grade 220)
SHELL Omala 68 Omala 150 Omala 220
STANDARD OF CALIFORNIA Chevron Gear Chevron Gear Chevron Gear

CHEVRON USA Compound NL68 Compound NL150 Compound NL220
SUN OIL Sunep 68 Sunep 150 Sunep 220
KEYSTONE Zeniplex - 2 Keygear 90 Keygear 110
LUBRICATION ENGINEERS Monolec 300 Almasol 604 Almasol 607

Manufacturer Petroleum-Based Oils (6EP - 8EP)

o
6EP/ISO 320 7EP/ISO 460 8EP/ISO 680
MOBIL/EXXON Mobilgear SHC 320 Mobilgear SHC 460 Mobilgear SHC 680
Mobilgear 600 XP 320 Mobilgear 600 XP 460 Mobilgear 600 XP 680
Spartan EP 320 Spartan EP 460 Spartan EP 680
AMOCO Permagear EP #320 Permagear EP #460 Permagear EP #680
GULF OIL EP Lubricant H.D. 320 EP Lubricant H.D. 460 EP Lubricant H.D. 680
TEXACO Meropa 320 Meropa 460 Meropa 680
PHILLIPS All Purpose Philgear All Purpose Philgear

(ISO Grade 320) (ISO Grade 460)
SHELL Omala 320 Omala 460 Omala 680
STANDARD OF CALIFORNIA Chevron

For additional Mobil Gear Chevron
Product information, Gear visit www.mobilindustrial.com.
please Chevron Gear
CHEVRON USA Compound NL320 Compound NL460 Compound NL680
SUN OIL Sunep 320 Sunep 460
KEYSTONE None Keygear 140 None

90
A.7.4 Petroleum-Based Oils (2EP - 5EP)
A.7.6 Grease
LUBRICATION ENGINEERS Almasol 605 Almasol 608 Almasol 609
Manufacturer Grease
NLGI No. 2**

EQUIVALENT
MOBIL Mobilgrease XHP 222
AMOCO Rykon #2
EXXON Ronnex MP
GULF OIL High-Temperature Grease
TEXACO Multipak EP2
PHILLIPS PET Philube 2 EP
SHELL Darina EP2
STANDARD OF RPM Multimotive #2

CALIFORNIA 
CHEVRON USA
A.7.5 Petroleum-Based
SUN OIL Oils (6EPSunaplex
- 8EP) 992 EP
KEYSTONE 81 EP-2
** NLGI #2 anti-wear (EP) lithium complex (high-temperature) grease
Do not mix lubricant types without first verifying product compatibility.
Consult a qualified lubrication engineer or your FLSmidth representative.
When changing to a product that is not compatible with the existing lubricant, the
existing lubricant (oil or grease) must be completely removed before the new
lubricant type is used.
A.8 Hydraulic Oil Precautions
A.8.1 Storage
• Ensure hydraulic oil is stored in its original container.
• Keep oil containers tightly sealed. Never store hydraulic oil in an open container.
• Store oil containers in a clean, dry area where it is protected from rain and dust.

91
A.8.2 Transferring Hydraulic Oil

• Ensure the oil containers are clean and dry before they are opened.
• Ensure the areas around the reservoir oil cap and the filters are clean before
removing filler caps, plugs, or filters.
• All equipment used to transfer oil, such as a funnel or pumps, must be clean.
Wipe the equipment clean afer each use and wrap it in a protective cover.
• Use a 10-micron filter when pouring oil into the reservoir to trap any
contaminates that might be in the oil.
Manufacturer ISO Grade

32 46 68
MOBIL DTE 24 DTE 25 DTE 26
AMOCO AW #32 AW #46 AW #68
EXXON NUTO H 32 NUTO H 46 NUTO H 68
TEXACO RANDO HD 32 RANDO HD 46 RANDO HD 68
SHELL TELLUS 32 TELLUS 46 TELLUS 68
KEYSTONE KLC-10 KLC-15 KLC 10/30
• Never reuse hydraulic oil.

