FC1200 Manual - Part B (Installation) - Moatise Project (English)

INSTALLATION & COMMISSIONING MANUAL FOR FC1200 CENTRIFUGE
PART B
INSTALLATION & COMMISSIONING
FC1200 CENTRIFUGE
CLIENT: VALE MOCAMBIQUE LIMITADA

(MOATISE PROJECT)
ORDER: CT02011
JOB NO: FC1200 – J16523
MALVERN ENGINEERING WORKS (Pty) Ltd
P.O Box 75002 Tel: (011) 873-9010 1287 Harriet Avenue

Gardenview 2047 Fax: (011) 873-9596 Driehoek Germiston
Gauteng, South Africa email: info@malvern.co.za Gauteng, South Africa
1
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PART B – INSTALLATION & COMMISSIONING MANUAL
SECTION
SECTION DESCRIPTION PAGE
NO.
1. INTRODUCTION 4
2. FC1200 PACKING LIST 4
3. STORAGE OF COMPONENTS PRIOR TO INSTALLATION 4
4. INSTALLATION REQUIREMENTS 5
4.1 FOUNDATION 5
4.2 MAIN FRAME 5
4.3 INSPECTION DOORS 5
4.4 INSTALLATION CLEARANCES 6
4.5 PROTECTION FROM TRAMP IRON 6
4.6 TRANSPORTATION OF CENTRIFUGE PRODUCT 6
4.7 FEED ARRANGEMENT 7
4.8 EFFLUENT SYSTEM 7
4.9 MAIN DRIVE/ELECTRICAL 7
5. INSTALLATION PROCEDURE 9
6. COMMISSIONING 10
6.1 PRE-COMMISSIONING CHECK LIST 10
6.2 STARTING FOR THE FIRST TIME 12
6.3 SHUT-DOWN 12
7. TROUBLE SHOOTING 13
7.1 VIBRATION 13
7.2 LOCKED ROTATION 13
7.3 MOTORS WILL NOT START 14
7.4 MACHINE SHUTS OFF DURING OPERATION 14
7.5 OIL PUMP PROBLEMS 14
7.6 NOISE 14
7.7 TROUBLE SHOOTING SUMMARY 15
7.8 POOR PRODUCT QUALITY 16
DRG No. 30/FC1200/01/003 – General Arrangement 17
DRG No. 30/FC1200/01/002 – Sectional Arrangement 18
DRG No. 30/FC1200/31/004 (Electrical Schematic) 19
2
SUPPLIER’S/MANUFACTURER’S DETAILS
MALVERN ENGINEERING WORKS
P.O BOX 75002 1287 HARRIET AVENUE TEL: (011) 873-9010

GARDENVIEW GERMISTON, EXT. 12 FAX: (011) 873-9596
2047 1400 Email: info@malvern.co.za
3
1. INTRODUCTION
This Installation and Commissioning manual outlines installation requirements,

which ensure that the necessary installation, maintenance and operation aids are in
place before the centrifuge is installed. Installation, commissioning procedures and
a trouble-shooting guide, are given to ensure trouble free operation.
These instructions must be executed carefully. For further advice contact Malvern
Engineering.
2. FC1200 PACKING LIST
A standard packing list is included here
• FC1200 centrifuge fitted with pulley

• Drive motor
• Drive guard
• V-belts
3. STORAGE OF COMPONENTS PRIOR TO INSTALLATION
The FC1200 centrifuge arrives on site completely assembled (complete with

basket). It has been designed to resist deterioration in harsh environments.
However, to prolong its life, it is recommended that the centrifuge be under-cover
whilst waiting to be installed.
4
4. INSTALLATION REQUIREMENTS
4.1 FOUNDATION
Refer to DRG No.’s 30/FC1200/01/004 – General Arrangement

30/FC1200/01/002 – Sectional Arrangement / Parts List.
30/FC1200/31/004 – Electrical Schematic
The foundation should be of sufficient weight to absorb the high unbalanced forces
and also provide a high degree of stiffness to transmit the remaining forces to the
ground.
(a) Strength Design - machine weight

- Empty 5 659 kg
- Operating 6 750 kg
- Choked 10 000 kg
(b) Vibration - natural frequency of support structure to be outside the range of