• Clean up all oil spills.
A.8.3 Types of Oils

Do not mix oil of different brands; some brands are not compatible with each other.
The reservoir and system must be completely drained before adding a new brand of
oil. Refer to A.8.4 “Hydraulic Oil Equivalents List”.
Note: Use only one brand of oil, as some brands are not compatible with each other.
The reservoir and system must be completely drained before adding the other oil.
A.8.4 Hydraulic Oil Equivalents List

92
Appendix B: Final Mechanical

Inspection
Contents
B.1 Final Mechanical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.94
93
B.1 Final Mechanical Inspection

Tag Number: 682-400-A-TH01
Sign off by initialing and dating each inspection made. When the final mechanical
inspection list is completed, both the FLSmidth representative and the installer/
erector must sign and date this inspection list and must return one copy of this
inspection list for each thickener raking mechanism and drive furnished to the
Inspection Reference Installer Sign- FLSmidth
Of Representative Sign-
Of
Make sure that all shipping braces have been
removed.
Inspect the elevation of the superstructure F.2 “1000255844—General
mounting surfaces (steel support columns). Arrangement” on page 125
and F.3 “1000255845—
Foundation Plan and Loads”
on page 127
Inspect the tank bottom for the specified Fabricator’s tank assembly
diameter around the entire circumference. drawings and 5.4.1 “Inspect-
ing the Tank Dimensions” on
page 46
Verify for specified tank bottom elevation at Fabricator’s tank assembly
the tank bottom center, at the bottom of drawings
the discharge cylinder, and at the tank wall.
Inspect the discharge cylinder for centering in Fabricator’s tank assembly
the tank. drawings and 5.4.1 “Inspect-
page 46
Inspect the launder for specified elevation. Fabricator’s tank assembly
drawings and 5.4.1 “Inspect-
page 46
Inspect the bridge mounting bolt hole/bolt 5.4.1 “Inspecting the Tank
locations for alignment with true center Dimensions” on page 46
and for correct orientation.
Inspect the bridge mounting bolts and nuts F.10 “1000265435—Mecha-
for specified size. nism Steel Assembly” on
page 135 and F.28
“1000265431—Connections
and Fasteners List” on
page 166
Inspect bridge mounting bolts and nuts for F.10 “1000265435—Mecha-
proper tightening. nism Steel Assembly” on
page 135 and F.28
page 166
Inspect the slide plates for proper installation F.10 “1000265435—Mecha-
on the steel support columns at the sliding nism Steel Assembly” on
end of the bridge. page 135
Inspect the fixed plates for installation on the F.10 “1000265435—Mecha-
steel support columns at the fixed end of nism Steel Assembly” on
the bridge. page 135
FLSmidth project management department to ensure warranty coverage.

94
Of
Inspect the bridge for proper assembly. F.12 “1000267910—Super-
structure Assembly” on
page 141 and 5.6 “Assem-
bling and Installing the
Superstructure” on page 47
Inspect bridge for proper installation and ori- F.12 “1000267910—Super-
entation. structure Assembly” on
page 141 and 5.6 “Assem-
Inspect the connections between the bridge F.10 “1000265435—Mecha-
and the steel support column for specified nism Steel Assembly” on
fasteners. page 135 and F.28
page 166
Verify that the superstructure drive center F.12 “1000267910—Super-
opening is directly over the center of the structure Assembly” on
tank. page 141, F.13
“1000267924—Superstruc-
ture Shop Assembly” on
page 144, and 5.6.1 “Install-
ing the Bridge” on page 47
Verify that the drive is directly over the center F.12 “1000267910—Super-
of the tank. structure Assembly” on
page 141, F.13
“1000267924—Superstruc-
ture Shop Assembly” on
page 144, and 5.6.1 “Install-
Inspect the drive-to-drive mount connections F.10 “1000265435—Mecha-
for specified fasteners. nism Steel Assembly” on
page 135 and F.28
page 166
Verify that the drive-to-drive mount mounting F.10 “1000265435—Mecha-
bolts are secure. nism Steel Assembly” on
page 135, F.28
page 166 and 5.12.1 “Shim-
ming for Level” on page 59
Inspect the superstructure for specified eleva- F.2 “1000255844—General
tion and level. Arrangement” on page 125,
F.12 “1000267910—Super-
structure Assembly” on
page 141, and 5.6 “Assem-
Verify that the connection fasteners between F.10 “1000265435—Mecha-
the superstructure and the steel support nism Steel Assembly” on
column are secure. page 135 and F.28
page 166
95