± 60% of machine running speed of 400 rpm.
(c) Horizontal force in normal operation is nominally zero. The structure (and
hold down bolts) should be able to withstand an applied force of 90,000 N (90
kN) in any direction in the horizontal plane acting at a point about 1200 mm
above the mounting plate. This is required in the event of an imbalance
malfunction. Live loads in vertical directions also have to be provided for, as a
result of the moment caused by this horizontal imbalance force.
4.2 MAIN FRAME
The centrifuge should be installed with the base accurately level. It should be
securely bolted to the supporting beams without distorting the machine when
tightening the bolts.
The supporting beams should form an octagonal opening into which the cylindrical
discharge rim may be placed. The external diameter of this rim is 1672 mm and it is
175 mm high. Refer to the General Arrangement Drawing for further information.
4.3 INSPECTION DOORS
The centrifuge should be installed in such a manner that the two inspection and
sampling doors are easily accessible.
5
4.4 INSTALLATION CLEARANCE
To facilitate the removal of the sheet steel cover, feed chute, the screen basket, and
for removal of the scraper drum, a minimum lifting clearance of 910 mm above the top
of the feed tube (Item No. 607) is necessary.
Note: 2.0 m lifting clearance is required for insitu bearing and shaft maintenance.
A chain hoist of two tonne capacity should be installed above the machine to be used
for assembly and disassembly of the machine during normal maintenance operation
or repairs.
The feed chute or sluice should be installed in such a way that no load is imposed on
the feed tube (Item No. 607). A load so imposed may deform the sheet steel cover
and cause contact and subsequent wear between the scraper drum cover (Item No.
605) and the feed tube (Item 607). It is also advisable to install the chute system in
such a way that it can be easily removed prior to machine maintenance and repair.
4.5 PROTECTION FROM TRAMP IRON
The design of the centrifuge feed system should include a device to remove the tramp
iron ahead of the feed chute.
Tramp iron within the machine may cause severe damage to the basket, and may
even damage the entire machine.
4.6 TRANSPORTATION OF THE CENTRIFUGE PRODUCT
It is essential that the discharge chute built around the cylindrical discharge opening in
the base of the machine, be designed in such a way that the dewatered coal is freely
transported away. The slope of the discharge chute or the sides of the collecting
hopper should be no less than 60 degrees to the horizontal. If the dried coal is not
transported away from the machine rapidly enough, and is permitted to build up,
plugging of the rotating elements of the centrifuge may result.
If the machine discharges to a mechanical conveying device, the motors of each

should be interlocked so that when the conveyor stops, the machine will also stop and
plugging will not occur.
CAUTION!
Should this interlock be installed, as advised, it should not include the
lubrication system of the centrifuge - see Part B, section 1.2 “Lubrication
System”.
6
4.7 FEED ARRANGEMENT
The feed can be delivered to the machine by means of chutes, pipes or conveyor.
However, for long machine life, low maintenance cost, and smooth operation, the feed
should be continuous and with as little variation as possible and low velocity.
4.8 EFFLUENT SYSTEM
On each side of the machine there is an effluent discharge port 200 mm nominal bore
with Table "D" flange. The slope of the effluent pipes, connected to the
aforementioned flanges, should be sufficient for good drainage, the minimum slope for
effluent lines is a 15° fall angle.
The effluent will contain between 5% and 20% solids, depending upon the size
content of the feed and the wedge wire aperture in the centrifuge basket. A pressure
flushing line should be available for cleaning the effluent trough inside the machine
and for flushing the drainage lines.
Efficient centrifuge operation is more readily achieved if the effluent can be easily
sampled. Combination sampling and venting ports should be installed in the
horizontal section of effluent pipe adjacent to the flange coupling at the machine.
4.9 MAIN DRIVE/ELECTRICAL
Ref: Drawing No. 30/FC1200/01/004 (General Arrangement Drawing)
The centrifuge is driven through connected pulleys and V-belts by a 55 kW, 4 pole,
1475 rpm, T.E.F.C. drip-proof motor. An uninterrupted Star Delta start (incorporating
a 15-second maximum start time) is used. (Refer to FC1200 Centrifuge Schematic
Diagram Star Delta Start, DRG No. 30/FC1200/31/004
The motor should have thermal as well as electrical protection. Furthermore, it is