Of
Inspect the grating for proper installation on F.12 “1000267910—Super-
the superstructure’s platform and walkway structure Assembly” on
sections. page 141 and 5.6.2 “Install-
ing the Grating and Hand-
rails” on page 48
Inspect the handrails for proper installation F.12 “1000267910—Super-
on the superstructure’s platform and walk- structure Assembly” on
way sections. page 141 and 5.6.2 “Install-
ing the Grating and Hand-
rails” on page 48
Inspect platform and walkway floor plates for F.12 “1000267910—Super-
proper installation. structure Assembly” on
page 141 and 5.6.1 “Install-
Inspect the control panel for proper installa- F.2 “1000255844—General
tion on the bridge. Arrangement” on page 125
and 5.7.8 “Installing the
Control Panel” on page 51
Inspect the drive for proper installation on the F.10 “1000265435—Mecha-

superstructure. nism Steel Assembly” on
page 135, 5.7.4 “Inspecting
Inspect the drive for concentricity. the Drive for Concentricity”
Inspect the connections between the drive on page 50, F.28
and the superstructure for specified fasten-
ers and ensure the fasteners are secure.
page 166, and F.29
“114808—Torque Values”
on page 168
Inspect the rake shaf for proper installation F.11 “1000265455—Raking
and alignment. Mechanism Assembly” on
page 139 and 5.8 “Installing
the Rake Shaf and Dis-
charge Scraper” on page 54
Inspect the connections between the drive F.10 “1000265435—Mecha-
flange and the rake shaf flange for speci- nism Steel Assembly” on
fied fasteners and ensure the fasteners are page 135, F.28
secure. “1000265431—Connections
page 166, and F.29
“114808—Torque Values”
on page 168
Inspect the connections between the rake F.11 “1000265455—Raking
arm and the rake shaf for the specified fas- Mechanism Assembly” on
teners and ensure the fasteners are secure. page 139 and F.28
page 166
brace and the rake shaf for the specified Mechanism Assembly” on
fasteners and ensure the fasteners are page 139 and F.28
page 166
96
Of
brace and the rake arm for the specified Mechanism Assembly” on
fasteners and ensure the fasteners are page 139 and F.28
page 166
Inspect the rake arms for specified slope and F.2 “1000255844—General
clearance with tank bottom on top of the Arrangement” on page 125
radial beams. and 5.4.1 “Inspecting the
Tank Dimensions” on
page 46
Inspect the rake arms for final level and align- 5.13 “Adjusting the Rake
ment. Arms” on page 60
Inspect the hydraulic lines for proper installa- F.22 “728425—Hydraulic Pip-
tion between the hydraulic motor and lif ing Assembly” on page 157
actuator (hydraulic cylinder/ram). and 5.7.11 “Installing the
Hydraulic Power Unit and
Piping Assembly” on page 52
Inspect the electrical wiring (not supplied by F.22 “728425—Hydraulic Pip-
FLSmidth) to the hydraulic pump’s motor, ing Assembly” on page 157
low level oil switch, pressure transmitter, and 5.7.11 “Installing the
and pressure switch.
Note: All interconnecting wir-
ing must meet local and
national electrical codes
Inspect the hydraulic pump’s motor for
proper direction of rotation.
Verify the hydraulic pump’s motor is wired so 5.7.9 “Connecting the Electri-
that an automatic restarting of the motor cal Wiring” on page 51
cannot occur afer an automatic shutdown
due to an overload.
Verify that all of the hydraulic piping to the F.22 “728425—Hydraulic Pip-
hydraulic motor has been connected to the ing Assembly” on page 157
proper ports on the motor. and 5.7.11 “Installing the
Inspect the feedwell supports for proper F.10 “1000265435—Mecha-