advisable to place an ammeter in the motor electrical circuit, permitting the load to be
read at all times.
A magnetic combination starter is used with a squirrel cage motor. The start-stop push
button station should be located in the immediate vicinity of the machine.
Heavy shocks when starting or during operation must be avoided since they will
damage the driving and driven gears and bearings.
The motor and horizontal driving shafts and the sheaves must be checked for
accurate alignment.
The main drive motor should be interlocked with the lubrication pump drive motor with
a 60-second delay between the starting of the lubrication pump motor and main drive
motor.
7
NO LUBRICATION – NO DRIVE
This will prevent damage to bearings and gears.
Another timer is incorporated with the main drive and lubrication pump to allow the
lubrication pump to continue running for one (1) full minute after the main drive is shut
down. This ensures full protection to bearings and gears during run down and start up
times.
8
5. INSTALLATION PROCEDURE
The following instructions are a guideline for how to install the FC1200 centrifuge.
Specific procedures will depend upon the plant layout.
Approximate Total mass of the FC1200 centrifuge: 5650 kg
1. For lifting, attach chains to the four gussets supporting the centrifuge housing.
CAUTION
Do not use the lifting lugs of the sheet steel cover to lift the centrifuge.
These lugs are designed to lift the cover only.
2. Lift the centrifuge to the point of installation.
3. Once in position, the machine should be levelled and set-up "true" on the
foundation.
4. Bolt the centrifuge down to its foundation, ensuring that the centrifuge remains
"true". Bolt torques should be according to the relevant South African Standard.
Note: Fixing bolts are not supplied with the centrifuge
5. Connect the electrical power supply to the centrifuge as per Section 4.9 "Main
Drive/Electrical". This must be done by a qualified electrician.
9
6. COMMISSIONING PROCEDURE
6.1 PRE-COMMISSIONING CHECK LIST
• Check that all power sources to the centrifuge are turned off
• Ensure that the electrical leads and wiring are not damaged
• Ensure that the coal feed is off
• Check that the foundation bolts of both the centrifuge and the drive motor are tight
• Check that the drive motor locking clamp has been removed
• Check that the motor and lubrication system is interlocked correctly as per section
4.9 Main Drive/Electrical.
• Check that the tension and alignment of the V-belts is correct. Refer to Part C,
Section 4.3 "Installation & Operation of V-belts" for instructions on tensioning and
alignment.
• Ensure that there is at least 40 litres of lubricant in the gearbox housing i.e. check
that the oil level is above the lower limit of the dip stick.
• Check the basket by removing the steel sheet cover. Remove any obstructions that
may prevent the basket from rotating freely. Check that the basket is not damaged.
• Check the water housing outlet and coal discharge chute to ensure that there are
no blockages
• Check the machine thoroughly inside and out.
10
PRE-COMMISSIONING CHECK LIST
Description Checked
1. Check that all power sources to the centrifuge are off
2. Ensure that the electrical leads and wiring are not damaged
3. Ensure that the coal feed is off
4. Check the bolts that secure the base frame to the foundation
5. Check the bolts that secure the drive motor to the base frame
6. Check that the motors are all interlocked correctly. Refer to drawing
number CC-0389. Refer Section 4.9.
7. Check that the drive motor locking clamp has been removed.
8. Check that the tension and alignment of the V-belts is correct.
Refer Part C, Section 5.5.
9. Check the oil level in the lubrication tank. Should be at the top mark on
dip stick
10. Check the bolts that secure the basket
11. Check that there is nothing to obstruct the basket from rotating.
12. Check the water housing outlet and coal discharge chute to ensure that
there are no blockages
13. Turn the machine by hand. Check for any unusual noises
14. Clean the machine thoroughly, inside and out
15. Turn on the power supply
11
6.2 STARTING FOR THE FIRST TIME
Go through the Pre-commissioning check-list (Section 6.1) and then follow the
instructions below.
1. Switch on electrical supply.
2. Switch oil pump motor on.
3. Start rotation motor (after 60 seconds)
4. Start coal feed to centrifuge.
6.3 SHUT-DOWN
1. Stop feed to centrifuge
2. After 60 seconds, stop the drive motor
3. After 60 seconds, stop the lubrication motor.
12
7. TROUBLE SHOOTING
If a problem arises, before calling out maintenance personnel, the following