installation on the superstructure. nism Steel Assembly” on
page 135 and F.28
Inspect the feedwell and feed pipe supports “1000265431—Connections
for parallel alignment and level. and Fasteners List” on
page 166
Inspect the connections between the mix F.10 “1000265435—Mecha-
trough support and the superstructure for nism Steel Assembly” on
specified fasteners and ensure the fasten- page 135 and F.28
ers are secure. “1000265431—Connections
page 166
Inspect the connections between the mix F.10 “1000265435—Mecha-
trough and the mix trough support beams nism Steel Assembly” on
for specified fasteners and ensure the fas- page 135 and F.28
teners are secure. “1000265431—Connections
page 166
97
Of
Inspect the connections between the feed F.10 “1000265435—Mecha-
pipe and the bridge for specified fasteners nism Steel Assembly” on
and ensure the fasteners are secure. page 135 and F.28
page 166
Inspect the feedwell for proper assembly. F.15 “1000265475—E-Volute

Feedwell Assembly” on
Inspect the feedwell for alignment of the seg-
page 147 and 5.9 “Feedwell,
ments and the upper rim. Mix Trough, Feedpipe, and
P-Duc Mixer Installation” on
page 55
Inspect the feed pipe and feedwell for align- F.10 “1000265435—Mecha-
ment. nism Steel Assembly” on
Mix Trough, Feedpipe, and
page 55
Inspect the P-Duc support for proper installa- F.14 “1000265480—Feed and
tion. Floc. System Assembly” on
Mix Trough, Feedpipe, and
page 55
Inspect feedwell for proper installation on the F.10 “1000265435—Mecha-

underside of the bridge. nism Steel Assembly” on
page 135
Inspect the feedwell for concentricity with the
rake shaf.
Inspect the feedwell for elevation and level
around the circumference.
Inspect the feed pipe for proper installation. F.14 “1000265480—Feed and
Floc. System Assembly” on
page 145, F.10
“1000265435—Mechanism
Steel Assembly” on
page 135, 5.9 “Feedwell, Mix
Trough, Feedpipe, and P-Duc
Mixer Installation” on
page 55
Inspect the flocculant piping for proper instal- F.14 “1000265480—Feed and
lation. Floc. System Assembly” on
page 145, F.10
“1000265435—Mechanism
Steel Assembly” on
page 135, 5.9 “Feedwell, Mix
Trough, Feedpipe, and P-Duc
Mixer Installation” on
page 55
Inspect the drive motor for proper installa- 5.7 “Installing the Drive Units
tion. and Wiring” on page 48
Inspect the drive motor wiring. Refer to the drive motor manu-
facturer’s instructions
Verify drive motor is wired so an automatic 5.7.9 “Connecting the Electri-
restarting of the motor cannot occur afer a cal Wiring” on page 51
drive control shutdown, following a torque
load.
Of
Copyright
© Verify the drive unit has been filled with oil to Appendix A: “Lubrication” on 2017 FLSmi
d the specified level (marked on sight glass). page 83 th A/S. All ri
g hts reserved
. 3/29/18
Verify that the drive unit has been filled with Appendix A: “Lubrication” on
9232504935
specified oil type/viscosity. page 83 FLSmidth is
c onstantly str
i
Verify that the upper bearing housing assem- Appendix A: “Lubrication” on ving to impr
o blies and the reducer housings have been page 83 ve its produ
c filled with oil to the specified level. ts and must
t herefore res
e Verify that the upper bearing housing assem- Appendix A: “Lubrication” on rve the righ
t bly and the reducer housings have been page 83 to change d
e signs, mater
i
filled with the specified oil type/viscosity. als, specifica
t ions, and pri
c
Verify that the main drive gearbox has been Appendix A: “Lubrication” on e without n
o filled with the specified quantity of oil and page 83 tice.
98 has been filled to specified level.
Inspect the main drive gearbox oil type/vis- Appendix A: “Lubrication” on
cosity. page 83
Inspect the main drive gearbox, upper bearing
housing assembly, and the reducers for
penetration of grit due to sandblasting.
Inspect the rake arms for proper installation. F.11 “1000265455—Raking
Mechanism Assembly” on
page 139, 5.11 “Installing
the Rake Arms” on page 56,
and 5.13 “Adjusting the
Rake Arms” on page 60
Inspect the drive for maximum out-of-level 5.12 “Inspecting the Drive for
tolerance of 0.005 inches (0.0127 cm) in 12 Final Level ” on page 56
inches (30.48 cm), by using only one of the
rake arms.
Verify that the specified shims were used to 5.12.1 “Shimming for Level” on
final level the drive unit. page 59
Inspect drive to bridge connection for speci- F.10 “1000265435—Mecha-
fied fasteners. nism Steel Assembly” on
page 135 and F.28
page 166
Verify that the mounting bolts connecting the F.29 “114808—Torque Val-
drive to the superstructure are secure. ues” on page 168
Verify that the drive jackscrews are not sup-
porting the drive.
Inspect the rake arms for final level. 5.13 “Adjusting the Rake
Arms” on page 60
Inspect the main motor for proper direction of 5.7.10 “Verifying Drive Rota-
rotation. tion” on page 52
Inspect the drive for specified direction of 5.7.10 “Verifying Drive Rota-
rotation. tion” on page 52
WARNING: The tank must be cleared of

debris, and the drive, rake shaf, rake arms,
and other moving parts free of obstructions
before rotating the drive. Observe from
outside of the tank.
Of
Verify that all warning and caution signs are
properly installed and clearly visible and
readable.
Make sure that all of the protective coverings
that were applied for sandblasting and/or
painting have been removed from the drive
assembly.
Verify all necessary gearbox breathers are cor- Refer to the manufacturer’s
rectly installed. instructions
Make sure all blocking and shoring used in the 5.2 “Lifing the Equipment” on
erection of the equipment has been page 41
removed from the tank.
Inspect superstructure-to-tank connections F.10 “1000265435—Mecha-
for specified fasteners. nism Steel Assembly” on
page 135 and F.28
page 166
Verify that the superstructure-to-tank fasten- F.10 “1000265435—Mecha-
ers are secure. nism Steel Assembly” on
page 135 and F.28
page 166
Verify proper installation of the nameplate on 5.6.3 “Installing the Name-
the superstructure. plate” on page 48
Inspect the monorail for proper installation on F.12 “1000267910—Super-
the superstructure. structure Assembly” on
page 141 and F.28
page 166
Inspect the pickets for proper installation. F.11 “1000265455—Raking
Mechanism Assembly” on
page 139 and 5.14 “Install-
ing the Pickets” on page 61
Inspect for final welds.
Inspect the guide pocket for proper installa- F.11 “1000265455—Raking

tion. Mechanism Assembly” on
page 139 and 5.15 “Guide
pocket and wear ring seg-
ment installation” on
page 62
99

100

Of
NOTES AND COMMENTS:

_________________________________ _________________
(Installer/Erector) (Date)
_________________________________ _________________
(FLS Service Representative) (Date)