symptoms should be checked.
7.1 VIBRATION
Centrifuge Unloaded
If the machine vibrates under no load conditions, it indicates that one or more of the
rotating parts are unbalanced. This must be corrected by re-balancing the faulty
part or parts, or by replacing if the part is too far worn. By a simple elimination
procedure of removing one piece at a time and running, the faulty part or parts can
be readily detected.
In the order listed below, remove each component below in order to isolate the
cause of vibration.
1. Basket
2. Scraper drum cover
3. Spoke piece cone
Centrifuge Loaded
Intense vibrations may occur for short periods of time. These are normally caused
by unequal feed distribution, sudden changes in the feed rate, or changes in the
size distribution of the feed. These vibrations should pass, but if they persist the
cause must be detected and corrected. Follow the procedure above.
CAUTION
Vibration in the machine may cause the foundation bolts of both the
centrifuge and its motor to become loose. These should be regularly
examined and re-tightened.
7.2 LOCKED ROTATION
(a) Material or object locked between scraper blades and screen.
(b) Build-up of discharged product into the base of spoke piece.
These two points are the most frequent causes and can be easily found. Should
there be something more serious, it will probably be in the gearing or bearings.
Consult Ludowici Mineral Processing Equipment Pty Ltd.
13
7.3 MOTORS WILL NOT START
Check the pressure switch. If you are attempting to restart hot, the oil pressure may
not be reaching the set start up pressure of 55 - 60 kPa.
7.4 MACHINE SHUTS OFF DURING OPERATION
If the machine shuts-off during operation, this is usually a result of a problem in the
lubricating system.
• Check the oil lines and ensure that there are no leakages. Replace hosing if
found to be damaged.
• Check the pressure switch. Ensure that it is set at the correct pressure (50 kPa)
and that it is not damaged
7.5 OIL PUMP PROBLEMS
Loss of oil pressure:-
(a) Leaks in suction line, check suction line from pump back through oil filter to
oil reservoir.
(b) Leak in pressure line, check lines.
(c) Pump shaft not rotating - coupling between motor and pump shaft may be
defective. Replace the coupling if this is the case.
(d) Defective pump. Replace the pump if this is the case.
7.6 NOISES
The gears, as well as the material being centrifuged, will produce a regular noise
varying with the rate of feed.
If a scraper blade touches the screen, it will cause a scraping sound about every six
seconds, or ten times per minute.
14
7.7 TROUBLE SHOOTING SUMMARY
Symptom Cause Solution

A. Vibration Unloaded 1. One or more of the 1. Rebalance faulty part and/or
Note 1. rotating parts are replace worn part
unbalanced.
2. Bad bearings. Still have 2. Replace bearings.
vibration without rotating
parts.
B. Vibration Loaded 1. Unequal feed distribution. 1,2 & 3. After a while, vibration
Note 1. should pass. If not, contact
Malvern Engineering.
2. Sudden changes in feed
rate.
3. Changes in size
distribution of feed.
C. Locked rotation 1. Material locked between 1 & 2. Remove obstructing material
scraper blades and screen. and clean basket as explained in
Part B Section 8.0 Daily Cleaning.
2. Build up of discharge
product into the base of
spoke piece.
Note. 2.
D. Motors will not start 1. Oil pressure is low 1. Wait for machine to cool and
because the machine is hot, then start motor.
or oil level is low. Check oil level and top up if
necessary.
2. Pressure switch is not 2. Replace pressure switch.
functioning.
E. Machine shuts off 1. Low oil pressure. 1. Check oil pressure. Refer to
During operation. SYMPTOMS F & G.
2. Faulty pressure switch. 2. Replace pressure switch.
F. Low oil pressure on 1. Dirty Filter 1. Clean Filter.
Pressure side of pump.
G. Low oil pressure. 1. Oil level low 1. Add oil.
2. Oil line stopped up. 2. Clean oil line.
3. Broken oil line (suction or 3. Replace bad line.
pressure).
4. Defective pump. 4. Replace pump.
H. High motor amperage. 1. Excessive feed. 1. Reduce feed.
2. Build-up of product fines 2. Clean base discharge area.
inside base that drag on
base.
3. Object lodged between 3. Remove object.
scraper blades.
I. Excessive solids in 1. Worn screen and particle 1. Replace screen/basket.
Effluent. size larger than screen
opening.
2. Worn product wear ring. 2. Replace product wear ring or
repair.
Note 1. Vibration in machine may cause the foundation bolts of both the centrifuge and its motor to become
loose. These should be regularly examined and retightened.
Note 2: The two causes occur the most frequently and can be easily found. Should there be something
more serious, it will probably be in the gearings or bearings. In this case contact Malvern Engineering Works
15
7.8 POOR PRODUCT QUALITY
Because of the wide variety of materials this continuous screen type centrifuge can
process, only general points of process information can be covered. Generally,
change of feed moisture, size consist, rate and cleanliness will change the
product quality. Here is a tabulation of overall process symptoms and their probable
cause:-
SYMPTOM CAUSE
Wet Product 1. Feed too wet
2. Excessive fines in feed
3. Foreign material in feed
4. Screen stopped up
5. Excessive scraper clearance or worn
scraper blades
6. Worn launder allowing return of effluent
to product or worn product wear ring
Poor Recovery 1. Excessive fines in feed
2. Worn screen
3. Screen opening to large
4. Worn scraper blades
Note that the above list is general. However, each of these items should be checked
when unsatisfactory results occur. Should these checks fail to reveal possible
troubles, contact Ludowici Mineral Processing Equipment Pty Ltd.
16
17