101


102

Contents
C.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104

103
C.1 Maintenance Schedule

Maintenance/ Frequency Lubricants Comments/References
Operation
Drive:
Inspect oil level. Weekly Refer to the planetary Add oil as necessary.
reducer manufacturer’s
instructions
Inspect oil. As necessary Refer to the planetary Replace oil as necessary.
reducer manufacturer’s Oil must be kept clean.
instructions
Drain condensate from Weekly Refer to the planetary Refill with oil as
the drive. reducer manufacturer’s necessary.
instructions
Have sample of drive oil Afer first 500 operating Refer to A.4 “Used Oil
inspected for condition. hours, then every 6 Cleanliness
months thereafer Specifications” on
page 87.
Change oil. When indicated by a Refer to the planetary Replace oil as necessary;
qualified oil analysis, or reducer manufacturer’s it must be kept clean.
annually/bi-annually if oil instructions Refer toAppendix A:
analysis is not used “Lubrication” on page 83
Reducer and motor - See comments See comments Refer to the
lubrication and manufacturer's
maintenance. instructions.
Thickener Mechanism:
Make sure all cover Weekly Inspect guards afer
guards are in place. maintenance.
Keep drive walkway and Weekly None Wipe up oil spills
platform clean and free immediately.
of oil, debris, and tools.
Inspect for loose bolts, Monthly Secure immediately.
nuts, and floor plates.
Inspect shaf cover boot. Yearly Replace if damaged.
Remove rust spots & Yearly
repaint as necessary.
Inspect connections Yearly or when tank is Refer to F.11
between the arms & rake drained “1000265455—Raking
shaf. Mechanism Assembly”
on page 139, F.28
“1000265431—
Connections and
Fasteners List” on
page 166, and F.29
“114808—Torque
Values” on page 168.
104
Table C-1: Maintenance Schedule Summary

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13 m Dia.

B Thickener, B60P-3 Drive

Installation, Operation, and Maintenance Manual

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

1.3.16 Pinch and Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chapter 4: Equipment Overview

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

5.7.10 Verifying Drive Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.4 Maintenance and Start-Up Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B: Final Mechanical Inspection

Appendix C: Maintenance Schedule

Appendix D: Recommended Spare Parts List

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

Appendix E: Parts List/Bill of Materials

Appendix F: Drawing Package

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

1.3.16 Pinch and Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Hazard Symbol Symbol Description

“Danger” indicates an imminently hazardous situation which,

“Warning” indicates a potentially hazardous situation which,

1.1 Important Safety Information

1.1.1 Hazard Signal Indicators

Table 1-1: Hazard Signal Indicators

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

1.1.2.1 Mandatory Action Symbols

Mandatory Action Symbols are referred to as Personal Protective Equipment (PPE)

Wear Eye Protection Wear Head Protection

Connect an Earth Terminal Wear High Visibility

Disconnect Plug from Wear a Mask

Wear Opaque Eye Wear a Safety Harness

Wear Safety Footwear Disconnect Before

Wear Protective Gloves Use This Walkway

No Thoroughfare Do Not Use Lif in Event of

No Access for People with No Eating or Drinking

No Metallic Articles or Do Not Use Lif for People

Do Not Touch No Running

No Heavy Load No Climbing

No Reaching In Do Not Enter

Table 1-3: Prohibition Symbols

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

1.1.2.3 Warning Symbols

mbols and their

Floor Level Obstacle Flammable Material

Drop Fall Sharp Element

Slippery Surface Corrosive Substance

Electricity Crushing of Hands

Forklif and Other Counter Rotating Rollers

Overhead Load Battery Charging

Toxic Material Oxidizing Substance

Hot Surface Explosive Atmosphere

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

1.2 Safe Working Practices

• Proper care is your responsibility.

1.2.1 Operator Responsibilities

1.2.2 General Safety Recommendations

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

1.2.3 Unauthorized Modifications

1.2.4 Lockout/Tagout (Energy Isolation)

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

1.2.5 Conveyor Belt

Do not attempt maintenance or lubrication near a moving belt.

Copyright © 2017 FLSmidth A/S. All rights reserved. 3/29/18 9232504935

1.2.7 Emergency Procedures