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INSTALLATION & COMMISSIONING MANUAL FOR FC1200 CENTRIFUGE

INSTALLATION & COMMISSIONING

CLIENT: VALE MOCAMBIQUE LIMITADA

JOB NO: FC1200 – J16523

MALVERN ENGINEERING WORKS (Pty) Ltd

P.O Box 75002 Tel: (011) 873-9010 1287 Harriet Avenue

PART B – INSTALLATION & COMMISSIONING MANUAL

MALVERN ENGINEERING WORKS

P.O BOX 75002 1287 HARRIET AVENUE TEL: (011) 873-9010

2047 1400 Email: info@malvern.co.za

This Installation and Commissioning manual outlines installation requirements,

2. FC1200 PACKING LIST

A standard packing list is included here

• FC1200 centrifuge fitted with pulley

3. STORAGE OF COMPONENTS PRIOR TO INSTALLATION

The FC1200 centrifuge arrives on site completely assembled (complete with

Refer to DRG No.’s 30/FC1200/01/004 – General Arrangement

(a) Strength Design - machine weight

(b) Vibration - natural frequency of support structure to be outside the range of

4.2 MAIN FRAME

4.3 INSPECTION DOORS

4.4 INSTALLATION CLEARANCE

4.5 PROTECTION FROM TRAMP IRON

4.6 TRANSPORTATION OF THE CENTRIFUGE PRODUCT

If the machine discharges to a mechanical conveying device, the motors of each

4.7 FEED ARRANGEMENT

4.8 EFFLUENT SYSTEM

4.9 MAIN DRIVE/ELECTRICAL

Ref: Drawing No. 30/FC1200/01/004 (General Arrangement Drawing)

The motor should have thermal as well as electrical protection. Furthermore, it is

This will prevent damage to bearings and gears.

Approximate Total mass of the FC1200 centrifuge: 5650 kg

2. Lift the centrifuge to the point of installation.

Note: Fixing bolts are not supplied with the centrifuge

6.1 PRE-COMMISSIONING CHECK LIST

• Ensure that the coal feed is off

• Check the machine thoroughly inside and out.

PRE-COMMISSIONING CHECK LIST

6.2 STARTING FOR THE FIRST TIME

1. Switch on electrical supply.

2. Switch oil pump motor on.

3. Start rotation motor (after 60 seconds)

4. Start coal feed to centrifuge.

1. Stop feed to centrifuge

2. After 60 seconds, stop the drive motor

3. After 60 seconds, stop the lubrication motor.

If a problem arises, before calling out maintenance personnel, the following

7.2 LOCKED ROTATION

(a) Material or object locked between scraper blades and screen.

(b) Build-up of discharged product into the base of spoke piece.

7.3 MOTORS WILL NOT START

7.4 MACHINE SHUTS OFF DURING OPERATION

7.5 OIL PUMP PROBLEMS

Loss of oil pressure:-

(b) Leak in pressure line, check lines.

(d) Defective pump. Replace the pump if this is the case.

7.7 TROUBLE SHOOTING SUMMARY

Symptom Cause Solution